Crude Export Pump.pdf

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. POM1002286690010-01 15062-V009-OP-OM-0003

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Operation and Maintenance Manual - Crude Export Pump

Status Code

V009 02 02 OM 1 of 340

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

Date

Schlumberger Review Distribution – Interdisciplinary Check Department

Name

Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

 SMK

Date

Comments Y/N

02

 11 Dec­17

 Review/ Approved

01

16-Aug-17

Review/Approval

SMK

 DP

DP

 NT

NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

1

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. PIN1002286690010-01 15062-V009-OP-OM-0001

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Operation and Maintenance Manual Index - Crude Export Pump

Status Code

V009 03 03 OM 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Date

19-07-17

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

7-Jun-17 5-May-17 13-Dec-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

2

OPERATING AND MAINTAINANCE MANUAL INDEX CUSTOMER

Khuff / Schlumberger

P.O.NO.

15062V009

PROJECT

Jurassic Production Facility (JPF) at Sabriya

PUMP MODEL

GSG 100-300 (E) (Bd)

SPIL REF.WO No.

1616020 ( WBS NO. 100228669-0010 )

ITEM NO.

JPF1-G-104A/B/C

SECTION

SUBSECTION

DOCUMENT NO. 15062-V009-OP-OM-0001

01

DESCRIPTION Operation and Maintenance Manual Index - Crude Export Pump PUMP DRAWINGS & DATA SHEETS :

PAGE NO. 02 -04 05

1.1

15062-V009-ME-GA-0001-001

Pump General Arrangement Drawing

06 - 09

1.2

15062-V009-PR-PI-0003-001 15062-V009-ME-DD-0003-001

Piping & Instrumentation Diagram Cross Section Drawing & Parts List

10 - 11

1.3 1.4

15062-V009-ME-DD-0001-001

Nameplate Detail Drawing

15 - 16

1.5

15062-V009-ME-DS-0001

Pump Datasheet

17 - 20

1.6

15062-V009-PR-DS-0001

Pump Curve

21 - 22

1.7

15062-V009-ME-DD-0007-001

Mechanical Seal drawings - Crude Export Pump

23 - 25

1.8

15062-V009-ME-DD-0009-001

Seal System drawings & Data sheet

26 - 37

1.9

15062-V009-ME-DD-0005-001

Coupling drawings

38 - 39

ELECTRICAL :

02

12 - 14

40

2.1

15062-V009-ME-GA-0003-001

Motor General Arrangement Drawing

41 - 42

2.2

15062-V009-ME-GA-0005-001

Motor Wiring / JunctionBox Termination Diagram

43 - 58

2.3

15062-V009-ME-DS-0003

Motor Datasheet & Curve

59 - 63

PACKING / STORAGE :

03

64

3.1

15062-V009-IN-IN-0001

Utilities List

65 - 66

3.2

15062-V009-OP-SH-0001

Lubrication schedule

67 - 68

3.3

15062-V009-QA-PR-0003

Painting Procedure of pumps

69 - 77

3.4

15062-V009-QA-PR-0006

Pump Packing & Preservation Procedureof pumps

78 - 85

SPARES :

04 4.1

15062-V009-AM-BM-0001

5.1

15062-V009-OP-OM-0003

05

Spare Parts Interchangeability Report (SPIR) - Commissioning,Start-up and Operation MANUALS : Operation and Maintenance Manual

86 87 - 88

89 90 - 157

5.2

NIL

Motor Manual - Not Applicable

158

5.3

NIL

Mechanical Seal Manual

159 - 180

5.4

NIL

Coupling Manual

181 - 188

5.5

NIL

Plan 53 Seal System Manual

189 - 340

3

Operation and Maintenance Manual OMM-1616020

INDEX

CUSTOMER

:- Schlumberger

P.O. NO.

:- TAE900034A DTD. 07.08.2016

PROJECT

:- Jurassic Production Facility (JPF) at Sabriya

SPIL REF.

:- W. O. 1616020-0010

Crude Export Pump

SERVICE

ITEM NO.

JPF1-G-104 A

JPF1-G-104 B

JPF1-G-104 C

PUMP TYPE

GSG 100-300 (E) (Bd)

GSG 100-300 (E) (Bd)

GSG 100-300 (E) (Bd)

PUMP SR.NO.

579802

579803

579804

4

SECTION 01 OMM-1616020

PUMP DRAWING AND DATA SHEETS

SECTION 01 - INDEX

DOCUMENT NO.

SR. No.

DOC. TITLE

01

Pump General Arrangement Drawing

02

Piping & Instrumentation Diagram

03

Cross Section Drawing & Parts List

15062-V009-ME-DD-0003-001

04

Nameplate Detail Drawing

15062-V009-ME-DD-0001-001

05

Pump Datasheet

15062-V009-ME-DS-0001

06

Pump Curve

15062-V009-PR-DS-0001

07

Mechanical Seal drawings

15062-V009-ME-DD-0007-001

08

Seal System drawings & Data sheet

15062-V009-ME-DD-0009-001

09

Coupling drawings

15062-V009-ME-DD-0005-001

15062-V009-ME-GA-0001-001

15062-V009-PR-PI-0003-001

5

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. PGA1002286690010-1 15062-V009-ME-GA-0001-001

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Pump General Arrangement Drawing - Crude Export Pump

Status Code

V009 04 04 GA 1 of 3

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Pradeep Bhuin

Date

19-07-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

04 03 02 01

29-May-17 8-May-17 1-Sep-16 22-Jul-16

Review/Approval Review/Approval Review/Approval Review/Approval

SMK SMK SMK SMK

DP DP DP DP

NT NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

6

A

B

C

D

E

SULZER DOCUMENT No. PCS1002286690010-01

1

CUSTOMER DOCUMENT No. 15062-V009-ME-DD-0003-001

F

G

H

DRIVER SPECIFICATIONS

REFERENCE DRAWINGS DESCRIPTION.

MOTOR: SISTEMI FRAME: ET 500 450 kW: PHASE: 3 FURNISHED BY: SULZER

CROSS-SECTION DRAWING

PPI1002286690010-01

15062-V009-PR-PI-0003-001

PIPING & INSTRUMENTATION DIAGRAM

SMD1002286690010-01

15062-V009-ME-DD-0007-001

MECHANICAL SEAL DRAWING

CCD1002286690010-01

15062-V009-ME-DD-0005-001

COUPLING DRAWING

PDS1002286690010-01

15062-V009-ME-DS-0001

PUMP DATA SHEET

MDD1002286690010-01

15062-V009-ME-GA-0003-001

MOTOR DRAWING

SSD1002286690010-01

15062-V009-ME-DD-0009-001

SEAL SYSTEM DRAWING

CONTRACT DATA

2980 RPM SPEED: VOLTAGE: 3300 50 CYCLE:

PURCHASER:

Khuff / Schlumberger

USER:

Kuwait Oil Company (KOC)

JOB/PROJECT:

KOC Jurassic Production Facility, Sabriya

CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

Crude Export Pumps Kuwait SULZER PUMPS (I) LTD 100228669-0010

1

IDENTIFICATION NUMBERS B

FLUSHING PLAN 53B

CUSTOMER TAG NO'S

SULZER SERIAL NO.

PUMP

DRIVER

579802

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

-

-

-

-

-

-

-

-

-

B

DO NOT SCALE. DIMENSIONS: mm CERTIFIED FINAL

UNLESS OTHERWISE SPECIFIED TOLERANCES

CERTIFIED FOR NOZZLE & FOUNDATION ONLY

≤ 500 mm > 500 mm

PRELIMINARY ONLY

 3 mm  12 mm

AUXILLARY CUSTOMER CONNECTION DIMENSIONS ± 25 mm

2

2

DRAWING CONTENT SHEET

SHEET DESCRIPTION

NO.

GA ISOMETRIC DATA SHEET

2 Nos. EARTHING LUG DIAGONALLY OPPOSITE

1

FOUNDATION AND NOZZLE

2

CONNECTION LAYOUT

3

C

ISSUED FOR APPROVAL

SSK

VVS

25.05.17

B A

ISSUED FOR APPROVAL FIRST SUBMISSION

SSK SSK

VVS VVS

25.08.16 22.07.16

REV.

DESCRIPTION

xx xx HOD PEM CHECKED APPRD.

DRAWN

DATE

CONTRACTOR REVISION

NOTES: 3

4

COUPLING SPECIFICATIONS

1. CAUTION! CAREFULLY CHECK ALIGNMENT BEFORE STARTING UNIT. ALL HOLES IN FLANGES STRADDLE CENTERLINES. UNIT SHOULD BE RELIEVED OF EXCESS PIPING STRAINS: 2. COLORS ARE NOT INTENDED TO REPRESENT "AS SHIPPED" PAINT REQUIREMENTS. THEY ARE FOR QUICK IDENTIFICATION OF PIPING AND EQUIPMENT. 3. PIPING AND EQUIPMENT ARE MODELED REPRESENTATIONS ONLY, ACTUAL LOCATION AND ORIENTATION MAY VARY PER SHOP STANDARDS, UNLESS OTHERWISE DIMENSIONED. 4. BASE PLATE SHALL BE AS PER SULZER STANDARD. 5. PUMP MAWP: 83 bar g @ 93° C, 6. HYDROTEST PRESSURE: 124.5 bar g @ AMB. 7. FLANGES IN ACCORDANCE WITH ASME B16.5 WITH SURFACE FINISH 125-250 AARH. 8. STATIC LOAD ON EACH FOUNDATION BOLT: 648 Kg. 9. DYNAMIC LOAD ON EACH FOUNDATION BOLT: 15 Kg. 10. MINIMUM 5D STRAIGHT RUN IS REQUIRED FOR SUCTION NOZZLE. 11. DRAIN PIPING SHALL BE PROVIDED WITH SUITABLE SUPPORT.

MFR: John Crane TYPE: API 610 SIZE: TLKS-0300 COUPLING-GUARD MATERIAL: BRASS

B

PROJECT TITLE:-

SIZE & TYPE: GSG 100-300/1d+6 Stg. SPEED: 2980 RPM ROTATION: CCW (AS VIEWED FROM PUMP NDE) DISCH FLG: 4" CLASS: 600 RF Standard: ASME B16.5 SUCT FLG: 8" CLASS: 600 RF Standard: ASME B16.5 MECH SEAL TYPE: DOUBLE SEAL MECH SEAL DRG: 09-H75VKP-D5/100-E1 API CODE: C2A3A53B API PIPING PLANS: 53B

JURASSIC PRODUCTION FACILITY (JPF) AT SABRIYAH

DRAWING TITLE:-

Schlumberger Document Review

GENERAL ARRANGEMENT DRAWING JPF1-G-104A/B/C

1. Review without Comment 2. Comment as noted Revise & Re-submit

PROJECT NO.

3. Rejected New Dwg/Doc Required

DRAWING NO. CONTRACTOR DRG. NO.

B

OPERATING DATA

B

C

PUMPING MEDIA:

Stabilized Crude Oil

OPERATING TEMP [ C] :

58

FLOW RATE [m /hr] :

152.36

DIFF. HEAD [m]3 :

765.2

EFFICIENCY [%]

67.5

RATED POWER [kW] :

362

570 161 11655 100 800 3849 27 4280 2599

APPROXIMATE WEIGHTS D

E

kg kg kg kg kg kg kg kg kg

REV.

4. Noted for Information Only Reviewed By:

Signature:

Revision No.:

15062-V009-ME-GA-0001-001 15062-V009-ME-GA-0001-001

Date:

XXX

Document No.:

SCOPE OF SUPPLY OTHER

C

COMPANY DRG. NO.

REV.

1

25.05.2017

25.05.2017

25.05.2017

S.KUDTARKAR

V.SHEDGE

V.SHEDGE

MODIFIED

CHECKED

APPROVED

FORMAT: A1 A DESIGN GROUP: - SUBSTITUTE FOR:

REPLACED BY:

GSG 100-300/1d+6 Stg.

- ORIGINAL SCALE:

100228669-0010

GA ISOMETRIC AND DATA SHEET

CHECKED:

20-07-2016 V. SHEDGE

APPROVED:

20-07-2016 V. SHEDGE

GENERAL ARRANGEMENT DRAWING PART NO.

G

-

GENERAL ARRANGEMENT -

Kuwait

4

FIRST ANGLE PROJECTION

DRAWN:

XXX F

1

1

MODIFICATION

NO

REV.

-

REV.

REVISED AS PER COMMENT

SEP. PARTS LIST:

KOC DRG. NO.

SHEET NO.

XXXXXXXX

SULZER PUMP: MECHANICAL SEAL BASEPLATE: SEAL SYSTEM FLUSHING PIPING COUPLING COUPLING GUARD MOTOR: MOTOR BOLTS & SHIM FOUNDATION BOLT

C4

1

SHEET NO.

SHEET NO.

COPYRIGHT © SULZER Ltd 2016. ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

A

EARLY PRODUCTION SYSTEMS (EPS)

PUMP SPECIFICATIONS

MOTOR ROTOR: PUMP ROTOR: TOTAL: ACCESSORIES: SEAL SYSTEM: BASEPLATE: COUPLING: MOTOR: PUMP:

3

Schlumberger

19-07-2016 S. KUDTARKAR

7 EN PGA1002286690010-01 1 /3 H

A

B

C

D

E

F

G

H

CONTRACT DATA

1650

755

590

1175

250 DBSE

755

REQUIRED MIN. DISTANCE FOR CARTRIGE REMOVAL

2550 25

525

176

1180

B

900

B

1

CABLE ENTRY FROM BOTTOM SIDE

O

N

Khuff / Schlumberger

USER:

Kuwait Oil Company (KOC)

JOB/PROJECT:

KOC Jurassic Production Facility, Sabriya

CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

-

CUSTOMER TAG NO'S DRIVER

579802

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

510

PUMP

2208

2315

1

SULZER SERIAL NO.

500

326

B

Crude Export Pumps Kuwait SULZER PUMPS (I) LTD 100228669-0010

IDENTIFICATION NUMBERS

6.4

R

O

T A T I

PURCHASER:

DO NOT SCALE. DIMENSIONS: mm

75 TYP.

 OF PUMP

 OF BASE PLATE

150

675

675

525

200

37.5

715

715

COG

COG COUPLING

PUMP

COG MOTOR

450

175 TYP.

715

5750

715

715

1262.5

1262.5

200

150

X

Y

Z

1394

0

1100 1100

COUPLING

2570

0

BASEPLATE

2875

175

MOTOR

3970

0

PACKAGE

2953

141

225 1100 2

37.5

2600

200

 3 mm  12 mm

AUXILLARY CUSTOMER CONNECTION DIMENSIONS ± 25 mm

& MOTOR

100 TYP. 100 TYP.

2

≤ 500 mm > 500 mm

PRELIMINARY ONLY

10

54

UNLESS OTHERWISE SPECIFIED TOLERANCES

CERTIFIED FOR NOZZLE & FOUNDATION ONLY

300

450

54

1090

CERTIFIED FINAL

COG BASEPLATE

Z + + +X Y

200

ZERO POINT

SIDE VIEW

843

COG PACKAGE

COG=CENTER OF GRAVITY

COG PUMP

ELEVATION

2900 750

18 Nos,  27 HOLES FOR ANCHOR BOLTS

1850

B 450

C

ISSUED FOR APPROVAL

SSK

VVS

25.05.17

B A

ISSUED FOR APPROVAL FIRST SUBMISSION

SSK SSK

VVS VVS

25.08.16 22.07.16

REV.

DESCRIPTION

B 300

75

300

75 TYP.

DRAWN

xx xx HOD PEM CHECKED APPRD.

DATE

CONTRACTOR REVISION VENT HOLES

75

ANCHOR BOLT DETAIL

B

3

1300

300

3

Schlumberger

25 mm GROUTED AFTER ALIGNMENT

18 Nos, M16 x 50L FOR BASE LEVELING

B

EARLY PRODUCTION SYSTEMS (EPS)

600

105

18 Nos. ANCHOR BOLTS M24 X 605 LG. SUPPLIED BY SULZER

B

1300

 OF PUMP

& MOTOR

30

JURASSIC PRODUCTION FACILITY (JPF) AT SABRIYAH

CEMENT GROUT

DRAWING TITLE:-

GENERAL ARRANGEMENT DRAWING JPF1-G-104A/B/C

B

450

450

602

B

10

PROJECT TITLE:-

 OF BASE PLATE

PROJECT NO.

 100

DRAWING NO. CONTRACTOR DRG. NO.

AS PER PROJECT SPECIFICATION DRAWING KOC DRAWING NO. 55-02-62 'TYPE-2'

XXX

B

330

FORCE IN (N) SPRING WASHER STAINLESS STEEL

PLAN

30

30

x

 40 M10

MATERIAL STAINLESS STEEL

COPYRIGHT © SULZER Ltd 2016. ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

A

C

D

y

Fz

Mz

60

B

DETAIL OF EARTHING BOSS B

REV.

E

Mx Fx

My F

Fy

Fx Fy Fz Fr Mx My Mz Mr

SUCT 7560 6220 9780 13840 7060 3520 5160 9420

DISCH 2840 2320 3560 5120 2660 1360 2000 3600

REVISED AS PER COMMENT MODIFICATION

SEP. PARTS LIST:

1

1

SHEET N O.

C

1

SHEET NO.

REV.

XXXXXXXX

MOMENTS IN (Nm)

z

GROUT HOLES

FORCE

4

590

MOMENTS

1500

REV.

C4

1

SHEET N O.

COMPANY DRG. NO.

MAXIMUM NOZZLE LOADINGS Forces do comply with 2.0 times of the forces shown in API 610 11th, Table 5

KOC DRG. NO.

REV.

15062-V009-ME-GA-0001-002 15062-V009-ME-GA-0001-001

NO

25.05.2017

25.05.2017

25.05.2017

S.KUDTARKAR

V.SHEDGE

V.SHEDGE

MODIFIED

CHECKED

APPROVED

FORMAT: A1 A DESIGN GROUP: - SUBSTITUTE FOR:

REPLACED BY:

GSG 100-300/1d+6 Stg.

- ORIGINAL SCALE:

100228669-0010

GENERAL ARRANGEMENT FOUNDATION AND NOZZLE

CHECKED:

20-07-2016 V. SHEDGE

APPROVED:

20-07-2016 V. SHEDGE

GENERAL ARRANGEMENT DRAWING PART NO.

XXX G

-

DRAWN:

-

Kuwait

4

FIRST ANGLE PROJECTION

19-07-2016 S. KUDTARKAR

8 EN PGA1002286690010-01 2 /3 H

A

B

C

D

E

F

G

H

CONTRACT DATA FVA

FVB

1175

FVA 176

FVB PI

PO

1

PO

PURCHASER:

Khuff / Schlumberger

USER:

Kuwait Oil Company (KOC)

JOB/PROJECT:

KOC Jurassic Production Facility, Sabriya

CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

-

PI

510 2208

326

FCB

PUMP

DRIVER

579802

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

-

-

-

-

-

-

-

-

-

1090

1090

FDB 450

150

DO NOT SCALE. DIMENSIONS: mm

CERTIFIED FINAL

54

AD2

CUSTOMER TAG NO'S

SULZER SERIAL NO.

FDA

PD

UNLESS OTHERWISE SPECIFIED TOLERANCES

CERTIFIED FOR NOZZLE & FOUNDATION ONLY

≤ 500 mm > 500 mm

PRELIMINARY ONLY

PD

AD2

1

IDENTIFICATION NUMBERS

6.4

FCA

Crude Export Pumps Kuwait SULZER PUMPS (I) LTD 100228669-0010

 3 mm  12 mm

AUXILLARY CUSTOMER CONNECTION DIMENSIONS ± 25 mm

2

2 5750

1300

450

850

ELEVATION 2600

SIDE VIEW 2900 750

FDB

FCB

FVB 300

FCA

75

FVA

FDA 300

75

1300

3

B

B

DESCRIPTION SIZE PUMP SUCTION NOZZLE 8" PUMP DISCHARGE NOZZLE 4" PUMP DRAIN 1" BASE DRAIN 2" FLUSHING HIGH POINT VENT (DE SIDE) 3/4" FLUSHING HIGH POINT VENT (NDE SIDE) 3/4" FLUSHING RESERVOIR DRAIN (DE SIDE) 3/4" FLUSHING RESERVOIR DRAIN (NDE SIDE)

PLAN 53B FILLING CONN. (DE SIDE) PLAN 53B FILLING CONN. (NDE SIDE)

ISSUED FOR APPROVAL

SSK

VVS

B A

ISSUED FOR APPROVAL FIRST SUBMISSION

SSK SSK

VVS VVS

DRAWN

CHECKED

REV.

CONNECTION LEGEND ITEM PI PO PD AD2 FVA FVB FDA FDB FCA FCB

C

DESCRIPTION

EARLY PRODUCTION SYSTEMS (EPS)

450 1300

450

JURASSIC PRODUCTION FACILITY (JPF) AT SABRIYAH

DRAWING TITLE:-

152

GENERAL ARRANGEMENT DRAWING JPF1-G-104A/B/C

PROJECT NO.

DRAWING NO. CONTRACTOR DRG. NO.

REV.

15062-V009-ME-GA-0001-003 15062-V009-ME-GA-0001-001

XXX PI

PLAN C

4

REV.

100-300/1d+6 Stg.

100228669-0010

E

F

CHECKED

APPROVED

G

4

FIRST ANGLE PROJECTION

- ORIGINAL SCALE:

-

GENERAL ARRANGEMENT CONNECTION LAYOUT

CHECKED:

20-07-2016 V. SHEDGE

APPROVED:

20-07-2016 V. SHEDGE

GENERAL ARRANGEMENT DRAWING XXX

D

MODIFIED

DRAWN:

PART NO.

C

25.05.2017 V.SHEDGE

-

Kuwait

B

25.05.2017 V.SHEDGE

- SUBSTITUTE FOR:

GSG

A

25.05.2017 S.KUDTARKAR

FORMAT: A1 A DESIGN GROUP: -

REPLACED BY:

COPYRIGHT © SULZER Ltd 2016. ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

1

1

MODIFICATION

NO

1

REV.

REVISED AS PER COMMENT

SEP. PARTS LIST:

REV.

SHEET NO.

COMPANY DRG. NO.

SHEET NO.

590

KOC DRG. NO.

C 4

1

SHEET NO.

XXXXXXXX

1500

3

PROJECT TITLE:-

30

PO

DATE

Schlumberger

AD2

PD

xx xx HOD PEM APPRD.

CONTRACTOR REVISION

TYPE CL. 600 RF CL. 600 RF CL.600 RF CL. 150 RF CL. 900 RTJ CL.900 RTJ CL.900 RTJ CL.900 RTJ NPT NPT

3/4" 1/2" 1/2"

25.05.17 25.08.16 22.07.16

19-07-2016 S. KUDTARKAR

9 EN PGA1002286690010-01 3 /3 H

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. PPI1002286690010-01 15062-V009-PR-PI-0003-001

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Piping & Instrumentation Diagram - Crude Export Pump

Status Code

V009 03 03 PI 1 of 2

Description

X

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

Pradeep Bhuin

Date

19-07-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

29-May-17 18/01/2017 7-Dec-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

10

D

C

A

B

COPYRIGHT c (DATE OF DRAWING) SULZER PUMPS ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

4

4

8

8

API PLAN - 53B, 61

9 3

3

9 8

11

11

8

9 8

8

9

8 10 4 3 2

7 1

6

8

5

9

10

2

2

03

CONTRACT DATA PURCHASER: KHUFF / SCHLUMBERGER USER: KUWAIT OIL COMPANY KSC JOB/PROJECT: KOC JURASSIC PRODUCTION FACILITY, SABRIYA CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

CRUDE EXPORT PUMPS KUWAIT SULZER PUMPS INDIA LTD. 100228669-0010

IDENTIFICATION NUMBERS CUSTOMER TAG NO'S

SULZER SERIAL NO.

1

PUMP

DRIVER

579802

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

REVISED AS PER COMMENTS

25-MAY-2017

25-MAY-2017

25-MAY-2017

V. SHEDGE

S. KAPREKAR

S. KAPREKAR

MODIFIED

CHECKED

APPROVED

c REV. MODIFICATION SEP. PARTS LIST

-

REPLACED BY

FORMAT A2 DESIGN GROUP

-

GSG 100-300/1D+6 STG. KUWAIT 100228669-0010

SUBSTITUTE FOR

P & I DIAGRAM_ PART NO.

-

D

C

B

SULZER PUMPS INDIA LTD.

A

-

1ST ANGLE PROJECTION ORIGINAL SCALE

DNS

DRAWN:

24-AUG-2016 P. NANDURKAR CHECKED: 24-AUG-2016 V. SHEDGE APPROVED: 24-AUG-2016 V. SHEDGE

EN PPI1002286690010-01

11

1/1

1

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PCS1002286690010-01 15062-V009-ME-DD-0003-001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Cross Section Drawing & Parts List - Crude Export Pump

Status Code

V009 02 02 DOC 1 of 3

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only X Reviewed By Signature

Date

01-08-16

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

02 01

29-Jul-16 6-Jul-16

Review/Approval Review/Approval

PSD PSD

SMK SMK

NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

12

D

C

A

B

CONTRACT DATA

COPYRIGHT c SULZER Ltd 2015 ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

PURCHASER: KHUFF / SCHLUMBERGER USER: KUWAIT OIL COMPANY (KOC) JOB/PROJECT: KOC JURASSIC PRODUCTION FACILITY, SABRIYA CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

4

. CRUDE EXPORT PUMPS KUWAIT SULZER PUMPS INDIA LTD. 100228669-0010

4

IDENTIFICATION NUMBERS CUSTOMER TAG NO'S

SULZER SERIAL NO.

PUMP

579802

DRIVER

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

3

3

2

2

JURASSIC PRODUCTION FACILITY (JPF) AT SABRIYAH

PUMP CROSS SECTIONAL DRAWING CRUDE EXPORT PUMPS

1

1 a

CASING DRAIN VALVE CHANGED FROM BUTT WELDED TO FLANGED TYPE. O-RING GRADE CHANGED TO FKM (PARKER-VG109) SUITABLE FOR THE APPLICATION.

REV. MODIFICATION SEP. PARTS LIST

FORMAT A2 DESIGN GROUP

.

GSG 100-300/1D+6 STAGES

KOC 100228669-0010

SUBSTITUTE FOR

. . XXX

C

B

28-JUL-2016

28-JUL-2016

D. VISHWAKARMA CHECKED

D. VISHWAKARMA APPROVED

SULZER PUMPS INDIA LTD. .

PUMP CROSS .SECTIONAL DRAWING

PART NO.

D

N. KOLI MODIFIED

.

REPLACED BY

28-JUL-2016

1ST ANGLE PROJECTION ORIGINAL SCALE

DNS

DRAWN:

01-JUL-2016 N. KOLI CHECKED: 01-JUL-2016 D. VISHWAKARMA APPROVED: 01-JUL-2016 D. VISHWAKARMA

EN PCS1002286690010-01 1 / 2

A

13

D

C

A

B

CONTRACT DATA PURCHASER: KHUFF / SCHLUMBERGER USER: KUWAIT OIL COMPANY (KOC) JOB/PROJECT: KOC JURASSIC PRODUCTION FACILITY, SABRIYA CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

. CRUDE EXPORT PUMPS KUWAIT SULZER PUMPS INDIA LTD. 100228669-0010

IDENTIFICATION NUMBERS

4

4

CUSTOMER TAG NO'S

SULZER SERIAL NO.

PUMP

579802

DRIVER

JPF1-G-104A

JPF1-GM-104A

579803

JPF1-G-104B

JPF1-GM-104B

579804

JPF1-G-104C

JPF1-GM-104C

3

3

2

2

COPYRIGHT c SULZER Ltd 2015 ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

1

a

CASING DRAIN VALVE CHANGED FROM BUTT WELDED TO FLANGED TYPE. O-RING GRADE CHANGED TO FKM (PARKER-VG109) SUITABLE FOR THE APPLICATION.

REV. MODIFICATION SEP. PARTS LIST

FORMAT A2 DESIGN GROUP

.

GSG 100-300/1D+6 STAGES

KOC 100228669-0010

SUBSTITUTE FOR

. . XXX

C

B

28-JUL-2016

28-JUL-2016

D. VISHWAKARMA CHECKED

D. VISHWAKARMA APPROVED

SULZER PUMPS INDIA LTD. .

PUMP CROSS .SECTIONAL DRAWING

PART NO.

D

N. KOLI MODIFIED

.

REPLACED BY

1 28-JUL-2016

1ST ANGLE PROJECTION ORIGINAL SCALE

DNS

DRAWN:

01-JUL-2016 N. KOLI CHECKED: 01-JUL-2016 D. VISHWAKARMA APPROVED: 01-JUL-2016 D. VISHWAKARMA

EN PCS1002286690010-01 2 / 2

A

14

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PNT1002286690010-01 15062-V009-ME-DD-0001-001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Nameplate Detail Drawing - Crude Export Pump

Status Code

V009 01 01 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Pradeep Bhuin

Date

29/9/2016

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

01

20/092016

Review/Approval

SMK

DP

NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

15

D

C

B

A

COPYRIGHT c (DATE OF DRAWING) SULZER PUMPS ALL RIGHTS RESERVED. NO PART OF THIS DRAWING MAY BE REPRODUCED, DISTRIBUTED, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS, ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING AND RECORDING, WITHOUT THE EXPRESS PRIOR WRITTEN CONSENT OF SULZER PUMPS

4

3

2

4

Equipment Number : JPF1-G-104A UTC Number : PO. Number : Serial No : 579802 Pump Model : 100-300/1d+6 Stg. Year of Manufacture : 2016 Motor Rating : 450 kW Speed : 2980 rpm Rated Capacity : 152.36 (23000) Discharge Pressure : 53.434 (775) barG (PSIG) Maximum Temperature : 60 (140) Differential Head : 765.2 (2510.5) m (ft) Specific Gravity : 0.770 Maximum Allow Working Pressure : 83 (1203.813) barG (PSIG) Hydrotest Pressure : 124.5 (1805.72) barG (PSIG) Brg. : NU 214 (DE) / 7312BECBM (NDE) Total Weight: : 2599 (5729.81) kg (lb)

Equipment Number : JPF1-G-104B UTC Number : PO. Number : Serial No : 579803 Pump Model : 100-300/1d+6 Stg. Year of Manufacture : 2016 Motor Rating : 450 kW Speed : 2980 rpm Rated Capacity : 152.36 (23000) Discharge Pressure : 53.434 (775) barG (PSIG) Maximum Temperature : 60 (140) Differential Head : 765.2 (2510.5) m (ft) Specific Gravity : 0.770 Maximum Allow Working Pressure : 83 (1203.813) barG (PSIG) Hydrotest Pressure : 124.5 (1805.72) barG (PSIG) Brg. : NU 214 (DE) / 7312BECBM (NDE) Total Weight: : 2599 (5729.81) kg (lb)

SULZER PUMPS INDIA LTD.

SULZER PUMPS INDIA LTD.

Equipment Number : JPF1-G-104C UTC Number : PO. Number : Serial No : 579804 Pump Model : 100-300/1d+6 Stg. Year of Manufacture : 2016 Motor Rating : 450 kW Speed : 2980 rpm Rated Capacity : 152.36 (23000) Discharge Pressure : 53.434 (775) barG (PSIG) Maximum Temperature : 60 (140) Differential Head : 765.2 (2510.5) m (ft) Specific Gravity : 0.770 Maximum Allow Working Pressure : 83 (1203.813) barG (PSIG) Hydrotest Pressure : 124.5 (1805.72) barG (PSIG) Brg. : NU 214 (DE) / 7312BECBM (NDE) Total Weight: : 2599 (5729.81) kg (lb)

3

2

CONTRACT DATA PURCHASER: KHUFF / SCHLUMBERGER

PLATE THICKNESS: 3mm MATERIAL: SS316 EXECUTION: BORDERS, LETTERS & DATA BLOCK EXPOSED METAL OR CLEAR COATED BACKGROUND: ETCHED & PAINTED BLACK FONT USED: ARIAL OR HELVETICA NAMEPLATE SHOWN ABOVE IS EXAMPLE ONLY, NAMEPLATE IS IN REVERSE IMAGE. (NEGATIVE IMAGE OF AS SHOWN ABOVE)

USER: KUWAIT OIL COMPANY KSC JOB/PROJECT: KOC JURASSIC PRODUCTION FACILITY, SABRIYA CUST. P.O. NO.: SERVICE: INSTALLED AT: PUMP OEM: SULZER ORDER NO.:

CRUDE EXPORT PUMPS KUWAIT SULZER PUMPS INDIA LTD. 100228669-0010

IDENTIFICATION NUMBERS CUSTOMER TAG NO'S

SULZER SERIAL NO.

SULZER PUMPS INDIA LTD.

PUMP JPF1-G-104A

-

579803

JPF1-G-104B

-

579804

JPF1-G-104C

-

-

1

DRIVER

579802

-

-

-

-

-

MODIFIED

CHECKED

APPROVED

1

-

NAME PLATE IS COMPLYING WITH THE REQUIREMENT OF KOC-G-012

REV. MODIFICATION SEP. PARTS LIST

-

REPLACED BY

FORMAT A2 DESIGN GROUP

-

GSG 100-300/1D+6 STG. KUWAIT 100228669-0010

SUBSTITUTE FOR

-

B

ORIGINAL SCALE DRAWN:

CHECKED:

APPROVED:

970

C

1ST ANGLE PROJECTION

-

NAME PLATE DRAWING_

PART NO.

D

SULZER PUMPS INDIA LTD.

DNS

19-SEP-2016 V. SHEDGE 19-SEP-2016 S. DABADE 19-SEP-2016 S. DABADE

EN PNT1002286690010-01 1 / 1

A

16

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PDS1002286690010-01 15062-V009-ME-DS-0001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Pump Datasheet - Crude Export Pump

Status Code

V009 03 03 DOC 1 of 4

Description

X

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

Pradeep Bhuin

Date

08-11-16

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

4-Oct-16 1-Aug-16 19-Jul-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

17

Pump Performance Datasheet Customer

: KHUFF GENERAL TRADING & CONTRACTING CO WLL

Sulzer Reference ID

: KWT.0466-AUH.16.0124-F0

Type / Size

: GSG 100-300 (E)(Bd)

Inquiry Number/ID

:

Stages

: 7 (6 / 1x(Bd))

Item number

: JPF1-G-104 A/B/C

Based on curve number

: 4611.04.512-02

Service

: Crude Export Pumps

Date of Last Update

: 26 Jul 2016 12:42 PM

Quantity

:3 Operating Conditions

Flow, rated

Liquid

: 23,000.0 USbl/day

Liquid type

: Other

Differential head / pressure, rated (requested) : 765.2 m

Additional liquid description

: Stabilized Crude Oil

Suction pressure, rated / max

: 10.00 / 10.00 psi.g

Solids diameter, max

: 0.00 mm

NPSH available, rated

: 5.0 m

Solids concentration, by volume

: 0.00 %

Frequency

: 50 Hz

Temperature, rated / max

: 58.00 / 60.00 deg C

Fluid density, rated / max

: 704.0 / 770.0 kg/m3 : 1.00 cP

Performance Speed, rated

: 2980 rpm

Viscosity, rated

Impeller diameter, rated

: 284 mm

Vapor pressure, rated

Impeller diameter, maximum

: 305 mm

Impeller diameter, minimum

: 275 mm

Efficiency

: 67.5 %

NPSH (3% head drop) / margin required

: 2.6 / 0.0 m

Ns (imp. eye flow) / Nss (imp. eye flow) MCSF

: 1,189 / 10,853 US Units Maximum allowable working pressure Maximum allowable suction pressure : 11,228.6 USbl/day

Head, maximum, rated diameter

: 868.1 m

Head rise to shutoff

: 13.45 %

Flow, best eff. point

: 27,556.8 USbl/day

Driver sizing specification

: Maximum power

Flow ratio, rated / BEP

: 83.46 %

Margin over specification

: 0.00 %

: 93.11 %

Service factor

: 1.00

Head ratio (rated dia / max dia)

: 84.53 %

Power, hydraulic

: 245 kW

Cq/Ch/Ce/Cn [ANSI/HI 9.6.7-2010]

: 1.00 / 1.00 / 1.00 / 1.00 Power, rated Power, maximum, rated diameter

Diameter ratio (rated / max)

: 19.80 psi.a Material

Material selected

: Carbon Steel (S-8) Pressure Data

Hydrostatic test pressure

: 83 bar.g : N/A

: 124.5 Driver & Power Data

: 362 kW : 429 kW

Minimum recommended motor rating 1,050 305 mm

1,000

52

950 900

59

MCSF Preferred operating region 65

68

284 mm

71

850

Head - m

: 450 kW / 603 hp

72

800

275 mm

71

750 700

68

650 600

NPSHr - m

550 4

3% head drop

2 0

Power - kW

600 450

Power

300 150 0

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Flow - USbl/day

18

Multiple Conditions Datasheet Customer Inquiry Number/ID Item number Service

: KHUFF GENERAL TRADING & CONTRACTING CO WLL : : JPF1-G-104 A/B/C : Crude Export Pumps

Condition # Description Temperature, max Fluid density, rated / max Viscosity, rated Primary condition Type / Size Stages Impeller diameter, rated Flow, rated Head, rated (requested) Suction pressure, rated / max NPSH available, rated Speed, rated Cq/Ch/Ce/Cn [ANSI/HI 9.6.7-2010] Efficiency NPSH (3% head drop) Power, rated

deg C kg/m3 cP

mm USbl/day m psi.g m rpm

% m kW

Quantity

:3

Type / Size

: GSG 100-300 (E)(Bd)

Sulzer Reference ID Date of Last Update

: KWT.0466-AUH.16.0124-F0 : 26 Jul 2016 12:42 PM

Stages Speed, rated

:7 : 2980

1

2

3

60.00 704.0 / 770.0 1.00

60.00 704.0 / 770.0 1.00

60.00 704.0 / 770.0 1.00

4

5

6

7

8

GSG 100-300 (E)(Bd) 7 284 23,000.0 765.2 10.00 / 10.00 5.0 2980 1.00 / 1.00 / 1.00 / 1.00 67.5 2.6 362

20,000.0 764.0 10.00 / 10.00 5.0 2926 1.00 / 1.00 / 1.00 / 1.00 65.5 2.4 324

12,000.0 764.0 10.00 / 10.00 5.0 2838 1.00 / 1.00 / 1.00 / 1.00 54.4 234

19

Multiple Conditions Curve 920

880

284 mm

840

800

Head - m

760

3

2

1

720

680

640 2980 600

2926 2838

560

520

NPSHr - m

4 2980 2926 2838 2

0 600

Power - kW

450

2980 2926 2838

300

150

0

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

Flow - USbl/day Customer

: KHUFF GENERAL TRADING & CONTRACTING CO WLL : : JPF1-G-104 A/B/C : Crude Export Pumps :3 : KWT.0466-AUH.16.0124-F0 : 26 Jul 2016 12:42 PM : 23,000.0 USbl/day : 765.2 m

Inquiry Number/ID Item number Service Quantity Sulzer Reference ID Date of Last Update Flow, rated Differential head / pressure, rated Fluid density, rated / max : 704.0 / 770.0 kg/m3

Type / Size

: GSG 100-300 (E)(Bd)

Stages Speed, rated Based on curve number Efficiency Power, rated NPSH (3% head drop) Viscosity Cq/Ch/Ce/Cn [ANSI/HI 9.6.7-2010]

:7 : 2980 rpm : 4611.04.512-02 : 67.5 % : 362 kW : 2.6 m : 1.00 cP : 1.00 / 1.00 / 1.00 / 1.00

Submergence

:-

20

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PPC1002286690010-01 15062-V009-PR-DS-0001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Pump Curve - Crude Export Pump

Status Code

V009 03 03 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Date

07-12-16

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

10-Oct-16 1-Aug-16 6-Jul-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

21

Pump Performance Curve 1,050

MCSF Preferred operating region

1,000

305 mm 52

59

950

65 68

900 284 mm

71

Head - m

850 72

275 mm

800

71

750

700 68 650

600

550

NPSHr - m

4 3% head drop 2

0

Power - kW

600

450

Power

300

150

0

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

Flow - USbl/day Customer

: KHUFF GENERAL TRADING & CONTRACTING CO WLL

Inquiry Number/ID

:

Item number

: JPF1-G-104 A/B/C

Service

: Crude Export Pumps

Quantity

:3

Sulzer Reference ID

: KWT.0466-AUH.16.0124-F0

Date of Last Update

: 28 Sep 2016 8:25 AM

Flow, rated

: 23,000.0 USbl/day

Type / Size

: GSG 100-300 (E)(Bd)

Stages

: 7 (6 / 1x(Bd))

Speed, rated

: 2980 rpm

Based on curve number

: 4611.04.512-02

Efficiency

: 67.5 %

Power, rated

: 362 kW

NPSH (3% head drop)

: 2.6 m

Temperature, rated / max

: 58.00 / 60.00 deg C

Fluid density, rated / max

: 704.0 / 770.0 kg/m3

Viscosity, rated

: 1.00 cP

Cq/Ch/Ce/Cn [ANSI/HI 9.6.7-2010]

: 1.00 / 1.00 / 1.00 / 1.00

Differential head / pressure, : 765.2 m rated Liquid type

: Other

Additional liquid description : Stabilized Crude Oil

22

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. SMD1002286690010-01 15062-V009-ME-DD-0007-001

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Mechanical Seal drawings - Crude Export Pump

Status Code

V009 02 02 DD 1 of 3

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required X 4: Noted for Information Only Reviewed By Signature

Pradeep Bhuin

Date

11-05-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

02 01

8-May-17 11-Aug-16

Review/Approval Review/Approval

SMK SMK

DP DP

NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

23

02/01/2013

ENGG DEPT. SULZER PUMPS (INDIA) LTD.

NAME:

By kolinit at 10:17 am, Aug 06, 2016 DATE:

THE REVIEW/APPROVAL DOES NOT RELIEVE THE VENDOR/  MANUFACTURER OF THE FULL RESPONSIBILITY AS TO DESIGN CORRECTNESS OF DIMENSIONS & COMPLIANCE WITH ALL APPLICABLE REGULATIONS AND WITH THE REQUIREMENTS MADE IN PURCHASER SPECIFICATIONS.  1. WORK MAY PROCEED.   2A. REVISE & RESUBMIT, WORK MAY PROCEED  SUBJECT TO IN CORPORATION OF CHANGE INDICATED.   2B. REVISE & WORK MAY PROCEED SUBMIT AS BUILT DRAWING ONLY. 3. REVISE & RESUBMIT, ENGG WORK MAY NOT PROCEED. DEPT. 4. REVIEW NOT REQUIRED, WORK MAY PROCEED.

1

15062-V009-ME-DD-0007-001

2

24

02/01/2013

ENGG DEPT. SULZER PUMPS (INDIA) LTD.

NAME:

By kolinit at 10:18DATE: am, Aug 06, 2016 THE REVIEW/APPROVAL DOES NOT RELIEVE THE VENDOR/  MANUFACTURER OF THE FULL RESPONSIBILITY AS TO DESIGN CORRECTNESS OF DIMENSIONS & COMPLIANCE WITH ALL APPLICABLE REGULATIONS AND WITH THE REQUIREMENTS MADE IN PURCHASER SPECIFICATIONS.  1. WORK MAY PROCEED.   2A. REVISE & RESUBMIT, WORK MAY PROCEED  SUBJECT TO IN CORPORATION OF CHANGE INDICATED.   2B. REVISE & WORK MAY PROCEED SUBMIT AS BUILT DRAWING ONLY. 3. REVISE & RESUBMIT, ENGG WORK MAY NOT PROCEED. DEPT. 4. REVIEW NOT REQUIRED, WORK MAY PROCEED.

1 15062-V009-ME-DD-0007-002

2

25

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No.

Sulzer Pumps India Ltd. SSD1002286690010-01 15062-V009-ME-DD-0009-001

Document Title

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Seal System drawings & Data sheet- Crude Export Pump

Status Code

V009 04 04 DD 1 of 12

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only X Reviewed By Signature

Date

19-07-17

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

04 03 02 01

1-Jun-17 8-May-17 1-Sep-16 1-Aug-16

Review/Approval Review/Approval Review/Approval Review/Approval

SMK SMK SMK SMK

DP DP DP DP

NT NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

26

SHEET 1 OF 4

1

PN5

PN3 2A 2B 5A

7G

7K

Schlumberger Document Review 1. Review without Comment

6G,7L 7N

2. Comment as noted Revise & Re-submit

3B

1A

PN2

4G,5E

2B

4F

6G,7L 7N

4C 4D

4A 5A

7B

7J

4. Noted for Information Only

ENGG DEPT. SULZER PUMPS (INDIA) LTD.

3A

2B

6G 7N

NAME:

4B 5A 3A

THE REVIEW/APPROVAL DOES NOT RELIEVE THE VENDOR/  MANUFACTURER OF THE FULL RESPONSIBILITY AS TO DESIGN CORRECTNESS OF DIMENSIONS & COMPLIANCE WITH ALL APPLICABLE REGULATIONS AND WITH THE REQUIREMENTS MADE IN PURCHASER SPECIFICATIONS. 

PN7

4B 5A

7P

3A 2B 2B

2B

2A 2B 6G,7L 7N

6H,7H 6J

3D 6G,7L 7N

4A 5A

NOZZLE SCHEDULE 5A

6G,7L 7N 2B

CONFIGURATION NO: 845A022

MARK SIZE & SCHEDULE ASME RATING

7F

6K

FLANGE STD/ TYPE FASTENERS

PN1

20NB SCH 160

900 #

TO SEAL

ASME B16.5 - WNRTJ

-

7C

PN2

20NB SCH 160

900 #

FROM SEAL

ASME B16.5 - WNRTJ

-

PN3

20NB SCH 160

900 #

VENT

ASME B16.5 - WNRTJ

6A, 6B, 6C

PN4

20NB SCH 160

900 #

DRAIN

ASME B16.5 - WNRTJ

6A, 6B, 6C

PN5

20NB SCH 160

900 #

TO COOLER

ASME B16.5 - WNRTJ

6A, 6B, 6C

PN6 PN7

20NB SCH 160 1/2" NPT

900 # -

FROM COOLER ASME B16.5 - WNRTJ FILLING CONNECTION -

6A, 6B, 6C 6A, 6B, 6C

General tolerances according to

EN ISO 13920 D No. Modification

Mechanical seal Drawing no.

-

SCHLUMBERGER LTD.

S.O. NO.

16404657

## - KOC - JURASSIC NON ASSOCIATED : PHE-2; SABRIYAH AND UMM NIQA FIELD

DESCRIPTION

7D PN1

Nominal Dimensions [ mm ] Tolerances [ mm ]

Date

2-30

30-120

120-400

400-1000

1000-2000

2000-4000

u1

u4

u7

u9

u 12

u 16

Name

Date Drawn 14/07/16 By Checked 14/07/16 By Approved 14/07/16 By

Customer

SULZER PUMPS INDIA LTD.

Consultant

Eqpt. Make

SULZER PUMPS INDIA LTD.

Job NO.

-

DOR NO.

NA

Scale

Eqpt. Type

GSG

Project

##

Site

SABRIYAH

SUPPLY SYSTEM TITLE

Eqpt. Size

100-300 (E) (Bd)

End User

KUWAIT OIL COMPANY, KUWAIT

Size/Area

NA

O.E.M. W.O. NO.

W/O.1616020/01

Eqpt. NOs.

JPF1-G-104 A/B/C (DE & NDE)

Vessel Capacity 35 LTRS

Media -

STABILIZED CRUDE OIL

Service

CRUDE EXPORT PUMPS

Master no.

NA

1 0

ORT. CHANGED

APPROVAL

08/08/16 14/07/16

SCP NGB

Drg. No.

Originated from - Ref. Drg. no. SYS04134

DRAWN

APPR'D

DATE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

2A. REVISE & RESUBMIT, WORK MAY PROCEED  SUBJECT TO IN CORPORATION OF CHANGE INDICATED.   2B. REVISE & WORK MAY PROCEED SUBMIT AS BUILT DRAWING ONLY. 3. REVISE & RESUBMIT, ENGG WORK MAY NOT PROCEED. DEPT. 4. REVIEW NOT REQUIRED, WORK MAY PROCEED.

Name NGB PRP

EARLY PRODUCTION SYSTEMS (EPS)

AJC

NTS

PROJECT TITLE:

API PLAN 53B

JURASSIC PRODUCTION FACIITY (JPF) AT SABRIYAH

Rev. Issue Ref No.

S Y S 0 4 3 1 4

1

A

All dimensions are in mm

Replacement for

If in doubt, ask AMENDMENTS

By Vaibhav Shedge at 5:25 pm, Aug 12, 2016 DATE:

1. WORK MAY PROCEED.  

6G,7L 7N

PN4

REV

Document No.:

3A

4A 5A 3A

REFERENCE DRAWINGS TITLE

Revision No.:

Date:

4A,4D 4E

3E

REF. DWGS. NO.

Signature:

4C 4D

2C

NO STITCH WELDING ALLOWED

Reviewed By: PN6

3C

7M

2B 6L

1C

1F 4C

6G,7L 7N

1E

3. Rejected New Dwg/Doc Required

1B 4C

4A,4D 4E 3A

7A 2B

7E

CAD A1

NAME

API PLAN53B FOR JPF1-G-104 A/B/C (DE & NDE) DRAWING NUMBER

KOC APPROVALS DESIGNATION GROUP/TEAM

DRAWING TITLE:

SIGNATURE

DATE

CONTRACTOR DRG.No. 15062-V009-ME-DD-0009-001 15062-V009-ME-DD-0009-001 PROJECT REFERENCE: 15062

REV. KOC DRG.No.

4A

SCALE:

REV.

NTS A1

DO NOT SCALE IF IN DOUBT ASK

27

SHEET 2 OF 4

cP lpm kg kg kg/cm²(g) / psi (g)

NAME PLATE DETAILS

VENT LABEL DETAILS

EagleBurgmann India Pvt. Ltd. API PLAN 53B S Y S 0 4 3 1 4 16404657

SR. No. REFER TABLE-1

W/O.1616020/01 COMPONENTS

84.64 kg/cm²(g) @ M.A.W.T. 93°C

STAINLESS STEEL

FLANGES & FITTINGS

A182 Gr. F316L A403 WP316L A312 TP 316L / SEAMLESS PIPES / TUBE / A213 TP 316L / PIPE CAP A403 WP316L NUTS (HEAVY) - Zn-Ni PLATED STUDS/BOLTS - Zn-Ni PLATED VALVES (BODY) A182 Gr. F316L PLATES / BARS A240 TYPE 316L / A479 TYPE 316L

126.96 kg/cm²(g) @ Amb. Temp. **** 1203.81 psi (g) @ M.A.W.T. 199.4 °F 1805.79 psi (g) @ Amb. Temp.

SS 316L COMM. GRADE

A36 / IS 2062 OR EQ.

**** RELEVANT YEAR TO BE INCORPORATED AT THE TIME OF DISPATCH.

COMPONENTS

DESCRIPTION

REF. STD.

FLANGE

ASME B 16.5

SW FITTINGS BW FITTINGS & PIPE CAP PIPE SEAMLESS GASKET

ASME B 16.11 ASME B 16.9 ASME B 36.10 ASME B 16.20

NO STITCH WELDING ALLOWED

TUBE SIDE

BARRIER MEDIA $$

TEMP. (°C)/(°F) INLET

OUTLET

FLOW RATE (LPM)

73.5°C / 164.3°F 60°C / 140°F

TABLE‐1 EQPT No.

SR.No.

5

$$ - OIL ISO VG10 (RECOMMENDED)

B1

AMBIENT TEMPERATURE : -3 TO 55 °C / 26.6 TO 131 °F COOLER DATA 5.37 m² 1) REQUIRED SURFACE AREA 2) ACTUAL SURFACE AREA 10 m² 3) TOTAL HEAT LOAD 1994.4 Watts

D1

JPF1‐G‐104 A (DE) JPF1‐G‐104 B (DE) JPF1‐G‐104 C (DE) JPF1‐G‐104 A (NDE) JPF1‐G‐104 B (NDE) JPF1‐G‐104 C (NDE) TOTAL QTY.

Mechanical seal Drawing no.

-

SCHLUMBERGER LTD.

S.O. NO.

16404657

## - KOC - JURASSIC NON ASSOCIATED : PHE-2; SABRIYAH AND UMM NIQA FIELD

230 1INSTRUMENTS

CONFIGURATION NO: 845A022

TABLE-2

QTY. 1 1 1 1 1 1

260 325

-

A194 Gr.2H A193 Gr.B7 A36 / IS 2062 OR EQ.

5D

DN20 SCH 160 PIPE WITH BW END

2FLANGES

RTJ GASKET OTHERS

CARBON STEEL -

5C

5D

DN20 SCH 160 PIPE WITH BW END

ASTM GRADE TABLE

REFER TABLE-1

DIMENSIONAL REF. STANDARD

5B

5-PIPES

TITLE GA DRG. No. P.O.No. EBIPL S.O. No. OEM W.O. No. EQPT. No. M.A.W.P. HYDROTEST PR. YEAR OF MFG. M.A.W.P. HYDROTEST PR.

2D

6- FASTENERS

ALL SEAL FLUSHING LINESMUST BE SUFFICIENTLY VENTED TO ENSURE THAT THERE ARE NO TRAPPEDAIR/GAS POCKETS. THIS IS A MANDATORY REQUIREMENT FOR SATISFACTORY PERFOR MANCE OF THE MECHANICAL SEAL.

R

1D

6D,6E 6F

7 - GENERAL

QHP 35 84.64 /1203.81 @ 93 °C /199.4 °F 126.96 /1805.79 @ Amb. Temp. 0.7 / 10 8.2 / 116.6 6.8 / 96.7 ASME SECTION VIII. DIV. 1 (WITH CODE STAMP) OIL ISO VG10 0.845 8.45 5 ~ 400 ~ 425 7.3 / 103.8

Ltrs. kg/cm²(g) / psi (g) kg/cm²(g) / psi (g) kg/cm²(g) / psi (g) kg/cm²(g) / psi (g) kg/cm²(g) / psi (g)

4 - FITTINGS

BARRIER MEDIA (RECOMMENDED) BARRIER MEDIA SP.GRAVITY BARRIER MEDIA VISCOSITY BARRIER MEDIA FLOW RATE REQUIRED SYSTEM TOTAL WEIGHT (EMPTY) SYSTEM TOTAL WEIGHT (FILLED) LOW PRESSURE ALARM (FALLING)

1) ALL WELDED FLANGES FITTINGS ARE BUTT WELD TYPE. 2) ALL STD. THREADED FITTINGS NPT ARE OF 6000 #. USE OF TEFLON TAPE IS NOT ALLOWED. 3) ALL RTJ 900# FLANGES GROOVES SHALL HAVE A SURFACE FINISH OF 63 AARH. 4) HYDROTEST WITH ALL INSTRUMENTS ISOLATED. 5) MOUNT THE PLAN AS NEAR TO THE SEAL AS POSSIBLE (NOT DIRECTLY ABOVE THE PUMP) 6) PUMP OEM TO PROVIDE SUITABLE SUPPORTS FOR HEAVY EXTENDED PIPE/CONNECTIONS. 7) AVOID 90 DEGREE SHARP BENDS, USE SMOOTH LONG RADIUS BENDS. 8) ALL LINES SHALL SLOPE UP FROM THE SEAL GLAND TO THE COOLER TO AVOID AIR POCKETS. 9) ALL C.S./M.S. PARTS TO BE ZINC CHROMATE RED OXIDE PRIMERED, FINAL PAINTING IN PUMP OEM SCOPE OF SUPPLY. 10) RADIOGRAPHY APPLICABLE AS PER APPROVED QAP. 11) NACE MR-0175/0103 & PMI TO BE DONE AS PER APPROVED QAP, IF APPLICABLE. 12) INSTRUMENTS & VALVES ARE INDICATIVE PICTORIALLY , ACTUAL SIZE, SUPPLY MAY NOT RESEMBLE THESE PICTURES. 13) U-STAMPING WILL BE APPLICABLE ONLY UPTO FIRST NOZZLE AS PER ASME & U-STAMPING STANDARDS. SO ONLY ACCUMULATOR WILL BE U-STAMPED. 14) ONLY SIZING OF BLADDER ACCUMULATOR IS DONE AS PER API 682 4TH EDITION.

DETAILS

3-VALVES

BLADDER ACCUMULATOR MAKE ACCUMULATOR CAPACITY SYSTEM M.A.W.PRESSURE @ M.A.W.T. SYSTEM HYDROTEST PRESSURE @ AMB. TEMP. STUFFING BOX PRESSURE SYSTEM OPERATING PRESSURE PRECHARGE PRESSURE DESIGN REFERANCE CODE FOR ACCUMULATOR

TO BE SUPPLIED LOOSE & MOUNTED AFTER NOZZLE PN1 & BEFORE SEAL

GENERAL NOTES:-

UNIT

170

DESIGN PARAMETERS DESCRIPTION

7N 7M 7L 7K 7J 7H 7G 7F 7E 7D 7C 7B 7A 6L 6K 6J 6H 6G 6F 6E 6D 6C 6B 6A 5E 5D 5C 5B 5A 4G 4F 4E 4D 4C 4B 4A 3E 3D 3C 3B 3A 2D 2C 2B 2A 1F 1E 1D 1C 1B 1A

Support Plate Angle Strainer (100 mesh) Angle Canopy - PT Air Fin Cooler Assembly with Mounting Stand Accumulator Bracket Mounting plate Lifting Lug Gusset Plate Pole With Top Plate Pole Base Plate - Top Pole Base Plate - Bottom (SPIL'S SCOPE) Vent Label Nameplate Hex Head Bolt Hex Head Bolt (SPIL'S SCOPE) Hex Nut Hex Head Bolt U Clamp with Nuts Gasket Stud Hex Nut Gasket Stud Hex Nut Tube Pipe Cap Pipe Pipe Pipe Plug Male Connector Plug Adapter St. Nipple Fourway Tee Quick Relief Coupling Non Return Valve Double Block & Bleed Valve Gate Valve - Welded Bonnet Gate Valve - Welded Bonnet Flange Flange Flange Blind Flange Pressure Transmitter-I Motor Temp.Gauge With Thermowell Pressure Gauge with gauge saver Pressure Transmitter Accumulator with clamp & support

NO. S.No. DESCRIPTION General tolerances Nominal Dimensions [ mm ] according to

2000-4000

u4

u7

u9

u 12

u 16

Date

SULZER PUMPS INDIA LTD.

Job NO.

-

DOR NO.

NA

Scale

Eqpt. Type

GSG

Project

##

Site

SABRIYAH

SUPPLY SYSTEM TITLE

Eqpt. Size

100-300 (E) (Bd)

End User

KUWAIT OIL COMPANY, KUWAIT

Size/Area

NA

O.E.M. W.O. NO.

W/O.1616020/01

Eqpt. NOs.

JPF1-G-104 A/B/C (DE & NDE)

Vessel Capacity 35 LTRS

Media -

STABILIZED CRUDE OIL

Service

CRUDE EXPORT PUMPS

Master no.

NA

Drg. No.

Originated from - Ref. Drg. no. SYS04134

REFERENCE DRAWINGS TITLE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

1

1

Name NGB PRP

EARLY PRODUCTION SYSTEMS (EPS)

AJC

NTS

PROJECT TITLE:

API PLAN 53B

JURASSIC PRODUCTION FACIITY (JPF) AT SABRIYAH

Rev. Issue Ref No.

S Y S 0 4 3 1 4

1

A

All dimensions are in mm

Replacement for

If in doubt, ask REF. DWGS. NO.

1

REMARKS

u1

Eqpt. Make

SCP NGB

MOC

1000-2000

Consultant

08/08/16 14/07/16

--150 X 150 X 8 Box Section 1870 mm Long Refer Sheet 3 OF 4 Refer Sheet 3 OF 4 --3/4" UNC x 75mm Long M20 X 40 Long M12 M12 X 50 Long M10 X To Suit DN 20 Pipe OCTAGONAL GASKET RING SIZE R-20 M24 X 150 LONG M24 OCTAGONAL GASKET RING SIZE R-14 M20 X 125 Long M20 1/4" OD X 0.065" thk. DN100 - SCH160 DN100 - SCH160 Seamless DN40 - SCH160 Seamless DN20 - SCH160 Seamless 1/4" NPT(M) 1/4" NPT(M) X TO SUIT 1/4" OD TUBE 1/2" NPT(M) - 6000# DN 20 BW X 1/2" NPT(M) - 6000# 1/2" NPT(M) - 6000# DN20 BW - SCH160 DN20 BW - SCH160 1/2" NPT DN20 BW - 1500# 1/2" NPT(F) X 1/2" NPT(F) DN20 BW - 1500# - Lock Closed DN20 BW - 1500# DN40 - 900# - WNRTJ DN20 - 900# - BLRTJ WITH 1/2" NPT BORE DN20 - 900# - WNRTJ DN20 - 900# - BLRTJ PTISYS04314 FCMSYS04314 TGSYS04314 PGSYS04314 PTSYS04314 BACSYS04314

400-1000

SULZER PUMPS INDIA LTD.

APPROVAL

Refer Sheet 4 OF 4 Refer Sheet 3 OF 4

120-400

Customer

ORT. CHANGED

1

--

30-120

Drawn 14/07/16 By Checked 14/07/16 By Approved 14/07/16 By

1 0

DN20 BW - 800# 50 X 50 X 5 THK

2-30

Name

6

SS 304 F 316L / ASTM A 351 Gr.CF3M M.S. M.S. (Powder Coated) -M.S. M.S. M.S. M.S. M.S. M.S. SS 304 SS 304 Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table SS 304 Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table TP 316L WP 316L TP 316L TP 316L TP 316L SS 316L SS 316L SS 316L F 316L SS 316L WP 316L WP 316L F 316L F 316L SS 316L F 316L F 316L F 316L F 316L F 316L F 316L As per Datasheet As per Datasheet As per Datasheet As per Datasheet As per Datasheet As per Datasheet

QTY

Tolerances

EN ISO 13920 D [ mm ] No. Modification Date

9 1 2.5 m 2 1 1 1 4 1 1 1 1 1 4 4 4 4 9 1 4 8 7 24 48 0.4 m 2 0.4 m 0.4 m 4.0 m 3 3 3 6 5 2 6 1 1 3 1 6 1 1 10 2 1 1 1 1 1 1

CAD A1

NAME

API PLAN53B FOR JPF1-G-104 A/B/C (DE & NDE) DRAWING NUMBER

KOC APPROVALS DESIGNATION GROUP/TEAM

DRAWING TITLE:

SIGNATURE

DATE

CONTRACTOR DRG.No. 15062-V009-ME-DD-0009-001 15062-V009-ME-DD-0009-002 PROJECT REFERENCE: 15062

REV. KOC DRG.No.

A 4

SCALE:

REV.

NTS A1

DO NOT SCALE IF IN DOUBT ASK

28

SHEET 3 OF 4 C.G. = CENTER OF GRAVITY

VIEW 'X'

1

PN4

PN7

~ 1940 300

700 270

'X'

75

210

300

180

250

PN2

75

PN3

PUMP

200

MOTOR

NOTE : - DIMENSIONS MARKED "$$" ARE CUSTOMER INTERFACING DIMENSIONS AND NEED TO BE MAINTAINED. OTHERS ARE FOR MANUFACTURING REFERENCE.

390

400 (TYP)

400

C.G. 1430 ±15

PN1

225

250 FOR PG

360 'PN2' ONLY 225

400

~ 950

210

$$ 550

C.G.

7D

$$ 250 SQ. = =

C.G. 150

O 20

550

10

$$ 300 SQ.

30 $$ 300

284

153

840

=

4 x O 14

4 X M20 20 THK.

General tolerances according to

EN ISO 13920 D No. Modification

NO STITCH WELDING ALLOWED

200

=

16 THK.

$$ 625

$$ 250

250 SQ. = =

70

120

$$ 150 225

300 SQ.

260

$$ 500

480 150

$$ 500

7C

7H

800

890 (C.G.)

800 640

CONFIGURATION NO: 845A022

210 316

$$ 4 x O 22

20 THK.

1

Mechanical seal Drawing no.

-

SCHLUMBERGER LTD.

S.O. NO.

16404657

## - KOC - JURASSIC NON ASSOCIATED : PHE-2; SABRIYAH AND UMM NIQA FIELD

Nominal Dimensions [ mm ] Tolerances [ mm ]

Date

30-120

120-400

400-1000

1000-2000

2000-4000

u1

u4

u7

u9

u 12

u 16

Name

Date Drawn 14/07/16 By Checked 14/07/16 By Approved 14/07/16 By

Customer

SULZER PUMPS INDIA LTD.

Consultant

Eqpt. Make

SULZER PUMPS INDIA LTD.

Job NO.

-

DOR NO.

NA

Scale

Eqpt. Type

GSG

Project

##

Site

SABRIYAH

SUPPLY SYSTEM TITLE

Eqpt. Size

100-300 (E) (Bd)

End User

KUWAIT OIL COMPANY, KUWAIT

Size/Area

NA

O.E.M. W.O. NO.

W/O.1616020/01

Eqpt. NOs.

JPF1-G-104 A/B/C (DE & NDE)

Vessel Capacity 35 LTRS

Media -

STABILIZED CRUDE OIL

Service

CRUDE EXPORT PUMPS

Master no.

NA

1 0

ORT. CHANGED

APPROVAL

08/08/16 14/07/16

SCP NGB

Drg. No.

Originated from - Ref. Drg. no. SYS04134

SPIL'S SCOPE

2-30

Name NGB PRP

EARLY PRODUCTION SYSTEMS (EPS)

AJC

NTS

PROJECT TITLE:

API PLAN 53B Rev. Issue Ref No.

S Y S 0 4 3 1 4

1

REFERENCE DRAWINGS TITLE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

A

All dimensions are in mm

Replacement for

If in doubt, ask REF. DWGS. NO.

JURASSIC PRODUCTION FACIITY (JPF) AT SABRIYAH

CAD A1

NAME

API PLAN53B FOR JPF1-G-104 A/B/C (DE & NDE) DRAWING NUMBER

KOC APPROVALS DESIGNATION GROUP/TEAM

DRAWING TITLE:

SIGNATURE

DATE

CONTRACTOR DRG.No.

15062-V009-ME-DD-0009-003 15062-V009-ME-DD-0009-001 PROJECT REFERENCE: 15062

REV. KOC DRG.No.

4A

SCALE:

REV.

NTS A1

DO NOT SCALE IF IN DOUBT ASK

29

SHEET 4 OF 4

7J - AIR FIN COOLER ASSYWITH MOUNTING STAND DETAILS.

7J.20

25 ±1

150

PN5

7J.22 7J.23 7J.7

20

=

2 x M16

20 (TYP)

20

100

60 ±1 = =

455

100

1090

150

60 ±1 = =

=

7J.21

30 (TYP)

20 Thk.

7J.1

7J.6 7J.13 7J.14

7J.16 7J.17 7J.22 7J.23

20 Thk. PN6

SPIL'S SCOPE

7J.8 7J.15

600

7J.26

7J.7

7J.2 7J.19

34

74

7J.4 7J.5

7J.18 7J.24

120

760

1006

200 390

CONFIGURATION NO: 845A022

620

800

184

376

7J.25

790

440 ±1 600

7J.26 7J.25 7J.24 7J.23 7J.22 7J.21 7J.20 7J.19 7J.18 7J.17 7J.16 7J.15 7J.14 7J.13 7J.12 7J.11 7J.10 7J.9 7J.8 7J.7 7J.6 7J.5 7J.4 7J.3 7J.2 7J.1

Earthing Boss With M6 Tapping Name Plate With Bracket Washer (SPIL'S SCOPE) Pipe Flange Base Plate - Bottom (SPIL'S SCOPE) Base Plate - Top C - Channel (Cooler Mounting Stand) Hex Bolt (SPIL'S SCOPE) Nut Hex Bolt Socket Head Cap Screw Nut Hex Bolt Nut Hex Bolt Nut Hex Bolt Pipe Clamps Plate Support Cover Assy Frame Assy. Base Frame Assy. Motor Cooling Coil Assy. Air Fin Cooler

1 1 4 0.3 m 2 4 4 4 8 5 5 4 14 14 6 6 4 4 2 1 1 1 1 1 1 1

NO.

DESCRIPTION

QTY

General tolerances according to

EN ISO 13920 D

1090

NO STITCH WELDING ALLOWED

No. Modification

Mechanical seal Drawing no.

-

SCHLUMBERGER LTD.

S.O. NO.

16404657

## - KOC - JURASSIC NON ASSOCIATED : PHE-2; SABRIYAH AND UMM NIQA FIELD

Nominal Dimensions [ mm ] Tolerances [ mm ]

7J.21 7J.20

Date

400-1000

1000-2000

2000-4000

u7

u9

u 12

u 16

Name

Date

SULZER PUMPS INDIA LTD.

Job NO.

-

DOR NO.

NA

Scale

Eqpt. Type

GSG

Project

##

Site

SABRIYAH

SUPPLY SYSTEM TITLE

Eqpt. Size

100-300 (E) (Bd)

End User

KUWAIT OIL COMPANY, KUWAIT

Size/Area

NA

O.E.M. W.O. NO.

W/O.1616020/01

Eqpt. NOs.

JPF1-G-104 A/B/C (DE & NDE)

Vessel Capacity 35 LTRS

Media -

STABILIZED CRUDE OIL

Service

CRUDE EXPORT PUMPS

Master no.

NA

SCP NGB

Drg. No.

Originated from - Ref. Drg. no. SYS04134

REMARKS

120-400

Eqpt. Make

08/08/16 14/07/16

-

MOC u4

Consultant

APPROVAL

0.75 kW Exd -

30-120

SULZER PUMPS INDIA LTD.

ORT. CHANGED

M16 DN20- SCH160 DN20 - WNRTJ - 900# ISMC 100 x 50 x 765 Long. M16 X 40 Long M12 M12 X 35 Long M6 X 20 Long M6 M6 X 20 Long M10 M10 X 25 Long M16 M16 X 35 Long

u1 Drawn 14/07/16 By Checked 14/07/16 By Approved 14/07/16 By

1 0

M.S. SS 304 M.S TP316 L F316 L M.S M.S M.S Refer ASTM Grade Table Refer ASTM Grade Table Refer ASTM Grade Table A2-40 A2-40 A2-40 A2-40 A2-40 Refer ASTM Grade Table Refer ASTM Grade Table SS 304 IS 2062 M.S M.S M.S SS 316L + Al. Fins -

2-30

Customer

Name NGB PRP

EARLY PRODUCTION SYSTEMS (EPS)

AJC

NTS

PROJECT TITLE:

API PLAN 53B

REFERENCE DRAWINGS TITLE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

JURASSIC PRODUCTION FACIITY (JPF) AT SABRIYAH

Rev. Issue Ref No.

S Y S 0 4 3 1 4

1

A

All dimensions are in mm

Replacement for

If in doubt, ask REF. DWGS. NO.

7J.19

IN BELOW BILL OF MATERIAL ONLY QTY. FOR MOTOR IS INCLUDED IN SHEET 2 OF 4.

7J.3

840 ±1

7J.19

NOTES: 1) FOR ASTM GRADE TABLE & PAINTING DETAILS REFER SHEET 2 OF 4 2) FOR NOZZLE SCHEDULE DETAILS REFER SHEET 1 OF 4

7J.11 7J.12

130

7J.9 7J.10

CAD A1

NAME

API PLAN53B FOR JPF1-G-104 A/B/C (DE & NDE) DRAWING NUMBER

KOC APPROVALS DESIGNATION GROUP/TEAM

DRAWING TITLE:

SIGNATURE

DATE

CONTRACTOR DRG.No.

15062-V009-ME-DD-0009-004 15062-V009-ME-DD-0009-001 PROJECT REFERENCE: 15062

REV. KOC DRG.No.

A 4

SCALE:

REV.

NTS A1

DO NOT SCALE IF IN DOUBT ASK

30

BLADDER ACCUMULATOR UNITS : Flow - Liquid - m3/hr., Gas - Nm3/hr., Steam - Kg/hr., Pressure - kg/cm²-(g), Temp.- C, Length - mm

TYPE

BLADDER ACCUMULATOR

MOUNTING

DIRECT

ACCUMULATOR VOLUME

35 L

EFFECTIVE GAS VOLUME

35.2 L

SHELL DESIGN PRESSURE

84.64 (1203.81) kg/cm²-(g)(psig)

HYDROSTATIC TEST PRESSURE

126.96 (1805.79) kg/cm²-(g)kg/cm²-(g)(psig)

SHELL MATERIAL

SS316L

BLADDER MATERIAL

NITRILE (BUNA - N)

SELECTION CRITERIA

ISOTHERMAL CONDITION 8.5(120.89)

PRECHARGE PRESSURE

10 (142.23)

SYSTEM WORKING PRESSURE [P2]

Notes for Plan

Notes for Spares

QHP

Model Decodification

4

kg/cm2 (psig)

BARRIER MEDIA (RECOMMENDED)

Oil ISO VG10

BLADDER DESIGN TEMP.

80 Deg.C

FLUID PORT CONNECTION

2" X 3/4" Flanged 900#/ 1500# RTJ

NITROGEN CONNECTION

1/4" BSP(M) Gas Valve

U Stamp Required

YES

SERVICE

ACC. FOR API PLAN 53B

2

Material Test, Hydrotest & NACE MR-0175 (Compliance) certificate required. (1) Accumulator shell to be hydrotested without bladder. (2) SS Tag plate required. (3) For 28L & below capacity Accumulator provide single Clamp & Bracket, Above this provide Two Clamp , & One Bracket. (4) Clamp & Bracket are included in MRP code 1 #(I1) Nitrogen Kit = 1 no (MRP CODE : 166800459)



NO-DEVIATION

DEVIATION Make

kg/cm2 (psig)

DE SIDE- 0.7 (10) kg/cm2 (psig) NDE SIDE- 2.23 (31.71) kg/cm2 (psig)

BOX PRESSURE [P1]

Certification

@ 93 (199.4) Deg C(Deg F)

Model No QBF-35-A0-6-2B-A7-08-5

MRP Code

Drawing No 869B111-0

166800447 QBF- Fabricated Bladder accumulator 35-35 Ltr volume A0- Bladder Material: Nitrile Elastomeric Seals: NBR 6- Standard 1/4" BSP(M) Gas Valve, 2B- All Wetted parts & Fabricated shell in SS 316 with stem (17/4ph), A7- Fluid End: Stainless Steel Process Connection: - 3/4" 900# / 1500# RTJ 08-Design Pressure: 84.64 kg/cm²-(g), 5- Design: In accordnce with ASME "U" stamp 3

3

Hydrotest Pr. Qty. (Plan/Spares)

Model Make GA Drg. No. DOR No. SO No.

REFER ABOVE 6/# REFER TABLE REFER TABLE SYS04314 16404657 (B1,D1)

1

Item No. Pump Type Client P.O. No. Service Work Order No. Project No. CLIENT END CLIENT CONSULTANT

PROJECT PLANT VENDOR

JPF1-G-104 A/B/C (DE + NDE) GSG 100-300 (E) (Bd) 4501002346 DTD :08.07.2016 CRUDE EXPORT PUMPS 1616020 SULZER PUMPS INDIA LTD KUWAIT OIL COMPANY, KUWAIT SCHLUMBERGER LTD. KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD SABRIYAH EAGLEBURGMANN INDIA PVT. LTD

1

4 3 2 1

As marked As marked As marked As marked

14.09.2016 11.08.2016 10.08.2016 29.07.2016

RUP RUP RUP RUP

PRP PRP PRP PRP

AJC AJC AJC AJC

0

For Approval

19.07.2016

RUP

PRP

AJC

Rev. No.

Modification

Date

Prepared By

Datasheet No

Checked By BACSYS04314

31

Approved By

PRESSURE GAUGE UNITS : Flow - Liquid - m3/hr., Gas - Nm3/hr., Steam - Kg/hr., Pressure - Kg/cm2g, Temp.- C, Length - mm

Direct

1. Type

1/2"NPT (M) Bottom

13. Connection Connection Location

Local

2. Mounting

SS316 NA NA NA NA NA NA NA NA NA NA

14. Movement 15. Diaphragm Seal

3. Dial

150 mm (6 inch) White with Black engraving

Size (mm) Color

Type Wetted Parts Matl. Other Matl.

4. Case Material

SS 316

5. Bezel Ring

Bayonet

6. Window Material

Shatterproof glass

7. Enclosure

Weather Proof to IP 67 as per IEC 60529

16. Over Range Protection

8. Pressure Element

Bourdon Tube

17. Blow Out Protection

9. Element Material

SS 316L

18. Options

10. Socket Material

SS 316L

B) Syphon

11. Accuracy

±1 % FSD

D) Liquid Filled Casing

12. Zero Adj.

Micrometer Pointer (External) (Refer Note-1)

Process Conn. Size & Rating Facing & Finish Capillary Material Capillary Length Armour Flexible-Material Filling Connection

150% of F. S.

No NA Yes ( MOC - SS 316L) Yes (Glycerin) NA S.S. Tag plate required with Tag No. NA Yes (SS 316L) (EBIPL scope of supply)_

A) Snubber C) Gauge Saver E) Vacuum Protection F) Tag Plate (S.S.) G) Solid Front H) Double Block & Bleed Valve

TAG NO.

104-PG-101 A/B/C 104-PG-102 A/B/C Service Certification

Notes for Plan

kg/cm2 (psig)

OPERATING PRESSURE kg/cm2 (psig)

0 to 20 (0 to 300)

10 (142.23)

RANGE

4

MAX. SERVICE PRESSURE

MAX. SERVICE TEMP.

kg/cm2 (psig)

Deg C (Deg F)

11 (156.45)

66.5 (151.7)

3

3

Back side

FLUID (Recommended)

OPTION ( Refer Sr No. 18)

Oil ISO VG10

C,D,F,H

Pressure Gauge for API PLAN 53B Material Compliance, Calibration, IP67 & NACE MR-0175 (Compliance) certificate required. 1.External means WITHOUT removing glass 2. PMI applicable for case and socket 3. The Pressure gauge shall be marked as follows : (a) Unit title. (b) Manufacturers full name. (c) Manufacturers full model number (d) Element material spec. and grade (e) Other key details, e.g., "To NACE MR01075"

2

4

Notes for Spares

Make BAUMER

Model Decodification

Hydrotest Pr.

NA

Item No.

JPF1-G-104 A/B/C (DE + NDE)

6/0

Pump Type

GSG 100-300 (E) (Bd)

Model

REFER TABLE

Client P.O. No.

4501002346

Make

REFER TABLE

Service

CRUDE EXPORT PUMPS

GA Drg. No. SO No.

MRP Code

853D433-0

055800809

3

AL- Model- H- Dial size 150 mm, 2-Direct bottom entry, 4NM-1/2" NPT (M) connection, Range - (0 to 20 kg/cm2-g )/ (0 to 300 psi-g),PY- Dampening liquid glycerine filled REIP67 Protection, RX- Shatter proof glass, GH- Material test certificates, EZ- External zero adjustment, SX- SS Tag plate, TF- NACE MR-0175 Certification, PW- 5 Point Calibration certificates, PS- Case & Bezel SS316 Bayonet type,SD- AISI 316 SS movement, ZL- Over range protection 150% of F. S. ED- Gauge Saver, E02- Piston type, BodySS316L, 4NM.4NF-Process Connection 1/2" NPT(MXF), TF- NACE MR-0175 Certification

Qty. (Plan/Spares)

DOR No.

DATASHEET No.

Model No. AL-H-2-4NM- (0 to 20 kg/cm2-g )/ (0 to300 psi-g))-PY-RE-RX-GH-EZ-SX-TF-PW-PSSD- ZL+ ED-E02-SS316L-4NM.4NF-TF

SYS04314 -

Work Order No.

1616020

Project No.

-

16404657 (B1,D1) CLIENT

DTD :08.07.2016

SULZER PUMPS INDIA LTD

END CLIENT

KUWAIT OIL COMPANY, KUWAIT

CONSULTANT

SCHLUMBERGER LTD.

PROJECT

KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD

PLANT

SABRIYAH

VENDOR

EAGLEBURGMANN INDIA PVT. LTD

1

4 3 2 1

As marked As marked As marked As marked

28.12.2016 14.09.2016 10.08.2016 29.07.2016

RUP RUP RUP RUP

PRP PRP PRP PRP

AJC AJC AJC AJC

0

For Approval

19.07.2016

RUP

PRP

AJC

Modification

Date

Prepared By

Rev. No.

Datasheet No

Checked By

Approved By

PGSYS04314

32

PRESSURE INSTRUMENTS (TRANSMITTER) UNITS : Flow - Liquid - m³/hr., Gas - Nm³/hr., Steam - Kg/hr., Pressure - Kg/cm²-g, Temp.- C, Length - mm

GENERAL 1. Function 2. Type

MEASURING UNITS TRANSMITTER (INDICATING) ELECTRONIC (Foundation Fieldbus) SST Housing Direct ZONE-1, Gas Gr. IIA /IIB, Temp. Cl. T3 Ex-proof + Weather proof NEMA 4X / IP66

3. Case 4. Mounting 5. Electrical Area Classification 6. Enclosure Enclosure class 7. Intrinsically Safe 8. Air Supply 9. Power Supply 10. Cable Entry 11. Accuracy 12. Repeatability

3

Yes (EExi-a) Not Applicable 9.0 to 17.5 VDC M20 X1.5 mm Dual (Refer Note-1 below) ± 0.04% of span Included in Accuracy. TRANSMITTER FF 9.0 to 17.5 VDC CONTROLLER Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

13. Output 14. Trans. Power Supply 15. Output 16. A/M Switch No. of position 17. Set Point Adjustment 18. Manual Regulator 19. Mode

TAG NO.

104-PT-101 A/B/C 104-PT-103 A/B/C

10 (142.23)

25. Body Material 26. Element Material 27. Process Connection 28. Process Conn. Location 29. Diaphragm Seal

SS 316 SS 316L 1/2" NPT (F) Bottom Entry Not Applicable

Wetted parts Material other Material Process Conn. Size & Rating Facing & Finish Capillary Material Armour Flexible Armour Flexible-Material Capillary Length Flush / Fill Conn. With Plug

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

30. Over Range Procetion

130% of range or maximum pressure, whichever is higher

31. Options A) IS Output meter B) Test jack (For calibration) 32. Load Driving Capablity

Not Applicable Not Applicable Not Applicable OPER. PRESS. kg/cm2 (psig)

PRESSURE Diaphragm

MISCELLANEOUS

RECORDER 20. Chart & Chart Drive 21. Moving Parts Material 22. Chart Speed

23. Service 24. Element

MAX. PRESS. kg/cm2 (psig)

Max. Temp. (Deg C)

RANGE kg/cm2 (psig)

11 (156.45)

66.5 (151.7)

-1,01 to 55,23 ('-14.7 to 800 psi )

SET PRESSURE kg/cm2 (psig)

CONTROL ACTION

FLUID (Recommended)

OPTION ( Refer Sr No. 31)

0 to 20 (0 to 300)

9 (128.01 ) (Falling )

Alarm

Oil ISO VG10

A

3

4

Certification Notes for Plan

Notes for Spares

Pressure Transmitter for API PLAN 53B Material Test, Calibration, NEMA 4X / IP66, IEC Ex , NACE MR 0175 (Compliance) & Intrinsically Safe Certificates required. 1. One entry with explosion-proof double compression SS 316 cable gland and other entry plugged with explosion-proof SS 316 plug.The cable glands should be with PVC hoods. 2. PMI applicable for socket only.

2

Model No.

Make Emerson

-

CALIBRATION RANGE kg/cm2

3

Service

Required -

DATASHEET No.

3051T-G-3-F-2B-2-1-K-K7-M5-Q4-Q8-T1-P1-Q15

858C210-0

3

MRP Code 3

062800602

Model De-Codification 3051T G 3 F 2B 2

In-Line Pressure Transmitter

K7

IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n

Gage -14.7 to 800 psi (-1,01 to 55,23 kg/cm2) FOUNDATION fieldbus Protocol 1/2–14 NPT Female (Process Connection Style) 316L (Isolating Diaphragm) SST(Process Connections Wetted Parts)

M5 Q4 Q8 T1 P1

LCD Display Calibration Certificate Material Traceability Certification per EN 10204 3.1. Transient Protection Terminal Block Hydrostatic Testing with Certificate

1

Silicone- fluid fill

K

SST/M20 × 1.5 -Electronics Housing Material

Hydrotest Pr. Qty. (Plan / Spares) Model Make

GA Drg. No. DOR No. SO No.

NA. 6/0 REFER TABLE REFER TABLE SYS04314 16404657 (B1,D1)

3

Q15

CONSULTANT

JPF1-G-104 A/B/C (DE + NDE) GSG 100-300 (E) (Bd) 4501002346 DTD :08.07.2016 CRUDE EXPORT PUMPS 1616020 SULZER PUMPS INDIA LTD KUWAIT OIL COMPANY, KUWAIT SCHLUMBERGER LTD.

PROJECT

KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD

Item No. Pump Type Client P.O. No. Service Work Order No. Project No. CLIENT END CLIENT

PLANT VENDOR

SABRIYAH EAGLEBURGMANN INDIA PVT. LTD

2

Certificate of Compliance to NACE MR0175/ISO15156 for wetted materials

1

4 3 2 1

As marked As marked As marked As marked

28.12.2016 14.09.2016 10.08.2016 29.07.2016

0

For Approval

19.07.2016

RUP

PRP

AJC

Rev. No.

Modification

Date

Prepared By

Checked By PTSYS04314

Approved By

Datasheet No

RUP RUP RUP RUP

PRP PRP PRP PRP

AJC AJC AJC AJC

33

PRESSURE INSTRUMENTS (TRANSMITTER) UNITS : Flow - Liquid - m3/hr., Gas - Nm3/hr., Steam - Kg/hr., Pressure - Kg/cm2g, Temp.- C, Length - mm

GENERAL 1. Function 2. Type

MEASURING UNITS TRANSMITTER (INDICATING) ELECTRONIC (SMART with HART 7 protocol) SST Housing Direct ZONE-1, Gas Gr. IIA /IIB, Temp. Cl. T3 Ex-proof + Weather proof NEMA 4X / IP66 Yes (EExi-a) Not Applicable 10.5 to 55 VDC / As per Emerson PDS M20 X1.5 mm Dual (Refer Note-1 below) ± 0.04% of span Included in Accuracy.

3. Case 4. Mounting 5. Electrical Area Classification 6. Enclosure Enclosure class 7. Intrinsically Safe 8. Air Supply 9. Power Supply 10. Cable Entry 11. Accuracy 12. Repeatability

3

TRANSMITTER 13. Output 14. Trans. Power Supply

4-20mA 2 Wire, 24V DC CONTROLLER

15. Output 16. A/M Switch No. of position 17. Set Point Adjustment 18. Manual Regulator 19. Mode

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

TAG NO.

104-PT-102 A/B/C 104-PT-104 A/B/C

10 (142.23)

Certification Notes for Plan Notes for Spares

Wetted parts Material other Material Process Conn. Size & Rating Facing & Finish Capillary Material Armour Flexible Armour Flexible-Material Capillary Length Flush / Fill Conn. With Plug

Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable Not Applicable

SET PRESSURE kg/cm2 (psig)

CONTROL ACTION

FLUID (Recommended)

OPTION ( Refer Sr No. 31)

11 (156.45)

66.5 (151.7)

-1,01 to 56.24 ('-14.7 to 800 psi )

0 to 20 (0 to 300)

9 (128.01 ) (Falling )

Alarm

Oil ISO VG10

A

3

3

Pressure Transmitter for API PLAN 53B Material Test, Calibration, NEMA 4X / IP66, IEC Ex , NACE MR 0175 (Compliance) & Intrinsically Safe Certificates required. 1. One entry with explosion-proof double compression SS 316 cable gland and other entry plugged with explosion-proof SS 316 plug.The cable glands should be with PVC hoods. 2. PMI applicable for socket only. 2 Model No.

DATASHEET No.

3051T-G-3-A-2B-2-1-K-HR7-K7-M5-Q4-Q8-D4-T1-P1-Q15

K

SST/M20 × 1.5 -Electronics Housing Material

GA Drg. No. DOR No. SO No.

NA. 6/0 REFER TABLE REFER TABLE SYS04314 16404657 (B1,D1)

858C211-0

3

HR7 K7 M5 Q4 Q8 D4

3

CONSULTANT

JPF1-G-104 A/B/C (DE + NDE) GSG 100-300 (E) (Bd) 4501002346 DTD :08.07.2016 CRUDE EXPORT PUMPS 1616020 SULZER PUMPS INDIA LTD KUWAIT OIL COMPANY, KUWAIT SCHLUMBERGER LTD.

PROJECT

KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD

Item No. Pump Type Client P.O. No. Service Work Order No. Project No. CLIENT END CLIENT

PLANT VENDOR

SABRIYAH EAGLEBURGMANN INDIA PVT. LTD

MRP Code 062800603

3

Configured for HART Revision 7 IECEx Flameproof, Dust Ignition-proof, Intrinsic Safety, and Type n LCD Display Calibration Certificate Material Traceability Certification per EN 10204 3.1. Analog Zero and Span

T1

Transient Protection Terminal Block

P1 Q15

Make

-

CALIBRATION RANGE kg/cm2

Silicone- fluid fill

Model

Required -

RANGE kg/cm2 (psig)

1

Qty. (Plan / Spares)

130% of range or maximum pressure, whichever is higher

Max. Temp. (Deg C)

Model De-Codification In-Line Pressure Transmitter 3051T Gage G -14.7 to 800 psi (-1,01 to 55,23 kg/cm2) 3 4–20 mA with Digital Signal Based on HART Protocol A 1/2–14 NPT Female (Process Connection Style) 2B 316L (Isolating Diaphragm) SST(Process Connections Wetted Parts) 2

Hydrotest Pr.

(for congealy. Corrosive service & highly viscous service)

MAX. PRESS. kg/cm2 (psig)

Make Emerson

SS 316 SS 316L 1/2" NPT (F) Bottom Entry

31. Options A) IS Output meter B) Test jack (For calibration) 32. Load Driving Capability

4

Service

25. Body Material 26. Element Material 27. Process Connection 28. Process Conn. Location 29. Diaphragm Seal

MISCELLANEOUS

Not Applicable Not Applicable Not Applicable OPER. PRESS. kg/cm2 (psig)

PRESSURE Diaphragm

30. Over Range Protection

RECORDER 20. Chart & Chart Drive 21. Moving Parts Material 22. Chart Speed

23. Service 24. Element

Hydrostatic Testing with Certificate 2

Certificate of Compliance to NACE MR0175/ISO15156 for wetted materials

1

4 3 2 1

As marked As marked As marked As marked

28.12.2016 14.09.2016 10.08.2016 29.07.2016

RUP RUP RUP RUP

PRP PRP PRP PRP

AJC AJC AJC AJC

0

For Approval

19.07.2016

RUP

PRP

AJC

Modification

Date

Prepared By

Checked By PTSYS04314

Approved By

Rev. No.

Datasheet No

34

TEMPERATURE GAUGE UNITS : Flow - Liquid - m3/hr., Gas - Nm3/hr., Steam - Kg/hr., Pressure - Kg/cm2g, Temp.- C, Length - mm FILLED SYSTEM Bi-metallic Every Angle Type

1. Type 2. Well

Required

3. Mounting

Local

4. Dial Size Colour

150 mm (6 inch) White with black engraving

5. Case Material

SS 316

6. Window Material

Shatterproof safety glass

7.Pointer & Movemnet MOC

SS 316

8. Conn. Location & size

Back & 1/2" NPT(M)

9. Accuracy

±1% FSD ,Class 1, as per EN 13190

10. Enclosure Enclosure Class 11. Zero Adjustment Screw 12.Stem Diameter 12A. TW Bore Diameter 13. Stem Length 14. Stem Material 15. Over Range Protection

Weatherproof IP 67 as per IEC 60529 Required (External) 9.5 mm ( 0.374 inch) 11 mm (0.43 inch) 400 mm (15.75 inch) SS 316 130 % of measuring range

16. SAMA Class Compensation 17. Bulb Type Bulb Material 18. Bulb Union threaded to 19. Extension Type 20. Bulb Diameter 21. Capillary Material

NA NA NA NA NA NA NA NA

THERMOWELL THERMOWELL

3

TEMP. TAG NO.

104-TG-101 A/B/C 104-TG-102 A/B/C

Certification for TG

Certification for TW

2 2

NA NA Required with Tag No.

WELL DIMN.

RANGE

Nor. / Max.

U - T

Deg. C (Deg F)

Deg. C (Deg F)

(mm)

0 to 100 (32 to 210)

55 / 66.5 (131 / 151.7)

AS PER 2 THERMOWELL DRG. 889A093-0

4

FLANGE MATERIAL

FLUID (Recommended)

OPTIONS ( Refer Sr No. 26)

Refer Sr. No 21 above

Oil ISO VG10

C

Material Compliance, Calibration & IP67 Certificate required. 1) 3.1 certifcation, Material Compliance, Hydrotest @ 125.5 (1785) kg/cm²-(g)kg/cm²-(g)(psig) Radiography for Bore concentricity & NACE MR-0175 (Compliance) certificate required. 2) PMI applicable for Thermowell. 3) Wake frequency calculation required Op. Pressure= 10 kg/cm2, Velocity= 0.092 m/sec , Fluid Sp.gravity = 0.8-0.9, Viscosity = 5-10 cP, Nozzel length = 170 mm 4) For Thermowell following information is required to be stamped on the flange rimor lagging extension: a.Instrument tag number b.Temperature range c.Flange rating & size d.Test presure e.Material f.Bore(elemnt) size

Notes for Plan

-

Notes for Spares

-

Make BAUMER

Model Decodification

Model No.

DATASHEET No.

CB-H-8-4NM-ZI-2I-400-(0-100 Deg C / 32 to 210 Deg F )-PS-PW-RS-RX-RH-GH-SX

060800453 3

CB- Industrial Bimetal Thermometer Basic Model, H-150 mm (Nominal Size) 8- Every angle back entry (Type of Mounting), 4NM- ½” NPT (M) (Gauge Connection), ZI- Adjustable (Process cnnection), 2I- 9.5mm (Stem Diameter), 400- 400 mm (Stem Length), (0-100 Deg C / 32 to 210 Deg F )-Temperature Range, PS- AISI 316 SS case & bezel, PW- Five point calibration certificate (for measuring range), RS-External zero adjustment, RX-Shatterproof / safety glass (Window Material), RH- Custom designed dial,GH- Material Certificates,SX- SS tag plate

Hydrotest Pr.

NA

Item No.

6/0

Pump Type

JPF1-G-104 A/B/C (DE + NDE) GSG 100-300 (E) (Bd)

Model

REFER TABLE

Client P.O. No.

4501002346

Make

REFER TABLE

Service

CRUDE EXPORT PUMPS

Work Order No.

1616020

GA Drg. No.

MRP Code

855B162-0 3

Qty. (Plan/Spares)

SO No.

SS316L Drilled bar stock 1 1/2 "-# 900 RTJ Flanged 1/2 "NPT (F) 889A093-0

Temperature Gauge for API PLAN 53B

Service

DOR No.

22. Material 23. Construction 24. Process Connection 25. Gauge Connection 26. Thermowell as per drg. 27. Options A) Liquid filled B) Mounting Bracket C) SS Tag Plate

SYS04314 16404657 (B1,D1)

DTD :08.07.2016

1

JOB NO

-

CLIENT END CLIENT

SULZER PUMPS INDIA LTD

CONSULTANT

SCHLUMBERGER LTD.

PROJECT

KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD

PLANT

SABRIYAH

VENDOR

EAGLEBURGMANN INDIA PVT. LTD

KUWAIT OIL COMPANY, KUWAIT

4 3 2 1

As marked As marked As marked As marked

28.12.2016 14.09.2016 10.08.2016 29.07.2016

0

For Approval

19.07.2016

RUP

Rev. No.

Modification

Date

Prepared By

Datasheet No

RUP RUP RUP RUP

PRP PRP PRP PRP

AJC AJC AJC AJC

PRP

AJC

Checked By TGSYS04314

Approved By

35

36

DATASHEET MEDIUM VOLTAGE SQUIRREL CAGE INDUCTION MOTOR

PURCHASER's DATA A. Site conditions 1 Ambient temperature,

2 B. 1 2 3 4 5 6

minimum: maximum: design:

1 50 45 95

Relative humidity: Technical particulars Motor tag no.: Driven equipment name: Voltage: Phase: Frequency: Fault level:

°C °C °C %

3 4 5 6

1

Atmospheric condition: Altitude: Location:

Humid & highly corrosive < 1000 m Outdoor

104-M-101 A/BC & 104-M-102 A/BC 440,+-10% V 3 50,+-5% Hz 50 KA for 1 sec

16 17 18 19

Hazardous area classification: Gas group/Temp class: Type of explosion protection: Type of ingress protection:

7 Method of starting:

Direct On Line

20 Color shade:

8 Winding connection:

Star

21 Thermisters:

9 10 11 12 13 14 15

No.of terminals: Cable size: Cable type: Temperature rise: Cooling: Insulation class:

3 1 * 3C, 6 sq mm Cu/Al cond. PVC insulated 75 °C TEFC F with temp rise limited to Class B.

1 2 3 4 5 6 7 8

Suggested motor rating: Manufacturer: BkW at full load: kW at end of curve: Speed: Rotation viewed from coupling end: Driven equipment: Coupling type:

1 2 3 4 5 6 7 8 9 10 11 12 13

Rating: Manufacturer: No. of poles: Frame designation: Full load speed: Mounting: Full load torque (FLT): Starting torque: Break down or pull out torque: Full load current (FLC): Starting current at 100% voltage: Rotation viewed from coupling end: Starting time at,

ZONE I IIA,IIB/T3 Ex d IP55 632 As per IS 5 Required

22 RTD: 23 BTD: 24 RTD/BTD monitoring device:

Not Required Not Required

Required

Not Required Required Not Required

1

25 Applicable specification:

1

KOC Spec. KOC-E-010

DRIVEN EQUIPMENT MANUFACTURER's DATA 0.75 EBIPL 0.62 NA 2820 Clockwise Fan NA

kW kW kW RPM

9 1

Torque required,

starting: maximum: including flywheel: excluding flywheel:

10 GD2 of eqpt., 11 Thrust,

up: down:

12 Starting condition:

NA NA NA NA NA NA Direct On Line

mkg mkg kgm2 kgm2 kg kg

MOTOR MANUFACTURER's DATA 0.75 kW CGL 2 E80 2820 RPM B3 (Foot mounted) 0.26 mkg 200 % of FLT 250 % of FLT 1.58 AMP 600 % of FLC Clockwise from DE <4 sec. <3 sec. 8/16 sec.

75% voltage: 100% voltage:

14 Locked rotor withstand time (cold/hot) at,

15 Space heater - voltage & power: 16 Applicable IS/IEC for hazardous area application:

N.A

IS:1231,IS:12075,IS:12065,IS:325,

17 Efficiency at,

75% voltage: 100% voltage: starting: 100% load:

18 Power factor at, 19 20 21 22 23 24

75 % 77 % 0.6-0.7 0.81 0.00 kgm2 BALL/6304ZZ BALL/6304ZZ Greased for life 23 kg no. quantity: type: no. quantity: type: no. quantity: type: NA V >125% RPM

Moment of inertia, GD2:

NDE bearing type & no.:

DE bearing type & no.: Type of lubrication: Weight of motor: Thermisters, make: 25 RTD, make: 26 BTD, make: 27 Shaft voltage: 28 Critical speed, 1st/2nd stage: 29 Canopy (FRP): 30 Vibration Level

Required

Not Required

Class B

1

Note: 1. The cable gland will be of M20 x 1.5P double compression fitting. Flying leads are not acceptable. 2. An engraved stainless steel name plate marked with equipment designation on the motor including area classification, area code, degree protection, bearing identification no. recommended lubricant and location of insulated bearing apart from the minimum information required by IS. 3. ATEX, Type test, Routine test certificate required. 4. All Performance figures are subject to IS 325-1996 tolerances. 5.For inverter driven motors, Max. allowed % THD for Voltage=3% & temp. rise is limited to ClassF limits 6.For inverter driven motors, Voltage spikes are allowed maximum1600 V &min. rise time of 0.1 microsecond. Cable length to be selectes accordingly. 1 7. Noise level at full load 79 dB(A) at 1 meter required

DATASHEET NUMBER 556A041-0 Hydrotest Pr.

NA

Item No.

Qty. (Plan/Spares)

6/0

Pump Type

GSG 100-300 (E) (Bd)

JPF1-G-104 A/B/C (DE + NDE)

Model

REFER ABOVE

Client P.O. No.

4501002346

Make

REFER ABOVE

Service

CRUDE EXPORT PUMPS

GA Drg. No. DOR No. SO No. & Item No.

SYS04314 16404657 (B1,D1)

MRP CODE 090800139

Work Order No.

1616020

Job No.

-

DTD :08.07.2016

Client

SULZER PUMPS INDIA LTD

End User

KUWAIT OIL COMPANY, KUWAIT

Consultant

SCHLUMBERGER LTD.

1

As marked

10.10.2016

RUP

PGT

AJC

Project

KOC - JURASSIC NON ASSOCIATED : PHASE-2; SABRIYAH AND UMM NIQA FIELD

0

For Approval

14.09.2016

RUP

PRP

AJC

Plant

SABRIYAH

Rev. No.

Modification

Date

Prep By

Vendor

EAGLEBURGMANN INDIA PVT. LTD

Datasheet No

Chkd By Appd By MOTORSYS04314

37

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. CCD1002286690010-01 15062-V009-ME-DD-0005-001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Coupling drawings - Crude Export Pump

Status Code

V009 01 01 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only X Reviewed By Signature

Pradeep Bhuin

Date

18-09-16

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

01

14-Sep-16

Review/Approval

SMK

DP

NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

38

DRAWING No.

ISSUE

GA-193308

MODIFICATIONS: 'A' ORIGINAL ISSUE 'B' :- GCN114467, KRM, 10-SEP-16. AS PER CUSTOMER COMMENT.

Ref

B

B

1 1.1 1.2 2 2.1 3 4 1.3 1.4

Part No.

Global Mat'l Code

Description

ASTM/AISI GRADES

Material

TLKS-0300-0A00-2500 TRANSMISSION UNIT ASSEMBLY 7933-0300-4700 FX01 MEMBRANE UNIT ASSEMBLY 7730-0300-1830-0484 0285 SPACER K-002-TBA 0285 MOTOR HUB 1332-3815-3040 0920 GRUB SCREW K-002-TBA 0285 PUMP HUB FT400B 0225 STRIPPER BOLT SET FT412B 0225 GAGGING BOLT SET 1851-0355-0001 0400 GAGGING SLEEVE

BS970-150M19 BS970-150M19 ALLOY STEEL, UNBRAKO BS970-150M19 ISO Grade 12.9 ISO Grade 12.9 BS970 080M40 (En 8)

Recomm Spares

Qty

ASTM A350-07LF3 ASTM A350-07LF3 ASTM A350-07LF3

ASTM A574 ASTM A574 ASTM A29 (1043)

1 X 2 1 1 1 X 1 1/Hub X 1/Cplg 8

ITEM 1.1 CONSIST OF

134

250

B

3

1.1a 1.1b 1.1c 1.1d 1.1e 1.1f

84

3131-0210-0150 7383-0300-0484 1044-0300-0058 1045-0300-0058 1161-0300-0058 1162-0300-0028

0453 0285 0336 0336 0336 0416

MEMBRANE GUARD RING OVERLOAD COLLAR SPACER WASHER DRIVE BOLT NUT

BS1449 301S21 1/2H BS970-150M19 BS PD970 709M40T BS PD970 709M40T BS PD970 709M40T ISO Grade 8.8

ASTM A666(301) ASTM A350-07LF3

AISI 4140 AISI 4140 AISI 4140 ASTM A325, A449

15 1 8 16 8 8

" JC RECOMENDS LIGHT INTERFERENCE FIT BETWEEN HUBS & SHAFTS"

1.1f 1.1b 1.1d 1.1a 1.1c 1.1e

2.1

2

1.2

42 B

24

B

B

O 92

O 116

B

B

O 116

O 155

103.19

GRUB SCREW M12 80.01

2

B TAPER 1:16

13.39 Kg.

9.75 Kg.

O 155

5 KEYWAY PARALLEL TO TAPER

B

##

1.3

1.4 GAGGING BOLT DETAILS

NOTE: - COUPLING SUPPLIED WITH GAGGS AT EACH END FOR TRANSIT PROTECTION. GAGGS ARE TO BE PAINTED RED. GAGGS TO BE REMOVED PRIOR TO INSTALLATION ON SITE.

PUMP SIDE

MOTOR SIDE

2 HOLES M10x20 DEEP EQUI-SPACED ON 78 P.C.D (PULLER HOLE)

T/Torque = 35Nm

1.3

4

183

4

T/Torque =35 Nm

1

ENGG DEPT. SULZER PUMPS (INDIA) LTD.

- GAGGING BOLT MAY BE USED TO FIT & REMOVE TRANSMISSION UNIT ASSEMBLY.FIT BOTH SIDE WITHOUT GAGGING SLEEVES & COMPRESS EACH MEMBRANE PACK BY EQUAL AMOUNT UNTIL DIMENSION # # IS NOT LESS THAN 9.1.

NAME:

2 HOLES M10x20 DEEP EQUI-SPACED ON 99 P.C.D (PULLER HOLE)

By Vaibhav Shedge at 10:27DATE: am, Sep 13, 2016

THE REVIEW/APPROVAL DOES NOT RELIEVE THE VENDOR/  MANUFACTURER OF THE FULL RESPONSIBILITY AS TO DESIGN CORRECTNESS OF DIMENSIONS & COMPLIANCE WITH ALL APPLICABLE REGULATIONS AND WITH THE REQUIREMENTS MADE IN PURCHASER SPECIFICATIONS.  1. WORK MAY PROCEED.  

MAX BORE Ø 82

MAX BORE Ø 82 B R 1.2

18 JS9

+0.0215 -0.0215

22 JS9

B

NOTE 1: ACTUAL RATING = 150.01kW /1000 rpm B COUPLING RATING = 300 kW /1000 rpm ACTUAL SERVICE FACTOR = 1.99

+0.026 -0.026

R 0.6

COUPLING DUTY

DUTY NORMAL

JOHN CRANE REFERENCE BALANCING DATA TO:- API 671 4th EDITION 9.2.2 METHOD 2 ( COMPONENT+ CHECK BALANCE)

B

REF 1 2 3

85.6 85.4

62.96 62.81

69.84 ( 69.69 )

O 64.998 B

O 58.123 H7

+0.030 0

-

B O 80 H7

BORE & KEYWAY DETAILS PUMP SIDE HUB @ SMALL END

2A. REVISE & RESUBMIT, WORK MAY PROCEED  SUBJECT TO IN CORPORATION OF CHANGE INDICATED.   2B. REVISE & WORK MAY PROCEED SUBMIT AS BUILT DRAWING ONLY. 3. REVISE & RESUBMIT, ENGG WORK MAY NOT PROCEED. DEPT. 4. REVIEW NOT REQUIRED, WORK MAY PROCEED.

SULZER JOB No. :- WBS Q/0100228669-0010 SULZER REF. No. :- 1616020 CUSTOMER : Schlumberger SULZER DOC No. :- CCD1002286690010-01 B PROJECT . :- KOC Jurassic Production Facility Qty: 3

REF

+0.030 0

1 2 3 -

BORE & KEYWAY DETAILS MOTOR SIDE HUB (SCALE: 0.75:1)

COMPONENT

COMPONENT Grade TRANSMISSION UNIT Gr0.66 HUB (@ MOTOR SIDE) Gr0.66 HUB (@ PUMP SIDE) Gr0.66 COUPLING CHECK (@ MOTOR SIDE) Gr6.3 COUPLING CHECK (@ PUMP SIDE) Gr6.3 ENGINEERING DATA

EQUIPMENT STANDARD EQUIPMENT STANDARD EQUIPMENT STANDARD EQUIPMENT STANDARD EQUIPMENT STANDARD EQUIPMENT

AXIAL MISALI GNMENT PARRALLEL LATERAL AXI AL FORCE ANGULAR TORSIONAL AXI AL DEFLECTION WEIGHT I NERTIA STI FFNESS NORMAL TRANSIENT MISALIGNMENT NORMAL TRANSIENT MISALIGNMENT (mm) (kN) (mm) (kN) (kg) (kgm²) (MNm / rad) (mm) (Degrees)

TRANSMISSION UNIT 10.74 0.0286 MOTOR HUB 4.38 0.0124 PUMP HUB 8.02 0.0195 TOTALS 23.14 0.0606

0.34 7.56 3.04 0.30

AX IAL FREQUENCY AT DIAMETRAL

COUPLING

STIFFNESS

FREE LENGTH

MAXIMUM

(Nm/Degree)

(Hz)

AXIAL FREQUENCY AT DISPLACEMENT (Hz)

± 1.4 ± 2.1 0.33 1.200 2.097 ±1.12 70.0 101.81 TORSIONAL STIFFNESS INCLUDES 1/2 SHAFT PENETRATION FOR PARALLEL SHAFT TORSIONAL STIFFNESS INCLUDES 1/3 SHAFT PENETRATION FOR TAPER SHAFT

DRIVER POWER

SPEED

CUSTOMER: CUSTOMER DRGS JOHN CRANE REF IPROJECTS No: PLANT ITEM No END USER: END USER LOCATION DRIVEN EQUIPMENT

SCALE 1:1

* Mass & Inertia figures for the hubs do not include the shafts. Shaft stiffness based on 1/3 or 1/2 hub length dependent on taper or parallel shaft * * Frequency Based on Suspended mass of 5.52 Kg. *** Whirling speed (lateral) is grater than 99000 rev/min # Weights are theoretically calculated values, actual values might vary considering tolerance etc.

GPN

DOR090724 231162-IN JPF1-G-104A/B/C B KOC KUWAIT PUMP

DATE

DRIVER EQUIPMENT

COUPLING DESIGNATION COUPLING DESCRIPTION CHECKED DRAWN

02AUG16

1442.1 N•M B

PO No

SULZER PUMPS INDIA LTD

144.07

TORQUE

2980 RPM B

450 KW

CUSTOMER DATA

TK

89800599

MOTOR

TLKS/0300/KA/GA193308 TLKS-0300-0537-2500

APPROVED

GN

AL

DRAWING No.

GA-193308

All intellectual property rights (including but not limited to copyright and design rights whether registered or unregistered) in relation to this drawing together with the information contained in this drawing (including but not limited to know-how and confidential information) is proprietary to John Crane. Reproduction (whether in whole or in part) or use in any way whatsoever of this drawing or of any information contained therein is prohibited except with the prior written consent of John Crane. All rights in relation to this drawing are reserved.

EARLY PRODUCTION SYSTEMS (EPS)

DESIGN AUTH. IN03

PROJECT TITLE:

ISSUE

JURASSIC PRODUCTION FACILITY (JPF) AT SABRIYAH

B A1

DRAWING TITLE:

COUPLING DRAWING PROCESS FLOW DIAGRAM

JPF1-G-104A/B/C XXXX REF. DWGS. NO.

REFERENCE DRAWINGS TITLE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

REV

AMENDMENTS

DRAWN

APPR'D

DATE

DRAWING NUMBER

KOC APPROVALS DESIGNATION GROUP/TEAM

NAME

SIGNATURE

DATE

CONTRACTOR DRG.No.

REV. KOC DRG.No.

15062-V009-ME-DD-0005-001

PROJECT REFERENCE: 15062 DO NOT SCALE IF IN DOUBT ASK

-

A

REV. -

SCALE: NTS

39

A1

SECTION 02 OMM-1616020

ELECTRICAL

SUB SECTION 03

DOCUMENT NO.

SR. No.

DOC. TITLE

01

Motor General Arrangement Drawing

15062-V009-ME-GA-0003-001

02

Motor Datasheet

15062-V009-ME-GA-0005-001

03

Motor Curve

15062-V009-ME-DS-0003

40

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. MDD1002286690010-01 15062-V009-ME-GA-0003-001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Motor General Arrangement Drawing - Crude Export Pump

Status Code

V009 02 02 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Pradeep Bhuin

Date

07-12-16

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

02 01

20-Sep-16 1-Aug-16

Review/Approval Review/Approval

SMK SMK

DP DP

NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

41

42

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. MWD1002286690010-01 15062-V009-ME-GA-0005-001

Supplier PO/Ref Supplier Revision Schlumberger Rev

Motor Wiring / JunctionBox Termination Diagram - Crude Export Pump

Status Code

Doc Type No. of Pages

V009 01 01 GA 1 of 16

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required X 4: Noted for Information Only Reviewed By Signature

Pradeep Bhuin

Date

11-05-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

01

28-Apr-17

Review/Approval

SMK

DP

NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

43

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

44

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

45

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

46

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

47

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

48

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

49

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

50

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

51

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

52

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

53

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

54

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

55

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

56

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

57

2900018566-02 DRAWN BY IT04\mvuolo on 02/02/2017 CHECKED BY IT04\rraso on 02/02/2017 printed by *GCO - DSANSA on 03/02/2017

58

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. MDS1002286690010-01 15062-V009-ME-DS-0003

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Motor Datasheet & Curve - Crude Export Pump

Status Code

V009 03 03 DOC 1 of 5

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Pradeep Bhuin

Date

03-01-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

7-Dec-16 8-Sep-16 1-Aug-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

59

60

61

62

63

SECTION 03 OMM-1616020

PACKING / STORAGE

SUB SECTION 01

SR. No.

DOC. TITLE

DOCUMENT NO.

01

Utilities List

15062-V009-IN-IN-0001

02

Lubrication schedule

15062-V009-OP-SH-0001

03

Painting Procedure of pumps

15062-V009-QA-PR-0003

04

Pump Packing & Preservation Procedure of pumps

15062-V009-QA-PR-0006

64

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PUC1002286690010-01 15062-V009-IN-IN-0001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Utilities List - Crude Export Pump & Effluent Water Disposal Pump

Status Code

X

V009 01 01 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

Pradeep Bhuin

Date

29-09-16

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

01

20/092016

Review/Approval

SMK

DP

NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

65

UTILITY LIST Purchaser P.O. No. Project End User SPI WO No SPI Doc No Customer doc no. Revision No. Sr.N Equipment Item o. Nos.

: Khuff / Schlumberger : : KOC Jurassic Production Facility, Sabriya : KUWAIT OIL COMPANY KSC : 1616020 (100228669) : PUC1002286690010-01 : 15062-V009-IN-IN-0001 0 WBS No.

Service

Pump Model

Total Qty.

API Seal Plan

Barrier Fluid

Flushing Plan 53B Pressure Temperature

Flow Rate

bar(g) / psi(g)

°C

LPM / pump

1

JPF1-G-104 A/B/C 100228669-0010

CRUDE EXPORT PUMPS

GSG 100-300

3

53B

OIL ISO VG10

8.2 / 116.6

Ambient

5

2

JPF1-G-204 A/B/C 100228669-0020

EFFLUENT WATER DISPOSAL PUMPS

GSG 80-260

3

53B

D M WATER

8.3 / 118.05

Ambient

5

Electric Power FOR MAIN MOTOR

FOR SEAL SYSTEM MOTOR

450 KW, 2980 RPM, 3 phase, 3300 V & 50 Hz 315 KW, 2980 RPM, 3 phase, 3300 V & 50 Hz

0.75 KW, 2920 RPM, 3 phase, 440 V & 50 Hz 0.75 KW, 2920 RPM, 3 phase, 440 V & 50 Hz

66

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PLL1002286690020-01 15062-V009-OP-SH-0001

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Lubrication schedule - Crude Export Pump & Effluent Water Disposal Pump

Status Code

V009 02 02 DOC 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only X Reviewed By Signature

Date

07-12-16

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

02 01

4-Oct-16 20-Sep-16

Review/Approval Review/Approval

SMK SMK

DP DP

NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

67

LUBRICANTION SCHEDULE Purchaser

: Khuff / Schlumberger

P.O. No. Project

:

End User

: KUWAIT OIL COMPANY KSC

SPI WO No

: 1616020 (100228669)

SPI Doc No

: PLL1002286690010-01

Customer doc no.

: 15062-V009-OP-SH-0001

Revision No.

: KOC Jurassic Production Facility, Sabriya

0 LUBRICANT DETAIL

SR NO

Equipment Item Nos.

WBS No.

Service

Pump Model

Pump Qty.

ISO Viscosity Grade

MAKER'S BRAND SHELL

MOBIL

BP

INITIAL CHARGE (Litres/Pump)

FIRST

REPLACEMENT Qty. SECOND (Litres/pump)

Qty. (Litres/pump)

LOCATION TO BE USED

1

JPF1-G-104 A/B/C

100228669-0010

CRUDE EXPORT PUMPS

GSG 100-300

3

Multigrade Engine Oil SAE 15W-40

HELIX STANDARD, ROTELLA MX 1540, RIMULA TX

SUPER 0.9 liters per bearing FORMULA, BP SB MOTOROIL, housing i.e. 1.8 liters DELVAC VISCO 2000 per pump SUPER 15W40

10-15 hours

0.9 liters per bearing housing i.e. 1.8 liters per pump

12 Months

0.9 liters per bearing housing i.e. 1.8 liters per pump

BEARING HOUSING

2

JPF1-G-204 A/B/C

100228669-0020

EFFLUENT WATER DISPOSAL PUMPS

GSG 80-260

3

Multigrade Engine Oil SAE 15W-40

HELIX STANDARD, ROTELLA MX 1540, RIMULA TX

SUPER 0.9 liters per bearing BP SB MOTOROIL, FORMULA, housing i.e. 1.8 liters VISCO 2000 DELVAC per pump SUPER 15W40

10-15 hours

0.9 liters per bearing housing i.e. 1.8 liters per pump

12 Months

0.9 liters per bearing housing i.e. 1.8 liters per pump

BEARING HOUSING

68

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. QPS1002286690010-01 15062-V009-QA-PR-0003

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Painting Procedure of pumps - Crude Export Pump & Effluent Water Disposal Pump

Status Code

V009 03 03 DOC 1 of 9

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature

X

Pradeep Bhuin

Date

03-01-17

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

03 02 01

15-Nov-16 4-Oct-16 14-Sep-16

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

69

Page 1 of 8

Painting specifications

QPS1002286690010-01

WOP No

: 1616020 (Q/0100228669)

CUSTOMER

: Khuff / Schlumberger

PROJECT

: KOC Jurassic Production Facility_ Sabriya

END USER

: KUWAIT OIL COMPANY (K.S.C)

Project Document No.

: 15062-V009-QA-PR-0003

WBS NO

PUMP

PUMP

MOC

MODEL

TAG NO.

Paint

Paint

TEMP

System

System

(°C)

for

for Base

Pump

plate

SERVICE

100228669-0010

GSG 100-300

JPF1-G-104 A/B/C

S-8 (NACE)

30 (min) / 60 (max)

3.1

3.1

Crude Export Pumps

100228669-0020

GSG 80-260

JPF1-G-204 A/B/C

D-1 (NACE)

10 (min) / 60 (max)

NA (R2)

3.1

Effluent Water Disposal Pump

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

70

Page 2 of 8

Painting specifications

QPS1002286690010-01

Surface preparation and paint procedure 1. Scope : Specification covers Coating material, Surface preparation, inspection for painting of external surfaces of pumps & auxiliary equipments. Reference Doc.: KOC-Poo1.Rev.3 2. Surface preparation & coating: Pressure-containing parts shall not be painted until the specified inspection and testing of the parts is Complete as per clause 8.2.1.2 of API 610. However Parts are primer coated at foundry end same has to be removed before hydro test & surface preparation has to be carried out at M/s. Sulzer a) Clean thoroughly all exposed parts to be painted, to remove scale rust, oil, grease, dirt and other foreign materials by wire brushing and solvent cleaning. If required grind the surfaces to remove the rough or sharp edges, parting line mark etc. before blasting operation. Blasting to be done to achieve the final surface finish Sa 2 ½ as per ISO 8501-1, SIS 05 – 5900 / SP10 [SSPC] near white blast cleaning and the required profile should be 35-50μm. Sand, copper slag or cadmium grits shall not be used .Aluminum oxide or iron grits or equivalent grits to be used for blasting. b) 1) Sand, copper slag or Cadmium shall not be used as abrasive material. 2) On a blast cleaned surface, the abrasive shall not leave any dust embedment greater than grade 2 of ISO 8502-. Checks on dust levels shall be made at least one per 100 m2 of prepared surface and a minimum of three checks per day. 3) Abrasive for Stainless Steel surface shall be nonmetallic. 4) For Manual Blasting, contaminated and/or recycles abrasives shall not be used. c) Surface Profile check: The surface profile height shall be in accordance with the requirement of painting system. As per system A1-1,the visual standard shall be Sa2 ½,profile 35-50μm & as per system A1.5 the visual standard shall be Sa2 ½,profile 4060μm. The measurement technique of surface profile testing are specified in ASTM D4417 or as per ISO 8503-5 Immediately after grit blasting and grinding, within 4 hours, dust shall be removed with compressed air, free of oil, moisture and then coat the castings with applicable primer DFT 50-75µ min., to protect surfaces from rusting. c) After acceptance of assembled pump set for painting, clean the surfaces to be painted with a general thinner so that the surface become free from dust, stain marks, traces of oil and grease. d) Clean the surfaces by dry air blow. e) The pump nozzles and other connections shall be properly covered while cleaning and painting. f) Coating shall not be carried on wet substrate; > 85% Relative humidity. Coating shall be applied when substrate temperature is at least 3ºC above dew point. NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

71

Page 3 of 8

Painting specifications

QPS1002286690010-01

g) Patch-up / repair the primer coat wherever required. Also ensure the components or surfaces, which are not to be painted, are masked properly and apply finish coat as per applicable paint system. h) Defects such as runs, sags, drips and voids shall be corrected as detected during application of coating. i) Stainless steel surfaces of Pumps & auxiliary piping shall not be painted. It will be cleaned by buffing & polishing.

j) All bearing housing internal unmachined surfaces are painted with Phenolic Epoxy paint. [Red or Gray]

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

72

Page 4 of 8

Painting specifications

QPS1002286690010-01

m) Storage, handling & safety precautions:

n) Blasting cleaning Technique: The blasting equipment & technique shall comply with the clause 8.5.5 of KOC-P-001 o) Paint mixing & thinning shall be followed as per cl.9.3 of KOC-P-001.Mixing of paint to an even consistency, manufacturer’s mixing instructions, environmental conditions & maximum pot life shall be strictly adhered paint application by airless spraying shall be preferred. 3. Painting System: 3.1

For carbon steel, cast iron, CA6NM, CA15 steel external surfaces having design temperature up to 120 C [A 1-1 page 44 of 51] Coat

Primer Intermediate Finish

Description

Zinc Rich Epoxy Epoxy HB Polyamide cured Aliphatic Polyurethane

DFT/Co at µm 70-80 125-200 50-75

No.of Coats 1 1 1

Total DFT µm 245-355

Final Color

Grey Brown/Grey Light Grey BS 4800 10-A-03

. 4

The coating system is based upon the paint supplied by Ms. Jotun Paints.

5

The details of thinners, mixing ratio and drying times are to be as per paint manufacturer recommendation.

6

Dry film thickness shown is minimum, excessive paint thickness will be kept as low as practically possible.

7

Cold parts like base plate, carbon steel cooling piping & coupling guard will always be painted as per 3.1 scheme. Final colour shade will be RAL 9006. ( R1)

8

Paint system shall be capable of withstanding the environmental conditions for period of 10 years to Ri3 per BS3900 H3 scale of degree of rusting

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

73

Page 5 of 8

Painting specifications

9

QPS1002286690010-01

Paint selection chart for different Paint manufacturer

Description

Hempel

Jotun

Zinc Rich Epoxy Epoxy HB Polyamide cured for CS Aliphatic Polyurethane Phenolic Epoxy for Bearing housing internals

Barrier 90 Phenguard mid coat MIO 80 Hardtop XP

Hempadur zinc 17380 Hempadur 45880 Hempathane 55210 Hempadur 85671

Tank guard storage

11. Inspection & Testing Equipment: Following inspection I testing equipment shall have an external calibration surface. -Surface Profile Gauge -Dry Film Thickness gauge -Pinhole / Holiday Detectors -Adhesion (pull off) Testers -Instruments to monitor ambient conditions

12. Painting inspection Personnel shall be at least Level 2 certified by NACE/B-GAS or an approved equivalent. Certificate attached. 13. Environmental conditions testing: a) Prior to commencing any blast cleaning/paint application work, ambient temperature, metal surface & relative humidity (RH) shall be measured & recorded in the respective formats & readings shall comply with Restrictions on painting clause mentioned above. b) Other environmental conditions e.g.wind speed,wave tide & sandy or rainyweather, shall be checked before commencement of work.

14. Blasted Surface Inspection/Testing: a) Visual Inspection Metal surface shall be checked to ensure spatter/protrusions removal, cleanliness etc. prior to blast cleaning. Blast clean surfaces shall be visually inspected to ensure the absence of all types of imperfections & contaminants & for the conformance with the specified visual standard mentioned in the painting schedules. b) Surface Profile Testing

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

74

Page 6 of 8

Painting specifications

QPS1002286690010-01

On dry blast cleaned surfaces the profile height shall be spot checked by means of replica tape & a calibrated micrometer to ensure the compliance with painting schedule requirements.

15. Visual inspection : 1. All painted surfaces shall be visually inspected to ensure the absence of skips,overspray,sags,foreign particles contamination,air pockets ,drips, holidays & any other paint defects. The repair of damaged / defected coating shall be done in accordance with clause 9.8 of KOC-P-001. 2. DFT of each coating /layer shall be checked & recorded. 3. Paint adhesion testing shall be done in accordance with Clause 12.5.4 of KOC-P001 on test plates. 4. Holiday detection shall be done.

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

75

Page 7 of 8

Painting specifications

QPS1002286690010-01

16. Final report shall be submitted on completion of the painting work. The Final report shall include a summary on all aspects covered e.g. surface preparation, painting systems used & inspection & testing records performed Sample report

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

76

Page 8 of 8

Painting specifications

NAME REV / DATE

VVS 0/12.08.16

SBG 1/30.09.16

SBG 2/20.10.16

QPS1002286690010-01

77

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PPP1002286690010-01 15062-V009-QA-PR-0006

Supplier PO/Ref Supplier Revision Schlumberger Rev Doc Type No. of Pages

Pump Packing & Preservation Procedureof pumps - Export Pump & Effluent Water Disposal Pump

Status Code

V009 02 02 DOC 1 of 8

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only X Reviewed By Signature

Date

03-01-17

Pradeep Bhuin

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

Date

Comments Y/N

02 01

14-Nov-16 28-Sep-16

Review/Approval Review/Approval

SMK SMK

DP DP

NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

78

Packaging, Shipping, Handling ,Preservation and Storage procedure

1.0

Packing

1.1

General:

Sheet No. 1 / 7 PSH-SPI Exp R1

The following instructions are designed to facilitate preservation, safe departure and expeditious movement of Goods dispatched to the ultimate destination and to give information to purchaser regarding the general packing procedure. Packing shall be to a standard to efficiently and effectively protect the Goods against the hazards associated with handing during loading and unloading, whilst in transit from SPI works and during storage at the job site for a period of at least six [6] months. Packing shall include all pre-crating protection activities including but not limited to the application of anticorrosion, coating and desiccants and end caps. Depending on their type the Goods shall be protected against mechanical damage (shocks, rupture, breakage, loss) and corrosion (rain, salty atmosphere, sand wind), Humidity, rain, high temperature and dust, Pilferage, Rough handling during Transit, Intrusive pests and organisms. 1.2 Preservation and packing All shipping units must be soundly packed for shipment in accordance with requirements of the following instructions. 1. All openings to equipment such as inlet and outlet piping feed and discharge openings etc. shall be plugged, capped or otherwise covered to prevent damage or the entrance of moisture and dirt. Fragile items shall be foam, plastic-cushioning material. 2. All the instruments shall be packed in cushioned polyethylene. 3. Waterproof case liners (HDPE Lining) shall be protection from all moisture.

used as an over wrap but do not require total

4. Openings in electrical equipment shall be sealed with waterproof tape or plugged. 5. All the suction and discharge flanges shall be covered with 5 mm metallic covers alongwith gaskets, bolts & nuts. 6. Bearing assemblies shall be fully protected from the entry of moisture & dirt. 7. Exposed shafts & shaft coupling shall be wrapped with water proof waxed cloth or Volatile corrosion inhibitor paper. 8. For vertical pumps Motor should be removed & packed separately if weight > = 25 kg or in the same box if weight of motor is < 25 kg with locking the movement of motor in the same box.

DEN/SF/016/03

9. For vertical pumps for > one shaft construction or Can length > 2 meters, Can should be packed separately. 10. In the cases of pumps with flushing pot along with instruments : a. Pumps shall be packed separately in one box or along with Flushing pot depending upon available space in the box. b. Flushing pot along with mounting brackets and pipes should be packed in one separate box if pump package height is > 2.7 meters. c. Instruments shall be packed in a small box and it should be kept in a box of flushing pot along with mounting brackets and flushing pots. 1.3 NAME REV / DATE

Shipping unit types and features : SPI shall comply with the following guidelines and instruments:

SAV 0/26.09.16

79

Packaging, Shipping, Handling ,Preservation and Storage procedure

Sheet No. 2 / 7 PSH-SPI Exp R1

1. Boxes: All lumber materials used shall be sound and well seasoned. Pine wood shall be used for Export seaworthy packing boxes. Shipping units shall be either weatherproof lined and / or have items weatherproof wrapped prior to packing. For maximum strength, nails shall be driven into side grain of lumber. All wood shall be exterior type and of 20 mm thick. 2. Requirement for heavier lifts: For boxes all having a gross weight in excess of 50 kilograms shall be lifted with skids for handling by forklift. Each skid shall be minimum of 70 mm height by 80 mm wide, the total number and size dependent on shipping unit length and weight. 3. Types of Boxes for shipment: A base for box having min. 1 1/2" to be used for all the pumps. If pump package is up to 7 Tonnes, use Type 2 boxes & if pump package is > 7 Tonnes weight, use Type 3 boxes. For Spares Use Type 1 Box up to 1 Ton. Type-1 Box

Type-2 Box

DEN/SF/061/04

Type-3 Box

80

Packaging, Shipping, Handling ,Preservation and Storage procedure

Sheet No. 3 / 7 PSH-SPI Exp R1

Box Details:

Sr.No.

1 2 3 4 5 6 7 8 9 10 11 12 13

Net Load NW Kg 100 500 100 500 501 1000 1001 3000 3001 5000 5001 7000 7001 8000 8001 10000 10001 12000 12001 15000 15001 18000 18001 20000 20001 23000

Box Type

Type 1 Type 1 Type 1 Type 2 Type 2 Type 2 Type 3 Type 3 Type 3 Type 3 Type 3 Type 3 Type 3

Long Member Sizes N h t no Inch Inch 2 3 3 3 3 3 3 2.5 3.5 3 2.5 3.5 3 3.5 5 4 4.5 5 5 5 4 5 6 4 6 6 4 7 6 4 8 6 4 9 6 4 10 6 4

Bottom Plank Thick T3 Inch 0.34 1.5 0.75 0.75 1 1.5 1.5 1.5 2 2 2 2.5 2.5

Cross Member Sizes N1 h1 t1 no Inch Inch 3 3.5 3.5 4 3.5 3.5 5 3.5 4.5 5 3.5 4.5 6 4 3 6 4 4 7 5 4 8 5 4 9 5 4 10 5 4 11 5 4

Batten Sizes T1 W3 Inch Inch 1 1.5 1 1.5 0.75 3.5 0.75 3.5 1 3.5 1.5 3.5 3 2 4 3 4 3 4 3 4 3 4 3 4 3

End, Side, Top Spacing Plank bet' cross Thick members From end T2 d d1 Inch Inch Inch 0.34 24 8 0.34 30 12 0.5 30 12 0.5 26 18 0.75 29 18 1 29 18 0.75 33 18 0.75 34 20 0.75 34 20 0.75 34 20 0.75 34 20 0.75 34 20 0.75 34 20

The plank thicknesses and the sizes of members are as per commercial sizes available in market.

4. Pumps base plate should be bolted on base box; along with HDPE Lining. Pumps should be totally covered with plastic. HDPE lining will be used all over sides and top of boxes. 5. Lifting points & lifting lug shall be clearly identified. 6. Packing box material will be as per ISPM 15 [Fumigated] 1.4

The common material used to provide the moisture vapour barrier is polythene sheet while Silica Gel is used as desiccant. The minimum thickness of polyethene sheet shall be 0.01 inch or 0.25 mm.

Quantity of Desiccant Desiccation Material Calculation: The following formula is based on DIN 55474. It considers shipment and Storage time, climate, the foils MVTR and additional packing material that may be used.

n =1/a· (V·b+m·c+A·e·D·t)

DEN/SF/061/04

Wherein Symbol n

Unit TME

a

g

V

m3

b

g/m3

m

kg

c

g/kg

Description/remark Units of desiccant material Water absorption capacity of one unit in grams in permissible final humidity a= 3 g 20% a= 6 g 40% at 23±2°C Inner package volume Absolute humidity content of trapped air b= 15 g/m3 85% relative humidity, 20°C Weight of supplementary hygroscopic package material Moisture content of the supplementary hygroscopic package material c= 220 g/kg Damp Wood c =180 g/kg Air-dry wood

81

Packaging, Shipping, Handling ,Preservation and Storage procedure

A

m2

e

-

t D

d g/m2 d

Sheet No. 4 / 7 PSH-SPI Exp R1

Area of barrier material Corrective factor relating to the permissible final humidity level e =0.7 40% relative humidity Total transport and storage time in days. MVTR of the barrier material. See Table below ,Insert at least 0.01 g/m2 d

MVTR (moisture vapour transmission rates) of different barrier materials

Material

MVTR as per DIN 53122 g/m2 d

Polyethylene foil (PE) Transparent Aluminum compound foil (polyethylene/aluminum/polyester)

< 0.30 < 0.01

VCI film

< 0.1

Remarks

Do not use foil containing fabrics To be used for tong term storage

1.5

When equipment is being prepared for a desiccated pack, all sharp edges and protruding items should be covered with felt or moldable wrap.

1.6

Mark each shipping unit as shown under SHIPPING MARKS in at least two (2) places. Marking shall be of waterproof ink or exterior grade paint in a color which produces high contrast with the background.

1.7

Preferably, marking lettering shall not be less than 13mm in height. The packages shall be numbered in sequence.

1.8

On all packages weighing 3 tonnes and/or over one meter high, the sling points and center of gravity shall be indicated by the appropriate international symbol.

DEN/SF/061/04

Auxiliary Shipping Marks:

82

Packaging, Shipping, Handling ,Preservation and Storage procedure

Sheet No. 5 / 7 PSH-SPI Exp R1

1.9

Pumps shall be covered with polyethylene foil/sheet to prevent corrosion due to exposure to moisture and packed in wooden boxes suitable for road/air/sea transport. The connection flanges of the pumps shall be closed airtight.

1.10

The provision of a moisture vapour barrier will minimize the penetration of moisture during transportation and storage. All moisture vapour barrier materials have an accepted vapour phase transmission rate and, in the light of this, it is normal to include desiccative material within the moisture vapour barrier.

1.11

For raw solid wood phytosanitary certificate (ISPM 15 certificate) will be provided.

1.12

Protective steel pads shall be used on boxes weighing above 1 ton at the lifting location.

1.13

In case of pump package is with length > 15’ or width > 8’ additional support of channels will be provided at Top &/or bottom depending upon package.

2.0 2.1

Final preparation for shipment Packing List

Packing itemizing contents on each box must be placed inside each shipping unit. A second copy together with any special instructions regarding preservation of contents must be sealed in a water-proof envelope and securely fastened to the outside of each shipping unit. Spare parts marking shall include the part name and number listed in the service manual bill of material. 3.0

Final preparation for shipment

All shipping mark shall be done as per project Contract requirement and/or as approved by the BUYER

4. PRESERVATION AND STORAGE OF PUMPS A) Preservation for dispatch All the pumps are shipped with smooth outside faces sprayed with Cortec VpCI 368M and pump internals with Rustlick 631 or VpCI 329.

DEN/SF/061/04

Pump will be packed in Seaworthy packing along with Polyethylene. In this case the preservation time will be 6 months, if the packing is not damaged. B) Preservation for Intermediate storage [ 6-12 months] Centrifugal pumps which are not installed and commissioned immediately after delivery can be stored for the period determined by the dispatch preservation. Attention : To avoid formation of condensate and resulting in corrosion (Especially in the gaps), bearing damage and contamination, a clean, dry and shock-free storage space shall be selected.

83

Packaging, Shipping, Handling ,Preservation and Storage procedure

Sheet No. 6 / 7 PSH-SPI Exp R1

In each case unfavorable climatic circumstances will have a negative influence on period of proper preservation. In case the units are not enclosed in special packing, the connection flanges of the pumps shall be closed airtight. C. Preservation for Long-term Storage [ more than 12 months] In case long-term storage is required in the stores of the client or on site or pumps affected by a longer shutdown of the plant or standby pumps are to be preserved, the following instructions shall be observed. Attention : If pumps have been in service before, the pump parts in contact with the pumped liquid must be cleaned and after drying shall be applied with rust preservative. For this purpose the disassembly of the hydraulic parts of the pump becomes necessary in most cases. I. Protection of machined surfaces / connections /bright parts (CS /SS) of the pump All machined surfaces of CS or SS shall be applied rust preventive as below. Recommended rust preventives - Cortec VpCI 368 M for external machined surfaces - Cortec VpCI 329 for internal hydraulic surfaces This protective film can be removed by means of solvents or alkaline cleansing solutions. II. Protection of the interior of the pump -

Pump casings

-

Stuffing box housings

-

Bearing frames etc.

For these parts, liquid rust preventive on a mineral – oil basis having a viscosity of approximate 60 – 70mm/s shall be used. Recommended rust preventives : For gaskets/O-rings in Buna rubber (NRB), Viton (FPM), Teflon (PTFE) and above parts. -

Rustlick 631, from ITW Signode India Ltd., Hyderabad.

-

VpCI 329 from OKS Specialty Lubricants

DEN/SF/061/04

For gaskets/O-rings in ethylene – propylene ( EPDM) -

Silicone Grease Any Vegetable Oil

III ) Procedure for applying rust preventive

Pump casing internals and bearing frames. At first the machined faces like suction and delivery flanges, pump shaft extensions, couplings shall be cleaned thoroughly and preserved with one of the rust preventives mentioned under I. On smooth / serrated finish flanges flat gasket shall be placed and closed tightly by means of 5 mm metal covers

84

Packaging, Shipping, Handling ,Preservation and Storage procedure

Sheet No. 7 / 7 PSH-SPI Exp R1

with bolt/nuts. The connections for the cooling water/circulation lines etc. shall also be closed by means of normal steel plugs, using Molykote. Then fill pump casing and bearing frame upto lower edge of the shaft, with rust preventive (See II). While filling in turn pump shaft manually several times (observe direction of rotation). Turn down the bearing frame so that all internal surfaces shall become wet by preservative. After a few minutes, drain out the preservative and plug the drain connections. For practical handling the casing interior of bigger pumps shall be sprayed. The preservation shall be repeated every 6 months. D) Maintenance of the stored centrifugal pumps For the parts which are filled with rust preventive (Pump casing / stuffing box housing/bearing frame) the condensate shall be drained every 6 months; and rust preventive shall be added, if required. To avoid corrosion damage at bearings, the pump rotor shall be manually turned during pouring, so that the preservation oil will be distributed over the running surfaces of the bearings. Attention: According to manufacturer indications preservation shall be repeated after 6 months. If the rust preventive is not renewed within this period the risk is to be taken by the storage keeper. In order to have a guarantee for the proper execution of the maintenance instructions, maintenance sheets

DEN/SF/061/04

shall be established.

85

SECTION 04 OMM-1616020

SPARES

SECTION 04 - INDEX

SR. No. 01

DOC. TITLE Spare Parts Interchangeability Report (SPIR) - Commissioning, Start-up and Operation

DOCUMENT NO.

15062-V009-AM-BM-0001

86

Jurassic Production Facility (JPF) at Sabriya PO No. 15062V009

Supplier Document Cover Sheet Supplier Name Supplier Document No. Schlumberger Doc No. Document Title

Sulzer Pumps India Ltd. PYS1002286690010-01 15062-V009-AM-BM-0001

Supplier PO/Ref Supplier Revision Schlumberger Rev

Spare Parts Interchangeability Report (SPIR) - Commissioning,Start-up and Operation - Crude Export Pump

Status Code

Doc Type No. of Pages

V009 03 03 BM 1 of 2

Description

1: Review Without Comment 2: Comments as Noted 3: Rejected – New Drawing/Document Required 4: Noted for Information Only Reviewed By Signature Date Pradeep Bhuin 08-12-17

X

Schlumberger Review Distribution – Interdisciplinary Check Department Project Management Engineering Manager Project Manager – SRU Project Manager - Gas Project Manager – Oil Piping Lead QA/QC Controls & Instruments Electrical DMG Civil/Structural Construction Manager

Name

Signature

Date

Comments Y/N

Heberth Taguado Michael Hess Matt Jackson Dale Meyer JP Clark Andrew McGill Sanoop Bhaskar Gregg Armstrong Andrew Little Collette Munnings Scott Murray Scott Murray

03 02 01

30-Nov-17 10-Aug-17 10-Jan-17

Review/Approval Review/Approval Review/Approval

SMK SMK SMK

DP DP DP

NT NT NT

SLB Rev

Date

Reason for Issue

Prepared

Checked

Approved

87

SPARE PARTS & INTERCHANGEABILITY RECORD

ITEM TAG

GSG 100-300(E)(Bd) 7 Stages JPF1-G-104A

INVENTORY

Pump Model No.

7

8

3

MANUFACTURER: SULZER PUMPS INDIA LIMITED, 9, MIDC THANE -BELAPUR ROAD,DIGHA,NAVI -MUMBAI400708. SPI Ref: Qtn 20145795 / OED 1616020

REVISION NO.:

4

MAIN EQUIPMENT DESCRIPTION

MAIN EQUIPMENT TAG

4501003008

5

JPF1-G-104A

6

SPARE PART PROPOSAL

MANUFACTURER

SIGNATURE

DATE

ASS

09.10.2017

Crude Export Pump

PART IDENTIFICATION

DESCRIPTION OF PART

SHEET

1

REVISION DATE: 09.10.2017 VENDOR

2 PURCHASE ORDER

REVISION AND FOLLOW UP

1

VENDOR: SULZER PUMPS INDIA LIMITED

MANUFACTURE

COMPANY USE

SERIAL

SPARE PARTS

SPARE PARTS

UNIT PRICE

NUMBER

COMMISSIONING

2 YEARS

USD

10

ITEM

3

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 088 089 090 091 092 093 094 095 096 097 098 099 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123

1 1 1 1 2 6 1 1 1 1 4 1 2 1 2 8 2 1 1 1 1 6 3 3 3 1 1 1 1 1 2 1 5 6 5 1 6 1 2 2 1 1 2 2 7 1 1 1 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 24 24 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 3 1 1 1 2 1 24 24 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 3 1 1 1 1 2 2 2 2 2 2 2

124 125 126 127 128 129 130 131 132 133 134

PART NUMBER

ITEM SERIAL NO. 13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

14

BEARING NUT BEARING NUT LOCK WASHER LOCK WASHER KEY KEY KEY KEY KEY KEY TAPER PIN RETAINING RING ANGULAR CONTACT BALL BEARING SPACER DISC OIL RING SEAL RING O-RING O-RING O-RING O-RING O-RING O-RING PROFILE SEAL PROFILE SEAL PROFILE SEAL CYLINDRICAL ROLLER BEARING BEARING ISOLATOR BEARING ISOLATOR BEARING ISOLATOR BEARING ISOLATOR GASKET FAN INTERSTAGE BUSHING IMPELLER RING IMPELLER RING BUSHING STATIONARY RING SPACER SLEEVE STATIONARY RING IMPELLER RING BALANCE DRUM BALANCE DRUM BREATHER PLUG CONSTANT LEVEL OILER SPLIT RING SPLIT RING SLEEVE SPACER SLEEVE SPACER RING PROFILE SEAL SPACER SLEEVE SPACER SLEEVE SHAFT NUT SPACER SLEEVE SPACER SLEEVE SUCTION IMPELLER IMPELLER D 305 "E" 2. STAGE IMPELLER D 305 "E" 3. STAGE IMPELLER D 305 "E" 4. STAGE IMPELLER D 305 "E" 5. STAGE IMPELLER D 305 "E" 6. STAGE IMPELLER D 305 "E" 7. STAGE SHAFT CARTRIDGE..DBL-B/B Seal Face Assembly Seal Face Assembly Thrust Ring Driver Sleeve - spring Spring Screw-Soc set O ring O ring Seat O ring Seat O ring Sleeve O ring Intermediate Cover Pin - Anti rotation Ring Retainer ring O ring O ring Cover Pin - Anti rotation Screw-Soc hd cap Assembly Fixture Bolt-Hex head Throttle bush Pressure Ring Plug - socket head CARTRIDGE..DBL-B/B Seal Face Assembly Seal Face Assembly Thrust Ring Driver Sleeve - spring Spring Screw-Soc set O ring O ring Seat O ring Seat O ring Sleeve O ring Intermediate Cover Pin - Anti rotation Ring Retainer ring O ring O ring Cover Pin - Anti rotation Screw-Soc hd cap Assembly Fixture Bolt-Hex head Throttle bush Pressure Ring Plug - socket head COUPLING Transmission Unit

MOTOR BEARING FOR DE NU217MC3+6217C3 MOTOR BEARING FOR NDE NU217MC3 Baldder Accumulator Pressure Gauge Pressure Indicating Transmitter- Alarm Pressure Indicating Transmitter- Trip Temperature Gauge Thermowell Double Block & Bleed Valve

15

16

17

Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited Sulzer Pumps India Limited EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd. EagleBurgmann India Pvt. Ltd.

920.17 920.15 931.01 931.02 940.04 940.01 940.02 940.09 940.05 940.03 560.02 932.01 320.02 551.04 644.01 411.08 412.05 412.08 412.09 412.07 412.14 412.01 410.10 410.05 410.20 320.01 423.12 423.11 423.10 423.14 400.07 831.01 541.01 503.01 503.03 540.03 502.06 525.12 502.07 503.02 603.01 605.01 673.01 638.01 501.03 501.01 520.01 525.03 504.05 410.11 525.05 525.04 920.34 525.01 525.02 231.35 230.26 230.27 230.28 230.29 230.30 230.31 210.12 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.2 1.3 1.4 1.5 2 3 4 4.1 5 6 7 8 9 9.1 10 11 12 13 14 15 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.2 1.3 1.4 1.5 2 3 4 4.1 5 6 7 8 9 9.1 10 11 12 13 14 15 1A 1C 1B 1 1D.1 1D.2 3C

015201805310 015201805910 015507500341 015507500381 017011405162 017011405302 017011405302 017011405302 017011506121 017011521461 017021103241 017033100030 017733615312 17779902129 018021020236 021051210326 021702025355 021710508532 021710519632 021710520232 021710530432 021710538032 104098246001 104098247001 104098248001 104916413644 104932051101 104932051111 104932051171 104932051281 104944166060 204400085001 204409697002 204409701003 204409702004 204411730002 204411757002 204411760002 204413172044 204413172045 204413172048 204413172049 204425013010 204500908001 204646085020 204646086016 204647167012 204647223009 204648641006 204649450001 204649571002 204649786002 204655556020 204655824002 204655953002 204656258206 204656855228 204656855229 204656855230 204656855231 204656855232 204656855233 204664067200 696304076/2 795900074/2 794900001/2 795801992 307800066/2 795801736 028801015 024802236 036800552/API 036801830/API 041803426 036814771/API 041803212 036802970/API 307800068/2 036800211/API 307800067/2 027801314 029804088/2 026801550/2 036801103/API 036801103/API 535802185/2 027801485 024802067 099800047 023800531 031880197 029802023 052800230 696304077/2 795900074/2 794900001/2 795801992 307800066/2 795801736 028801015 024802236 036800552/API 036801830/API 041803426 036814771/API 041803212 036802970/API 307800068/2 036800211/API 307800067/2 027801314 029804088/2 026801550/2 036801103/API 036801103/API 535802186/2 027801485 024802067 099800047 023800531 031880197 029802023 052800230 CPL100228669001001 CPL100228669001002 166800447 55800809 62800603 62800606 60800453 60800446 66800082

John Crane John Crane -

19

6 3 3 3 3 18

6 3 3 3 3 18

6

6

SCHLUMBERGER

ORDERED BY

BY VENDOR

RECOMMENDED

ORDERED BY

BY VENDOR

18

SCHLUMBERGER

(IF DIFFERENT) RECOMMENDED

SERIAL NO.

REFERENCE /

579802/579803/579804

REMARKS

9

Price / Delivery Time (Week)

20

21

22

2 2 2 2 3 9 2 2 2 2 6 2 6 2 3 12 6 3 3 3 3 18 5 5 5 2 2 2 2 2 6 2 8 9 8 2 9 2 3 3 2 2 3 3 11 2 2 2 3 5 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 2 1 24 24 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 3 1 1 1 2 1 24 24 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 4 1 1 3 1 1 1 1 1 1 1 1 1 1 1

1 1 2 2 1 3 1 1 1 1 6 2 2 1 3 6 0 0 0 0 0 0 2 2 2 1 0 1 1 1 6 2 3 4 3 1 3 1 1 1 1 1 3 1 5 1 1 1 1 2 1 1 2 1 2 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 0 1 0 0 0 0 1

59.05 56.01 21.16 49.42 47.37 54.88 54.88 54.88 11.81 47.33 9.47 7.89 2,874.56 37.89 34.86 28.77 244.55 1,172.29 1,825.25 1,223.68 1,854.17 1,223.68 1,789.21 3,966.69 2,790.67 3,186.41 2,352.95 3,369.56 3,369.56 2,352.95 5.75 480.55 1,303.50 2,400.63 3,181.26 2,857.22 2,505.16 3,258.85 2,515.31 950.84 5,826.84 6,533.69 27.47 268.42 241.22 334.74 848.68 450.96 172.39 2,803.70 82.57 110.28 103.58 142.26 117.53 18,356.05 17,263.89 17,263.89 17,263.89 17,263.89 17,263.89 17,263.89 24,159.63 87701.10 10293.78 7720.34 2511.06 4367.06 77.98 77.98 623.87 2885.38 3134.92 16485.65 3758.79 10059.83 4226.69 10917.65 1949.58 9747.90 77.98 1325.71 1481.68 3134.92 3134.92 14582.86 77.98 31.19 77.98 15.60 1403.70 7720.34 389.92 87701.10 10293.78 7720.34 2511.06 4367.06 77.98 77.98 623.87 2885.38 3134.92 16485.65 3758.79 10059.83 4226.69 10917.65 1949.58 9747.90 77.98 1325.71 1481.68 3134.92 3134.92 14582.86 77.98 31.19 77.98 15.60 1403.70 7720.34 389.92 8,982 6,302 1,201.93 1,031.91 61,610.62 943.60 11085.31 11085.31 943.60 3290.89 1758.52

23

14 14 10 10 10 10 10 10 10 10 16 14 16 12 14 12 12 12 12 12 12 12 12 12 12 16 16 16 16 16 12 10 14 18 18 14 18 12 18 18 14 14 10 12 16 16 12 12 12 12 12 12 18 12 12 24 24 24 24 24 24 24 22 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 12 12 10 10 20 20 20 20 20 20 20

001 002 003 004 005

TERMS AND CONDITIONS : 1. Quoted prices are on Ex-Works,Navi Mumbai basis in USD 2. Freight and Duty shall be to your account 3. Packing (Sea Worthy) : Included 4. Payment: 50% advance and balance against Proforma Invoice prior to despatch 5. Delivery :As mentioned against individual line item on EXW, SPI basis. 6. Insurance: In your scope 7. Offer Validity : 31.12.2017 8. Certificates required, if any, shall be provided at an extra charge. 9. Third Party Inspection, if required, shall be at an extra charge with delivery implication. 10. Above SPIR shall be valid with Sulzer Pumps India Ltd. Terms and Conditions

88

SECTION 05 OMM-1616020

MANUALS

SR. No.

DOC. TITLE

DOCUMENT NO.

01

Operation and Maintenance Manual

15062-V009-OP-OM-0003

02

Motor Manual – NOT APPLICABLE

NIL

03

Mechanical Seal Manual

NIL

04

Coupling Manual

NIL

05

Plan 53B – Seal System Manual

NIL

89

PUMP MANUAL

90

OPERATING MANUAL

Doc. No. OPM/GSG-HPI/004 Issue No.-2 / June 2011

GSG

Document no. OPM/GSG-HPI/001   OPM/GSG-HPI/006_02

Sulzer Pumps India Ltd.

9, MIDC, Thane Belapur Road, Digha, Navi Mumbai – 400708. India. Tel. (091)22 55904321, Fax- (091)22 55904306 

91

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93

2. SAFETY This operating manual contains basic information, which has to be observed on the installation, commissioning, operation and maintenance. Therefore this operating manual has to be available constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or assembly/disassembly of the pump. Not only have the general safety instructions to be observed, which are given under this main point "Safety", but also the special safety instructions given below in the operating manual.

2.1 Marking of instructions in the operating manual The safety instructions contained in these operating instructions, which – if not observed - may result in harm to persons, are indicated with the general danger sign or, in the case of warnings against electrical voltage, with and in terms of explosion protection with the special sign For safety instructions which – if not observed – may cause risks for the machine and its ACHTUNG is inserted. operation, the word Indications which are directly attached at the machine itself such as - arrow for rotational sense - marking for fluid connections etc. have to be kept in good, legible condition, as they have always to be observed.

2.2 Qualification and training of personnel The personnel for service, maintenance, inspection and assembly has to hold the necessary qualifications for this kind of jobs. Range of responsibility, competence and the monitoring of the personnel have to be fixed clearly by the user. In case the personnel should not have the required knowledge, they have to be trained and instructed. This may be undertaken by the manufacturer of the machine, if required, on user's request. Further the user has to ensure that the personnel has a complete understanding of the contents of the manufacturer's instruction manual.

2.3 Danger on non-observation of the safety regulations By non-observation of the safety regulations danger may arise for persons as well as for environment and machinery and may lead to a complete loss of any claims for damages. -

Non-observance may lead for example to the following dangers:

-

Failure of important functions of machine/plant

-

Failure of required procedures of maintenance and repair

-

Endangering of people by electrical, mechanical and chemical impacts

-

Endangering of environment by leakage of dangerous materials

2.4 Safety-guided working The safety regulations given in this operating manual which consist of national regulations on accident prevention, as well as company- internal job, operating and safety regulations issued by the user, have to be observed.

0000/e2-0-00-000 Page 1

94

2.5 Safety instructions for user / operator -

In case hot or cold machine parts may lead to any danger, they have to be secured by user against touching.

-

Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.

-

Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be disposed of in such a way as to prevent any endangering of people and environment. Legal regulations have to be observed.

-

Endangering by electricity has to be excluded (details see for example in the regulations by the VDE and local energy suppliers).

-

The special safety instructions in the following paragraphs of this operating manual have to be observed.

2.6 Safety instructions for maintenance, inspection and assembly jobs -

The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by authorized and skilled personnel only, who have been adequately informed by studying the operating manual carefully.

-

Basically any works on the machine may be carried out only during shut-down of the machine. The procedure described in the operating manual for the shut-down of the machine has to be strictly adhered to. The machine has to be locked against unauthorized or involuntary start-up.

-

Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be worn. There is a risk of injury as a result, for example, of such objects getting caught or pulled in.

-

Pumps or aggregates delivering media hazardous to health have to be decontaminated.

-

Immediately following the end of the works, all safety and protective devices have to be reassembled respectively have to be put to work again.

-

On a repeated start-up all points given in the paragraph initial commissioning have to be observed again.

2.7 Prohibition of unauthorized rebuilding measures or alterations -

Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer. Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee safety. The use of other parts may lead to a loss of the manufacturer's liability for the consequences.

2.8 Inadmissible operating modes -

The operational safety of the delivered machine is only guaranteed by proper use acc. to the data under item 1.4 of the operating manual.

-

The limits given in the data sheet must not be exceeded in any case.

2.9 Explosion Protection -

Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g. electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at separately.

-

Improper operating methods that result in the specified temperatures being exceeded (exceeding or falling short of the operating data, falling short of the minimum delivery flow, reduction or failure of cooling water or circulation delivery, etc.) should be avoided at all costs.

-

Before starting the pump make sure that the pump system (suction pipe, pump casing and shaft seal) is completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere in the system.

-

Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters, ammeters, etc.).

-

Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe operation.

0000/e2-0-00-000 Page 2

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4. DESCRIPTION

Sketch 4.1-1 Typical view

4.1 General Pumps of the SULZER series GSG are horizontal, radially split, multi-stage, high pressure barrel casing pumps in „Cartridge-pull-out“ design. They are correspond to the requirements of API 610. These pumps are suitable for pumping clean and slightly polluted liquids. The permissible ATTENTION operating pressures and permissible operating temperatures depend upon the material specification. See 1.4.8 for safety limit data. The materials of construction have been selected for the liquids specified in your order. ATTENTION Before the pump is operated with other liquids or at other temperatures it is essential that the manufacturer be consulted. Explosion Protection In accordance with EU Directive 94/9/EC (ATEX), the pumps may – based on their designation – be used in the following areas: Group II Category 2

Category 3

G (zone 1) D (zone 21) G (zone 2) D (zone 22) G – potentially explosive gas atmosphere D – potentially explosive dust atmosphere Temperature classes Ensure that the pumps are classified according to their group and provided with the appropriate certificates. Each group is determined by the ambient gas or ambient dust and temperature o class, at a max. ambient temperature of 40 C. The maximum temperature permissible for the conveyed material must also be observed for the temperature class in question. The responsibility for observing the conveyed material temperature always lies with the operator. Temperature class Maximum temperature

T1 o 450 C

Max. medium temperature

430 C

o

Example of pump component designation

T2 o 300 C o

280 C

T3 o 200 C o

180 C

T4 o 135 C

T5 o 100 C

o

o

115 C

80 C II

2G

T6 o 85 C o

65 C T3

Group Category Temperature class

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4.2 Description of the pump Barrel casing: The cylindrical barrel casing is a machined casting or forging with integrated suction and discharge flanges and are closed on the discharge side by a casing cover. The fastening of the casing cover is arranged by heavy bolts and nuts. A variety of alloys are optional to provide compatibility with pumpage. The barrel casing is an integral part of the pipework. For overhauls the heavy piping has not to be removed. Internal block The internal parts form a unit held together by assembling bolts. The internal block with bearings and shaft seals can be removed as cartridge towards non-drive side. The surface pressure between the integrated stage casings will be produced hydraulically by the pressure of the pumped liquid. The internal parts are surrounded on all sides by the liquid and thus uniform heating is assured. Sealed and shouldered on the suction side and centered on the discharge side the internal block can freely expand and thus presents a high thermal elasticity. Impellers: The impellers are key-driven, have closed channels and are sealed against the casing elements by replaceable casing wear rings. The flow is guided from stage to stage by stationary diffusers. Shaft: Accurate machining provides precision fits and clearances for assembly and operation. Machined shoulders provide positive location of mounted parts. Shaft seal: The inner chamber of the pump which is filled with liquid is sealed at the shaft by mechanical seals. See 7.2 or description of the seal manufacturer for further information. The stuffing box housings are fitted with a cooling chamber as required. In order to prevent ATTENTION evaporation in the vicinity of the shaft seal, the cooling water quantity given under 1.4.3 must be assured. Non-compliance can lead to total failure of the shaft seal. Coupling: Flexible couplings must be used to connect the pump to the driver: These couplings must be able to absorb small axial, radial and angular shaft misalignments.

4.3 Bearing bracket and lubrication Bearing housings: The bearing housings flanged on both pump sides are equipped with ring-oil-lubricated antifriction bearings and automatic oil level regulation. The bearing at the coupling end absorbs radial forces, while the opposite bearing determines the axial position of the rotor. Antifriction bearings: Roller bearings are used as bearings for the massive pump shaft in the bearing bracket on the drive side, whereas paired tapered roller bearings or angular ball bearings take up the axial forces at the non-drive side. Fan: A fan assembly is provided to enhance air cooling of the bearing bracket non-drive side. Constant level oiler: An oiler is installed on each bearing housing. The oiler automatically maintains bearing housing oil level and provides a means of monitoring and refill. See also 7.3 Sight glass: A sight glass is provided to allow visual monitoring of bearing housing oil level. Lube oil system: Both bearing housings are provided with rotation-independent lube oil systems. The oil ring rotates with the shaft and continuously distributes lube oil from the bearing housing sump into the bearing cover whence it circulates through the antifriction bearings back into the oil sump. The lube oil quantity is given under 1.4.2 and 7.3. Bearing bracket non-drive side angular ball bearing (or taper roller bearings)

Bearing bracket drive side roller bearing Vent (Oil filling plug)

Oil drain plugs

Sketch 4-2.1 Bearing housings

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4.4 Absorption of the Axial Thrust - Balance drum General During operation of the pump an axial thrust is exerted on the rotor towards the suction side. This arises because the area of the back shroud of the impeller is larger than that of the front shroud which is interrupted by the impeller eye, both being subjected to the same liquid pressure. In multi-stage pumps the forces per stage are cumulative and considerable axial loads result. These forces are absorbed by the hydraulic balance device. Working principle The balance device consists of a balance drum (603.01) rotating with the shaft and a balance drum c liner (605.01) fixed in the discharge casing. The pressure difference between the pressure within the pump "a" (discharge pressure) and the pressure in the balance chamber "b" (suction 605.01 pressure + frictional resistance in the balance pipe) a creates an axial force "F" on the balance drum. b This axial force is opposite in direction to the pump F 603.01 axial thrust. The magnitude of the force "F" A depends on the area "A" of the balance drum which is sized in such a way that the axial thrust at the operating point is almost completely compensated. The residual axial thrust is compensated by a thrust bearing. The pressure difference between "a" and "b" also sets up a flow through the clearance "c" into the balance chamber. axial thrust A perfect balance is only achieved if there is no Sketch 4.4-1 Balance drum working principle pressure build-up in the balance chamber "b" as a result of the balance flow being restricted. Balance pipe ATTENTION

Severe damage to the pump will result, if the instructions for the laying of the balance pipe are not strictly observed.

To prevent a pressure build-up in the balance chamber there must be a drain for the admitted liquid. A tapping for this purpose is provided in the pump balance chamber (the position is indicated on the dimension drawing). ATTENTION

- The routing of the balance pipe depends on the operating conditions. It is either: returned to the suction tank or returned to the suction casing. The data on the installation drawing is decisive for the pump supplied. Note! With flow returning into the suction tank the following must be observed: ATTENTION

The frictional resistence of the balance pipe must not exceed 0,8 bar. Choose corresponding nominal diameter.

ATTENTION

A valve should be fitted in this pipe for maintenance purposes. Steps must be taken to ensure that this can be locked in the open position to prevent unauthorized and/or accidental

closure. Damages on the balancing device may lead to a heating of the balancing liquid causing inadmissible pressure in the balancing tube. A security valve has therefore to be built into this tube. Adjust opening pressure at 5 bar over inlet pressure.

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5. INSTALLATION 5.1 Mounting of the pump (see dimension drawing / installation plan) General Machinery intended for use in potentially explosive areas must satisfy the “Ex” protection requirements. Check the documentation relating to the machinery and accessories (and nameplates). Good planning and preparation result in fast, simple and correct installation. Safe running conditions with maximum accessibility are assured. When preparing for installation of the machine, it is necessary to take the following aspects into account: The main dimensions, connections, position of fixing bolts etc., are shown on the dimension drawing/installation plan. Suitable lifting devices must be available for installation and repair work. Good lighting is important and sockets for portable lights should be available. The pump should be readily accessible from all sides. The pump foundations and type of installation should be designed so that vibration is kept to a minimum both during operating and when the pump is at rest, otherwise the pump life will be reduced. A drain must be provided so that gland leakage, cooling water (open system) and liquid drained from the pump during overhaul can be led away. The draining of the pump respectively the disposal of the leakage for pumps delivering toxic, explosive, hot or in any other ways dangerous fluids, must not lead to any endangering of operator(s) and environment. Following manufacture the pump flanges and external tappings are protected by plastic plugs which should not be removed before the pipework is ready to be attached to the pump. The pump should be protected, if further site work is necessary nearby. The foundation or any other necessary building work must be finished, set and dried. Roughen and clean the foundation. All preliminary work for erection must be completed. With large units, suitable door and wall openings are to be provided for transport to the installation site.

Grout selection Select a non-shrinking grout that is compatible with the highest and lowest temperatures to which it may 2 be exposed. Use concrete from a concrete company with a final strength of 25 N/mm (B25) or better. If the service of a concrete company is not available the figures given below may be taken as a guide. - The concrete mixture suitable for grouting machine baseplate should contain 300 to 350 kg cement per 3 3 1 m (20 to 22 pound per cu. ft.) of concrete. The sand and gravel proportion for 1 m (1 cu. ft.) of 3 finished concrete (1.2 m (1.2 cu. ft.) mixture) is as follows: For grouting of the foundation bolts:

65% Fine sand

grain size

1 - 5 mm

(0.04 – 0.2 in.)

35% Coarse sand

grain size

5 - 10 mm

(0.2 – 0.4 in.)

water as required The use of so called „fast cement“ with short setting time is possible. For grouting (filling) of the baseplate:

40% Fine sand

grain size

1 - 5 mm

(0.04 – 0.2 in.)

60% Coarse sand

grain size

5 - 15 mm

(0.2 – 0.6 in.)

100 - 140 liters (7 - 10 gallons) of water ATTENTION

Only clean, washed sand may be used. The water-cement ratio has a decisive influence on the final strength of the concrete.

A high concrete strength will be attained with high standard strength of the cement, low water-cement ratio, and compacting by vibrating.

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Installation of pump and driver Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. With separate baseplates for pump and driver first erect the pump, then align the driver. - Roughen and clean the foundation. Walls of the grouting holes must have rough surfaces and must be free from pollution. Remove any loose particles, dirt or oil-soaked concrete. All baseplate surfaces which will be in contact with grout must be clean. Remove rust, paint or other extraneous material. - Attach wire rope slings to the baseplate transport eyes (see 3.1 transport/lifting) and lift the baseplate with pump and driver. Insert foundation bolts into the holes in the baseplate and tighten the nuts a few turns. - Lower the baseplate carefully into position on the foundation. The foundation bolts have to be lowered into the foundation holes.

Levelling - Place steel shims under the adjusting screws and align the pump unit horizontally with the aid of the adjusting screws. Provide proper grouting clearance between foundation and baseplate (see installation plan). Check levelling in the direction of the pump axis and also at right angles along the ATTENTION horizontal flange with a spirit (machinist’s) level. The flanges must be vertical on horizontal branches. See sketch 5.1.1. Preferred variance : 0.2 mm over 1 m (0.003 in./ft.). Maximum allowable variance: 0.5 mm over 1m (0.006 in./ft.). - Push steel shims into line to the right and left of the foundation bolts. The shims must be thick enough so that there will be only minimal clearance between baseplate and shim. The space between baseplate and shim must be filled with one or two thin parallel sheet metals which must be available in different thickness. See sketch 5.1-2. - Loosen adjusting screws and check levelling. If required correct levelling. spirit level pump flange

foundation bolt

adjusting screw

baseplate sheet metal

disc

shim

shim

concrete shaft

5.1-1 Levelling the unit

foundation

5.1-2 Grouting foundation bolts

Grout in the foundation bolts - Before grouting wet the foundation holes. Fill foundation holes with concrete. - After setting tighten the foundation bolts (see table 5.1-1) and check horizontal alignment again. If the position of the pump has changed, correct alignment. Do not bend the baseplate since this will cause development of vibration and noise during ATTENTION operation or the alignment of the coupling will not possible. - Before grouting the baseplate align the coupling as described under 5.2 (alignment report).

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Completion of grouting (when properly aligned) Grouting of the machine into the foundation is a very important part of the installation. Problems can arise, if materials are of poor quality, which may show up early or after several months of operation. ATTENTION

- Build a dam around the foundation. Forms must be strong enough to withstand the grout pressure. Attach a chamfer strip on the form inside, at grout grade elevation, to provide a neat beveled edge. See sketch 5.1-3. - Finish grouting the baseplate in conformity with the corresponding installation plan. Fill the baseplate with thinbodied concrete through grout holes. Take care that the baseplate is completely filled with grout, vibrate as necessary. The concrete must neither dry out nor freeze ATTENTION during the first 48 hours. During this time the o temperature of the foundation should not fall below 10 C o (50 F). The optimum temperature for the setting process is o o o 20 C +/-10 C (65 +/-15 F).

grout hole

baseplate

chamfer strip grout

foundation

5.1-3 Grouting of baseplate

- If necessary: Seal the grout openings by covering with a quality paint or with grout hole covers. When the concrete has set, re-tighten foundation bolts (see table 5.1-1) and check coupling alignment, see 5.2 (alignment report).

Tightening torques for foundation bolts (Table 5.1-1) M 12 (0.40)

M 16 (0.60)

M 20 (0.80)

M 24 (0.95)

M 30 (1.18)

before grouting of baseplate

15 (10)

30 (20)

70 (55)

140 (105)

280 (210)

FINAL after grouting of baseplate

20 (15)

50 (40)

100 (75)

180 (135)

350 (260)

Thread size (OD in.) Tightening torque Nm (lbf.ft)

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107

$OLJQPHQWRIFRXSOLQJ $*HQHUDO If the Sulzer scope of supply does not include the coupling / coupling protection, ensure that only approved materials and designs are used for applications in potentially explosive areas. 'ULYHU³1R/RDG´UXQ Before final aligning the coupling, and with the pump and driver uncoupled, check the direction of rotation of the driver corresponding with the direction of rotation arrow on the pump. The assembly of auxiliary equipment, and the electrical hook-up in the case of an electric motor, must be completed in accordance with the manufacturer’s requirements. Refer to the driver manufacturer’s manual for details. "No-Load" driver testing will allow the driver rotation to be checked and provide an opportunity to make final equipment adjustments before coupling to the pump. Flexible couplings need very careful alignment of the shafts which can be achieved by placing thin shims under the machine feet. Negligence in alignment will destroy the coupling and damage the pump and motor bearings, too. $77(17,21

$77(17,21

When applicable, ensure that any rotor locking devices are removed before attempting to turn rotors.

$77(17,21

Bearings must be lubricated BEFORE attempting to turn rotors. Avoid any unnecessary turning of machine rotors.

$77(17,21

Whenever practical, the pump must be filled with product before turning by hand.

$77(17,21

Stainless steel fitted pumps are particularly susceptible to “pick-up” and turning by hand should be avoided whenever possible.

6FRSH This section describes recommended procedures for aligning the motor (driving machine) to the pump (driven machine) for the pumpset supplied. 1. Determine which machine is to be levelled and positioned correctly and then used as the UHIHUHQFH PDFKLQH(normal pump). The position of this machine will then remain fixed, and the adjacent machine(s) will be moved as necessary to align with it. See sketch 5.2-1. 2. Ensure that the UHIHUHQFHPDFKLQH (pump) is level and positioned correctly. 3. Work outwards from the reference machine, and position the next machine $ in the train with the correct gap between coupling flange faces or shaft ends (as applicable) and align the shaft to the shaft of the reference machine. 4. Where a further machine % is included in the drive train, use machine $as the reference machine to position and align % to $. In the same way, position and align & to %, etc. %

$

'

&

Reference Machine

%

$

$

%

Reference Machine

6NHWFK Reference machine – next machine

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%0LVDOLJQPHQWW\SHV There are three basic types of misalignments between the pump and driver shafts:

6NHWFK $QJXODUPLVDOLJQPHQW Shafts with axes that  intersect at a point 

6NHWFK 3DUDOOHORIIVHW Shaft with axes parallel but offset

6NHWFK $[LDOGLVWDQFH Shaft with axes parallel but wrong distance

&$VVHPEO\ The assembly of the coupling must be carried out in accordance with the coupling manufacturer's instructions. For mounting the coupling halves onto shaft ends see also maintenance manual.

'&KHFNIRUÄVRIWPDFKLQHIHHWV´ Before coupling alignment the driver and pump fixation must be checked regarding “soft feet“ issue. Loosen machine feet fasteners one after the other and check with feeler gauge if a gap between machine feet and baseplate occur. If the gap is larger than 0.05 mm (0.002 in.), then the gap have to be compensated by shimming. If the base plate has not grouted yet, the “soft feet” may also be compensated by re-adjustment of the baseplate. If the pump or driver are not properly fixed to the base plate higher intermittent vibrations or excessive misalignment due to nozzle loads can be expected .

(3XPSIRRWWLJKWHQLQJWRUTXHV For the transport the tie bolts have to be tightened at the pump feet. To render possible a tension-free thermal expansion of the pump during operation, the screws loosened again for the precision alignment of the coupling must not be screwed so tight on the non-drive side as on the drive side. Essential values for the tightening torque of tie bolts on drive side and non-drive side are shown in the table below. 7KUHDGVL]H nominal diameter mm in. 0 (0.6) 0 (0.8) 0 (0.95) 0 (1.05) 0 (1.18) 0 (1.30) 0 (1.42) 0 (1.66) 0 (1.88) 0 (2.20) 0 (2.51) Table 5.2.1

7LJKWHQLQJWRUTXH Drive side Non-drive side Nm Nm lbf.ft lbf.ft 60 40 44 30 120 80 88 60 220 140 160 100 350 220 255 160 480 320 350 230 680 450 490 325 900 600 650 435 1500 1000 1080 725 2400 1600 1740 1160 3900 2600 2820 1900 5900 3900 4270 2800

Non- drive end

Tightening torque acc. to table

Drive end

Tightening torque acc. to table

6NHWFKPump foot tightening torques



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)&RPSHQVDWLRQRIWKHUPDOJURZWK Temperatures have a considerable influence and should therefore be considered during the alignment. The shaft centreline of each pump and driver will rise when they reach operating temperature. Therefore, the difference between the two anticipated growths should be incorporated into the cold alignment so that the shafts will come into alignment when operating temperature is attained. Shaft The unit with the greater thermal growth must be set lower than the other unit, by the difference between their thermal growth. 3XPSWKHUPDOJURZWK At pumps with feet at axe level (see sketch 5.2-6) the thermal growth can be negligible.

Thermal growth negligible

6NL]]H Pump thermal growth 'ULYHUWKHUPDOJURZWK $77(17,21 The thermal growth of the driver equipment must be obtained from manufacturer instructions. Thermal growth varies with temperature, load and ambient conditions. With drive equipment by gear or steam turbine an additional lateral and/or axial thermal growth have to be considered.

*$[LDOVKDIWGLVWDQFH The axial distance between the coupling halves must be observed. Please see installation drawing and hints on coupling assembly. Refer also to manufacturer’s instruction. The shaft of a driver without a thrust bearing must be set in proper running position before distance between shafts is adjusted. Refer to driver manufacturer instructions. &RXSOLQJ+XE6SDFLQJ Note: Where coupling flange faces do not align with shaft ends, (see sketch 5.2-7) distance between coupling flange faces (DBCFF or DBFF) is normally specified on the appropriate drawings, and should be used as the reference dimension for setting correct spacing between machines. The distance between shaft ends (DBSE) may also be shown but is not to be used as a reference dimension. Where coupling flange faces do align with shaft ends, distance between coupling flange faces, DBSE is normally specified on the appropriate drawings, and should be used as the reference dimension for setting correct spacing between machines.

'%&))RU'%))

'%6(

6NHWFKCoupling hub spacing

+$OLJQPHQW *HQHUDO Any change in elevation can be accomplished by shimming between equipment feets and baseplate pedestals. The maximum number of shims is four. After alignment tighten pump foot fasteners according to the given torques (see pump foot tightening torques) and re-check alignment. The coupling alignment certificate 7& have to filled in during each alignment check / procedure. Each alignment check / control has to be done only with pump in cold condition and under $77(17,21 consider of the thermal growth of pump and driver. Hot alignment procedure after stop from hot service are not allowed. Alignment of coupling must also be monitored GXULQJ pipework connection DQGUHFKHFNHG DIWHU pipework connection to ensure that pipework connection does not adversely affect alignment. If alignment is affected, the pipe connections must be re-made until alignment remains correct. Do not adjust driver OR driven machine positions to correct alignment errors caused by $77(17,21 pipe connection.

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$GMXVWPHQWGHYLFH For axial and lateral moving of heavy equipment (motor) a device has normally been fitted at the baseplate machine fastening pedestals. See sketch 5.2-8. Loosen equipment fastening screws and move the machine by tightening the adjusting screw into appropriate direction. Note: Before moving the machine be sure oposite adjusting screw are loosened. $77(17,21 After alignment and tightening the machine fasteners loosen all adjustment screws. Adjustment devices

Adjustment screws Machine feet

Baseplate pedestals

Moving machine

Baseplate pedestal

9LHZ; 6NHWFKAdjustment device

;

&RXSOLQJDOLJQPHQWSURFHGXUH Every alignment check must be preceded by a run-out measurement. Record the results always in the coupling alignment Test Certificate. Vertical alignment is checked first, and any required adjustment is applied. Then, the horizontal alignment is checked and any required adjustment is applied. Loosen the hold-down bolts on the moveable machine, lift the machine and insert sufficient shims under the mounting feet to approximately align the shaft with the shaft of the reference machine, taking into account the cold-offset (thermal growth). Slotted shims of at least the same size as the mounting foot must be used. The shim stock should ideally be stainless steel and be available in various thicknesses. For horizontal alignment in most case positioning jack screws are provided. Tighten or loosen jack screws as required to align the shaft with the shaft of the reference machine. After shimming and horizontal aligning tighten down the reference and moveable machine hold-down bolts to the correct torque value and recheck alignment. If required correct alignment.

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7ROHUDQFHV The maximum admissible axial misalignment is 0.05 mm (0.002 in.) on diameter, although ” 0.03 mm (0.0012 in.) is preferrable. The maximum admissible radial misalignment is 0.1 mm (0.004 in.) on diameter, although ” 0.05 mm (0.002 in.) is preferrable. &ORFNJDXJHDOLJQPHQW Alignment should be carried out with clock gauges in radial and axial direction (see sketch 5.2-9). Ensure that the supports for each indicator are sufficiently rigid to eliminate any sag that may cause spurious readings. All readings for radial and axial misalignment are determined in the gauge positions: top, bottom, right and left, i.e. every 90o, while both shafts are simultaneously turned. 2SWLFDO$OLJQPHQW Instead of using a clock gauge assembly, optical (laser) alignment equipment may be used. Laser optical alignment is the most exact shaft aligning method. The transmitter is a laser diode mounted on one side of the coupling and the prism is mounted on the other side. The laser beam emitted by the laser diode is reflected by the prism to the localizer. The offset can be detected by rotating the shafts.

6NHWFKAlignment of spacer couplings

6NHWFK Optical Alignment

,&RXSOLQJVDIHW\JXDUG The pump must only be operated with mounted coupling safety guard. After each alignment check the coupling guard must be refitted immediately. Check for correct assembly, fastening and distance to rotating coupling.

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5.3 Suction and discharge pipework General Welding, burning and grinding work should only be carried out on the pump where specifically authorised, e.g. there may be a risk of fire and explosion. Pipe diameters will have already been determined at the planning stage and many factors unknown to the pump manufacturer will have been taken into account. As a general rule the liquid velocity should not exceed 2 m/sec (6.5 ft./sec) in the suction pipework and 3 m/sec (10 ft. sec) in the discharge pipework. It is also good engineering practice to increase the size of both suction and discharge pipes at the pump nozzles in order to decrease the head loss from friction. For the same reason piping should be arranged with as few bends as possible and even then should be made with a long radius wherever possible. A few useful hints are given below which should be observed when the pipework is installed. In case the possibility of dangerous recirculation may occur after shut-down of pump, ATTENTION especially with "emergency trip out", back-flow preventors (check valve) have to built in.

Assembly The pipework must be supported in an adequate manner to ensure that no inadmissible bending moments or stresses caused by the weight of the pipework or thermal expansion are transmitted to the pump flanges (install an expansion piece). All supports and expansion equipment must be installed before making connections to pump flanges. Ensure that the correct gasket is used at all flanged joints and that the gasket is mounted concentric with the bore of the pipe. ATTENTION

Stress free pipe connection The stress free pipe connection is to be checked (cold condition, pump empty) in the following way: • The pipe has to be suspended over the pump flange and there must be space enough to easily build in the sealing. • The supports have to be designed in such a way that the weights of the pipe and the fluid are compensated and will not put inadmissible high pressure on the pump branch (observe nozzle loads in the installation plan). Higher than the given max. admissible nozzle loads may lead to a sudden leakage of medium delivered, life danger occurs. • If the pipe supports (especially fixed points) are not near to the pump with 1 or 2 elbow ( 45 or 90° direction change ) the pipe can be considered as flexible. In such cases following tolerances can be used for “stress free connections” :

A

Pipe

Pipe

S

Pump case Sketch 5.3-1 Radial misalignment

Pump case Sketch 5.3-2 Angular displacement

Stress free connection for flexible suction and discharge pipes (cold condition) Pipe nominal diameter

up to 200 (8 in.)

Radial misalignment

A

Angular displacement

S

over 200 (8 in.)

max. 0.5 mm (0.02 in.) max. 0.2 mm (0.008 in)

max. 0.4 mm (0.016 in.)

• If the pipe is considered as not flexible, so 50 % of the tolerances of flexible piping can de used. Be sure the max. admissible nozzle loads ( see installation plan) are not exceeded. Adjustments must be made to the piping, if these limits are exceeded or serious damage to ATTENTION the pump may result.

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Pipe fittings Discharge line A check valve and a shut-off valve should be installed in the discharge line. The check valve, placed between the pump and the shut-off valve, is to protect the pump from reverse flow and excessive back pressure. The shut-off valve is used in priming, starting and when shutting down the pump. Suction line In the suction line a shut-off valve should be installed for extended shut downs, repairs and for pump draining. It must be fully open during operation, and must not be used for pump regulating. Fittings having the same nominal bore of the pipework should be used. If the pump branches ATTENTION have a smaller nominal bore than the fittings suitable taper pieces should be installed.

Suction pipe On flooded suction applications, the horizontal sections of the pipework should descend towards the pump and on suction lift applications they should steadily rise towards the pump to prevent air locking.

Sketch 5.3-3 Flooded suction (Suction head)

Sketch 5.3-4 Suction lift

The pieces should be designed and constructed so as not to obstruct the free flow of the liquid. The transition from small to large pipe diameters must be gradual. As a general guide the length of a concentric taper piece must be 5-7 times the difference in pipe diameters. Sudden reductions in pipe cross sectional area and sharp bends should be avoided especially in the suction or inlet pipework, as these greatly increase the frictional resistance within the pipework. A high frictional resistance within the suction or inlet pipework leads to reduced pressure available at the suction branch. Too low pressure leads to cavitation at the impeller inlet. To prevent turbulent flow into the pump, do not position the shut-off valve in the suction piping adjucent to the pump suction nozzle. The suction valve should be positioned with the handwheel horizontally or vertically downwards to prevent air pockets forming. Install between flow disturbances as fittings or elbows a straight pipe with length of 5 to 8 time pipe diameter. Multi-pump installations should have separate suction pipes to each pump. Excepted are duty and standby pumps which may have common suction pipework since only one pump operates at any time.

Cleaning the Pipework Before a pumpset is commissioned, all traces of foreign bodies and impurities must be carefully flushed out of the supply tank and pipework. Where pipework has been welded, all welding slag etc. must be removed. ATTENTION

Suction strainer In order to prevent any of the above impurities entering the pump, it may be necessary to install a suction strainer made of stainless steel in the inlet pipework. The strainer insert should consists of a supporting strainer (plate with round holes 5 to 8 mm, (0.2 to 0.32 in.) to which a wire screen (wire cloth 0.315 x 0.2 mm, (0.0125 x 0.008 in.) is fixed by welding. The effective area of passage of this strainer must be at least 1.5 to 2 times the pipe ø 0.2 mm 0.315 mm diameter. (0.015 in.) Monitor the pressure drop across the strainer by a differential pressure (0.008 in.) gauge. If at any time, a reduction in pump suction pressure is observed, the Sketch 5.3-5 Wire cloth strainer should be removed and cleaned. The differential pressure ≥0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5 bar ATTENTION (7 psi.) the pump is SHUT OFF; higher differential pressures may lead to the damage of the strainer result in serious damage to the pump. ATTENTION The given values are limits for the load on the strainer. As NPSHavailable at the suction branch is reduced by the max. admissible differential pressure at the strainer whereas NPSHavailable has always to exceed NPSHrequired , lower regulation limits for ALARM / SHUT OFF may have to be set accordingly.

Pressure test ATTENTION

The pipework should be pressure tested in accordance with the statutory regulations.

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5.4 Ancillary equipment General Ancillary equipment is used to monitor the pump (measuring equipment for pressure, temperature etc.) and to maintain operation (cooling, flushing, sealing etc.). The extent depends on the application and installation requirements. For type, position and dimensions of the ancillary connections please see installation drawing. In case the failure of any auxiliary devices (e.g. cooling, circulation) may lead to an inadmissible pressure build-up in the pump suitable safety devices have to be installed by user (e.g. alarm, emergency shut-down or similar). ATTENTION Do not mix up connections. After laying the pipes (and also after repairs), check the pipe runs. The following instructions may be used as a guide insofar as they apply to the pump as delivered.

Electrical connections Electrical connections for motors and controlling devices may only be implemented by skilled personnel. The instructions of the electrical equipment manufacturers have to be observed as well as the valid national regulations on electrical installations and the legal regulations of the local power suppliers. The applicable standards and guidelines in respect of terminal connections should be observed.

Pressure measuring equipment -

The start-up and monitoring of the operating point of the pump is made easier with pressure gauges. See also 6.1 and 6.3. Pressure gauges should be mounted on a common gauge panel and connected to the tappings in the pump branches or adjacent pipework using a hydraulic tube with an expansion loop. Isolating and vent valves should be installed in the pipework for ease of maintenance.

-

If case of external flushing of the shaft seal, pressure gauges are installed in this pipes for monitoring the pressure (see 1.4.5).

Temperature measuring instruments -

If pump operates near the vaporization point of liquid, thermometers are recommended for control of liquid temperature. See also point 5.4 "Minimum flow device". At installation of thermometers in the pipework let submerse the temperature gauge at least 40 mm into the fluid. At pressures over 16 bar use protection tube (DIN 43763).

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If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid vaporization in the sealing range (see 1.4.5).

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At heating the max. temperature of heat carrier has to be controlled (see 1.4.4).

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A measuring possibility of cooling water outlet temperature is favourable, as the adjustment of outlet o temperature smaller than 40 C avoids deposits in the cooling water pipings.

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At pumps with high loaded bearings numerous controls of bearing- or oil temperature are required. If necessary control by means of contact thermometer. Execution and measuring points see pipework scheme or installation plan. Limit values see 7.3 and 1.4.2.

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It's useful to control temperature under sound insulation covers with tele-indication. Align such a way, that oil- or bearing temperature respectively of pump and driver cannot exceed the permitted limit.

Bearing monitoring (impact impulse measurement, only possible with antifriction bearings) -

Advancing bearing damage can be recognised and monitored by means of impact impulse measurement. This requires a special measuring unit which is connected near the bearing through screw fittings (e.g. SKF connecting nipple No. 1649013 and SKF measuring unit MEPA 21 A).

Flow indication or flowmeters - According to technical requirements flow indicators are installed in the reflux of supply pipework. Don't start-up pump before auxiliary pipings are open and the liquid stream can be determined on flow indicator. -

If there is danger for mechanical seal in case of too low circulation, a flowmeter is installed in the circulation piping, which causes alarm when circulation quantity decreases or which shuts the pump down.

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Filter / strainer / cyclone separator are absolutely necessary at rinsing of mechanical seal with spoiled rinsing liquid. Attention in case of operation with strainer or filter (is not valid in case of cyclone ATTENTION separator). If the pump may not be shut-down for change of filter, switchable, parallel arranged filters are installed. Rising temperature at cover of mechanical seal or inadmissible high differential pressure between measuring points in front of and behind the filter indicate dirty filter. Exchange or clean filter immediately. For operation safety reasons it is recommended to carry out the surveillance of filter not only locally, but also by tele-indicator in the central switch office.

Ancillary pipework -

Drainage of the pump casing can be effected by leading a pipe into the drip tray of the baseplate or into a collection pipe. Isolating valves must be installed in the pipe and must have a pressure rating at least equal to the rating of the casing. The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to any endangering of operator(s) and environment.

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Gland leakage from the shaft seal can also be led into the drip tray or collection pipe. The leakage of dangerous fluids has to be drained or quenched in such a way as to prevent any dangers to persons and environment.

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Cooling through cooling liquid: Connections and scope see installation plan or separate drawing respectively. Don't confuse inlet and outlet connection. (Inlet lowest, outlet highest point of cooling chamber). For the adjustment of cooling water quantity regulating valves are installed in the supply pipings. At open system lead the drain pipings over a funnel.

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Heating: Connections and scope see installation plan or separate drawing respectively. Don't confuse inlet and outlet connection. (Inlet highest, outlet lowest point of heating chamber). In the supply pipings regulating valves are installed. Lead reflux in a collecting piping, if necessary via steam trap.

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Flushing and / or sealing of the shaft seal: Connections and scope see installation plan or separate drawing respectively. For pipings which lead to a heat exchanger, pressure transmitter or supply reservoir, a vent possibility is provided at the highest point. In case of thermosyphon revolution the biggest pipework diameter possible will be used. Supply piping is layed evenly ascending and without sharp bend.

- Quench: In case the necessity arises to quench any leakage from the mechanical seal see 1.4.7 for information on quench media and quantity.

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6. OPERATION 6.1 General The following recommended start-up and operating procedures apply to the pump only. For information on any equipment (driver, shaft coupling, shaft sealing system ...) refer to manufacturer’s instructions.

Safety information Do not start or operate the pump, - unless the installation has been verified to be correct and all safety and control functions have been checked. - unless you have a complete understanding of the location and function of all components of the pump aggregate including valves and any upstream and downstream equipment that my effect the flow of medium to or from the pump. - unless you have a complete understanding of the all auxiliary mechanical, electrical, and hydraulic systems as well as the function of all monitoring gages and warning devices. When starting the pump, be prepared to execute an emergency shutdown in case of failure of the pump or auxiliary system.

6.2 Commissioning Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. The items described individually have to be carried out, as far as applicable, step by step during commissioning. With electric drive it has to be assured by qualified personnel that the necessary protection measures work. Earthing, reset, residual current failure operated device etc. have to be ready for service acc. to approval by skilled personnel.

ATTENTION

Before commissioning a. Connections Check bolted connections and plugs. Inspect ancillary pipework for correct installation. b. Lube Rinse bearing housing with light oil and allow to drain. Fill with lubricating oil, see also 1.4.2 / 7.3 and lubricant table T3. c. Alignment Remove coupling guard. Check alignment of coupling (see 5.2) d. Shaft seal Check shaft seal (see 7.2). In case of double acting mechanical seal fill and vent sealing system (refer to manufacturer’s instruction). e. Filling the pump In case of hot product: To prevent thermal shock the pump should slowly and controlled ATTENTION filled up with small fill up rate. Filling the pump - feeding operation Filling the Pump - suction lift • Slowly open shut-off valve in inlet line • Fully open shut-off valve in suction pipe • If existing (see installation plan) Open • If existing (see installation plan): Open vent (not valid for self-venting casing) vent (not valid for self-venting casing) • In case of mechanical seal: Shaft sealing • In case of mechanical seal: Shaft sealing chamber has to be vented (see also 5.4 chamber has to be vented (see also 5.4 Flushing and Sealing) Flushing and Sealing) • As far as existing: Close vent when • Fill pump (suction pipe must have foot pumped medium flows without bubbles, valve) fully open shut-off valve in inlet line • As far as existing: Close vent when • Mount coupling guard pumped medium flows without bubbles • Mount coupling guard Before starting the pump, the suction piping, pump case and shaft seal chamber must be completely filled with liquid. If there is danger of frost, protect the pump casing, bearing housing and cooling chambers ATTENTION against freezing. f. Minimum flow line (if fitted) Open and lock the valve in the minimum flow line (see also 5.4 - para. Minimum flow device). g. Balance line If the balance line is returned to the suction tank, also open and lock the valve in this line. (see Installation Plan or P & I Diagram). ATTENTION

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6.3 Pump start-up and Operation Pump operation is based on the assumption that the pump system is always completely full of delivery fluid. This prevents the existence of any potentially explosive mixture in the pump. If this is not guaranteed, appropriate safety systems (e.g. liquid detectors or motor load controllers) must be provided on the equipment. A pump shut down for more than 30 days must have bearing pre-lubricated before start-up. Open connections on the bearing housing upper side and spray lube oil direct into the bearings (see sketch 7.3 Pre-lubrication). ATTENTION

a. Ancillary equipment If available, put ancillary equipment into operation (e.g. cooling, heating, sealant pressure...), open the valves in the ancillary pipework (open Quench after pump start-up), vent pressure gauge (see also 5.4). b. Start-up with non-pressurized system • Close shut-off valve in the discharge pipe (minimum flow must be guaranteed). • Start driver and bring the pump rotor immediately to operating speed.

Start-up with pressurised system (precondition is non-return valve in discharge pipe) • Start driver with open discharge valve and bring the pump rotor immediately to operating speed

• Open discharge valve slowly, until the differential pressure drops to the value given on the data sheet. Warning: The differential pressure must not fall below the design point even with plants with fluctuating system pressure. Note: The pressure gauge on the discharge side shows the differential pressure plus the suction pressure. c. Observe ammeter reading The full load amps given on the rating plate of the motor must not be exceeded. d. Adjustments The pump capacity can be adjusted by the discharge valve. Do not operate pump below minimum flow (see 1.4 and 5.4 Minimum flow). During pump ATTENTION operation the valve in the suction line must be fully open. Non-observance may result in an unacceptable temperature increase and cause the pump to run dry. In extreme cases the pump casing may burst.

6.4 Inadmissible operating modes Overloads have to be avoided by all means as they may lead to a failure of parts due to too stringent mechanical requirements. Overloads occur, if the pump is run beyond its original application range, i.e. z exceeding of the max. admissible speed z remaining of the min. speed (low speed rotation e.g. by turbine drive, high velocity flushing through the pump, damage of discharge non-return valve causes serious damage to the pump) z exceeding or remaining of the medium viscosity z exceeding of the max. admissible inlet pressure z exceeding of the max. admissible temperature z exceeding or remaining under the operating range of the pump z running of the pump without proper venting of pump interior z running of the pump without required safety devices ( safety valves, electrical overload protection etc.) z operation of the pump with closed or strongly throttled shut-off device in the discharge line without having a minimum flow device (exception: during start-up). z operation of the pump with closed or throttled shut-off device in the inlet line (dry running)

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z operation of the pump for the delivery of fluids, for which the pump are not suitable (chemical, solids, gas content ...) z operation of the pump with wrong sense of rotation z operation of the pump with inadmissible bearing lubrication or with wrong lubricant Operating modes like that and other inadmissible operating modes may lead to heavy damage on the pumps and other parts of the plant. Danger may arise by the bursting of pressure-holding parts and people within the range of danger may be hit by pieces or fluid, which may be hot, aggressive or toxic, as the case may be. There may be mortal danger.

6.5 Shut-down (observe sequence) a. If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shut-down is for a short time only. For lengthy shut-downs, for repairs and where there is no non-return valve, the discharge valve must be closed. b. Stop the driver, when doing this pay attention to whether the rotor runs down smoothly. Standby service Ancillary systems as cooling- , sealing- and quench systems are operational. Standby pumps should be started at regular intervals to ensure their readiness for immediate service. We recommend to start-up the pump unit once every month and run for 30 minutes. Extended shut down c. If the pump works on a suction lift and is not to be left ready for start-up, the suction valve should also be closed. d. If existing, close quench piping. e. If fitted, close the valves in the ancillary pipes with the exception of the cooling water, which should only be switched off when the pump has cooled down. Freeze damage, preservation g. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including external heat exchangers and pipings.

6.6 Restart procedure If the pump is switched off by emergency shut down or trip, do not restart before the causes of the emergency has been found and removed. a. Before restarting, check that the pump shaft is at a standstill. If the non-return valve in the discharge pipe is leaky, the pump shaft may rotate in reverse direction due to the backflow of the medium delivered. The pump must not be switched on when the pump shaft is rotating in reverse direction, as ATTENTION this may damage the pump shaft. b. Proceed restart as given in section 6.3 Start-up and operation.

6.7 Service Control General A pump must be looked after and carefully supervised to ensure trouble free running. During the first period of operation (24 hours) supervision should be intensive. Read and check the operating parameters every hour. During the next period of operation (first week) supervision should be done every 24 hours. During normal use checking should be done together with the regular inspections at least ones a week. ATTENTION

If any vibrations, unusual noises or faults are observed stop the pump unit at once. Refer to section “Operating faults”.

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Number of starts The pumps are designed for continuous operation. Too many and too frequent starts can accelerate ageing and result in abnormally high wear and short life time. In case of many starts we recommend an intensive supervision and maintenance intervals should be shortened. The recommended number of start-ups are as following: - Commissioning phase: up to 200 start / stops (max. 6 starts / day) - Commercial operation:

up to 3 starts / day

Cumulated number of starts max. 600 starts / year Remark: In case of many start / stop cycles we recommend to perform a general overhaul of the pump after 6 years running time.

Checking the duty point (design point) of the pump Particularly important at the initial start-up: • Check the speed. • Read the discharge pressure and subtract the suction pressure. Convert this pressure (generated pressure) to a head and compare it with the generated head shown on the pump duty plate at the corresponding speed.

generated head (m) = Metric units

generated pressure (bar) x 10 200 3

density of liquid (kg/m ) 3

generated pressure (bar) =

generated head (m) x density of liquid (kg/m ) 10 200

The generated pressure must not fall below the value given in the pump data sheet, otherwise the maximum allowable capacity could be exceeded, the driver could be overloaded or the suction pressure could fall below the minimum required by the pump.

ATTENTION

Checking the capacity

pump characteristic curve

The capacity is determined from the pump performance curve and the generated head (m) as calculated above.

Minimum capacity

Head in (m)

* If the characteristic curve sheet only includes the pressure of one stage divide head by number of stages of the pump supplied.

Maximum capacity

Operating range

Find the calculated value of the generated head on the vertical axis of the performance curve.* Draw a horizontal line through this point until it intersects the curve. The corresponding capacity is read on the horizontal axis vertically below the point of intersection.

3

Capacity in (m /h)

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6.8 Operating faults Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable operating faults in the plant. There is usually a certain connection between the different types of faults. It is, therefore, expedient to list and compare the symptoms as well as the possible causes. Assistance can be found for individual operating faults in virtually all cases.

Symptoms / Possible causes of faults / Remedies Symptoms

Possible causes of faults

Remedies

1 Pump does not work. No discharge pressure. (Failure at start-up)

Driver out of service, speed too low

Check - refer to manufacturer‘s manual Check and correct Check-refer to pump rotation arrow Vent pump Inspect and correct Inspect foot valve Inspect pump internals Fill the system Check operating data (1.4)

Rotor blocked Wrong direction of rotation Pump not primed Suction valve/line blocked Foot valve blocked or damaged Impeller passages blocked 2 Loss of discharge Suction pipe not completely full pressure after start-up Too much air or gas in the pumped liquid Leakage of air into pump suction 3 Pump flow too small. Suction or Discharge valve not fully Differential pressure open too low. Suction strainer blocked Efficiency loss Minimum flow line open, minimum flow valve damaged or bypass orifice worn Furring of the pump internals and/or pipework

4 Pump vibrates or causes too much noise

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Check and correct (seal) Check valve position and correct as required Disassemble and clean strainer Check minimum flow line, minimum flow valve, bypass orifice (5.4)

Clean and flush pipework. Disassemble and clean pump internals. Impeller passages blocked Disassemble and inspect pump internals Pump internals worn (gap clearances) Disassemble and inspect pump clearances (8.) Coupling alignment faults Check coupling alignment (5.2) Worn shaft coupling Check coupling condition and replace Suction valve not fully open Check and correct (open fully) Suction strainer blocked Disassemble and clean strainer Pump runs with cavitation Check operation data (1.4). Create more pressure at the pump suction. Piping strain, excessive high nozzle Piping should be properly supported forces and moments to prevent strains from being imposed on the pump Foundation too weak, base not or not Inspect foundation bolt tightening and correctly grouted baseplate grouting (5.1) Impeller damaged or blocked Inspect pump internals Bearings damaged Disassemble and replace bearings (8.) Unbalanced rotor – causes vibration Check balance of coupling, driver and pump rotating parts Shaft bent Disassemble and check shaft runout (8.)

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Symptoms

Possible causes of faults

Remedies

5 High shaft seal temperature. High leakage of mechanical seal. Short shaft seal life

Seal flush insufficient (flow rate) or missing Wrong orifice size or worn orifice Solids block seal rings/springs

Check flow requirements

6 High bearing temperature. Short bearing life.

7 Lube oil leakage

8 Excessive wear of pump internals - Corrosion - Erosion - Loss of material 9 Pump overheating/seizure

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Check size, flow requirements Disassemble and remove solids, review application Vaporisation in the seal ring area Check circulation flow or cooling requirements (1.4, 7.2) Seal fluid not suitable (abrasive) Review application, install filter or separator Seal rings, auxiliary gaskets (O-rings) Disassemble and replace damaged or springs damaged seal parts (8.) Dry operation of seal. Seal system not Fill and vent shaft seal correctly filled or vented chamber/system Seal face material inadequate Review application with seal manufacturer Pump shaft bent Check shaft runout at seal area Pump not running at operating point Review operating parameters (1.4) Coupling alignment faults Check coupling alignment (5.2) Too much grease or oil in the bearing Check and correct (7.3) Oil level too low or high Check and correct oil level (7.3) Wrong lube oil quality Verify that recommended lubricant is used (7.3, T 3). Change lube oil. Bearings loaded during assembly Examine assembly and condition of bearing and associated parts (8.) Insufficient bearing cooling (air / Check air intake (environmental water) temperatures under noise hoods). Check cooling water requirement (1.4) Bearings damaged Disassemble and replace bearings (8.) Excessive pump thrust Check hydraulic balance device, balance pipe. Disassemble and inspect pump internal clearances (8.) Shaft bent Disassemble pump and check shaft runout (8.) Oil level too high Check and correct oil level (7.3) Labyrinth seal or shaft seal ring Examine assembly (labyrinth leakage improperly installed bore downwards) Bearing cover gasket or seal Disassemble and replace damaged gaskets/seal (8.) Vent blocked Check and clean vent connection Pump not running at operating point Review pump operating parameters with a Sulzer representative, make Insufficient suction pressure. necessary correction to unit design. Operating fluid differs from specified Refurbish pump with correct parts, value (temperature, specif. gravity...) clean system. Assemble filter or Materials of construction not separator. compatible with medium delivered Operating below minimum flow Review hints for minimum flow. (1.4, (pump dry running) 5.4) In case of seizure disassemble and repair unit.

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7. MAINTENANCE 7.1 Maintenance - Pump general Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. The operating personnel shall inspect the machine frequently. The purpose of the inspection is to thoroughly familiarize personnel with the equipment. This is imperative if abnormal occurrences are to be detected and remedied in time. It is vital that the inspections cover the following points: 1. Leakage > Check main connections on pump suction and discharge > Check leakage on shaft sealing, auxiliary connections > Check for oil leakage on bearing housing 2. Gauges > Check pressure gauges (pump suction, discharge, ...) > Check temperature (fluid, bearings, driver, ...) > Check ammeter (motor) 3. Bearings > Check the bearing temperature > Feel the bearing vibrations (measure the SPM- values) > Check the oil level, refill constant level oiler 4. Vibration, Noise > Feel the machine > Check for undue vibration > Check for unusual noises 5. Fastening elements > Check that all screw fasteners are correctly tightened Safe operation can only be guaranteed if the pump unit is kept in perfect technical condition. This, in turn, can only be achieved through constant monitoring and proper maintenance. ATTENTION

If any vibrations, unusual noises or faults are observed stop the pumpunit at once. Ascertain the cause and rectify (see Operating faults).

Monitor ancillary equipment during operation (if fitted) Gauges: Cooling: Flushing/Sealing:

pressure, temperature, ammeter at regular intervals flow and temperature pressure, temperature, (quantity)

Any deterioration in pump performance not caused by alteration or furring of the pipework is probably due to wear of the pump internals. The pump should be taken out of service and overhauled. See section 8. for details on overhauling the pump. The pressure in the balance chamber should always remain constant. If the balance ATTENTION pressure increases by 2-3 bar over the pressure when the equipment is new, the balance device must be checked for damage. In most cases it will be necessary to change the balance parts. The increase in balance pressure can, however, also be attributed to the increase in resistance in the balance line due to furring.

Bearings For information about lubrication see chapter 7.3. Bearing housings has to be kept clean on the outside, since the radiation of heat is reduced by deposits of dust or dirt. Bearing monitoring: Check the bearing vibration during running. In case of antifriction bearing, by means of shock impulse method. Carry out checks according to the operating instructions of the measuring gauge in fixed intervals. During first start-up the initial values must be recorded to find out deviations of later measurement. After measuring put coloured caps on measuring nipples distinguishing, = everything o.k > green cap = increased attention > yellow cap = beginning bearing damage > red cap With correct maintenance and unhindered heat dissipation, it is possible – in the area of the rolling o bearings - to maintain temperature class T4 (135 C) at the surface for ambient temperatures up to o +40 C. Special measures (cooling) must be taken for higher ambient temperatures, or for o o temperature classes T5 (max. 100 C) and T6 (max. 85 C).

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Vibrations These can be detected by hand or with electronic equipment (frequency or amplitude analyser). Horizontal pumps, which are fastened to the foundation with anchors should not exceed a vibration speed given in the following table. Bearing vibration level unfiltered RMS / 10-1000 Hz -1 -1 Operating speed up to 3000 min up to 3600 min Continuous operation 4.5 mm/s (0.18 In/s) 5.6 mm/s (0.22 In/s) Alarm at 7.1 mm/s (0.28 In/s) 9.0 mm/s (0.35 In/s) Shut off aggregate 11.0 mm/s (0.43 In/s) 11.0 mm/s (0.43 In/s) This values are valid for operation at rated point / preferred operating range (from >70% Flow to <120% BEP) only. Flow < 70% BEP - part load operation acceptance criteria: +1.5 mm/s (0.06 In/s) RMS compared to the value for preferred operating range. Measured values which are too high can also be caused by the plant (pipings/accessories) or by other vibration sources (machines). In order to determine the reason for high vibration values a vibration analysis is necessary. ATTENTION

Noise Some abnormal noises can be heard immediately, such as those due to rolling element indentations because of improper mounting; others are progressive. Noise is usually an indication of incipient failure and varies in intensity and frequency with the extent of damage.

Alignment During shut-down (according to operating requirements) check the alignment of the coupling (at least once a year). Re-align if necessary (see 5.2).

Operating log It is recommended to enter operating data and data on lubrication, repairs etc. in an operating log. An ongoing operating record will assist troubleshooting and machine service decisions. Analyse machine performance regularly.

Spare parts It is recommended that spare parts listed below are always kept in stock. This modest investment can often prevent minor faults from developing into serious trouble. The following parts should be stocked: > Antifriction bearings, in case of plain bearing (set bearing shells, pads) > Balance drum and liner (set balance discs) > Wear rings and setscrews > Gaskets and O-rings > Mechanical seals For pumps used in extremely important service or if several identical machines are operating in the same plant, it is recommended that a complete machine be stocked at job site. Orders for spare parts should always include the following information: > Type of pump (rating plate or operating manual) > Order number (rating plate or operating manual) > Quantity and designation of parts / article-number (parts list) > Part number (parts list or sectional drawing) Pump safety can only be ensured if repairs are carried out by expert specialist personnel using original replacement parts.

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7.2 Maintenance - Shaft seal Single-acting mechanical seal (for make, type and size see sectional drawing) General remarks Mechanical seals intended for use in potentially explosive areas must satisfy the “Ex” protection requirements. In the case of mechanical shaft seals the exit of the medium delivered is prevented by two plane parallel lapped ring surfaces which are pressed together with the help of spring force and liquid pressure. Seal rings (stationary and rotating) are sealed against adjacent pump parts with the help of adjoining sealings (as for example O-rings) serving simultaneously as elastic bearing.

Conditions In order to have trouble-free operation a liquid film has to form between the slide faces and therefore the following conditions have to be fulfilled by the medium delivered: - sufficient lubricating properties - evaporation temperature higher than working temperature - no impurities in the slide ring region

ATTENTION

If auxiliary facilities like - flushing - blocking - cooling - heating - cyclone separator/filter (in case of an impure medium delivered) are necessary for arriving at the operating conditions required the details given in paragraph 1.4.3 / 1.4.4 / 1.4.5 / 5.4 and in the installation plan of the pump have to be observed. Failure of an auxiliary device (cooling, circulation, etc.) may cause the temperature of the casing surface to rise to an unacceptable level. If necessary, provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with emergency switch-off).

Maintenance The maintenance of the mechanical seal is limited to the control of the leakage, of the temperature and, if fitted, to the auxiliary facilities. A small leakage of the mechanical seal is normal. It is impossible, however, to make special statements with regard to the leakage of the mechanical seal, as the quantity of leakage depends on a lot of different factors (e.g. size, material, liquid pumped, temperature etc.). In case of high leakage seal ring pairs may also leak. If so the damaged parts have to be replaced. Secondary seals (e.g. Orings) have to be replaced during each assembly. Rotating and stationary seal rings must be replaced together. ATTENTION

0000/e7-2-01-001

126

Recommended Lubricants

T3

Proper lubrication is particularly important for the operational safety of centrifugal pumps. If suitable lubricants are correctly applied, an optimum performance is obtained and trouble and its consequences are avoided. Supplementing the operating instructions, the table gives the lubricants which are recommended for the lubrication of centrifugal pumps which are suitable for an ambient temperature between -20°C up to +40°C. The lubricants have been listed in alphabetical order which does not say anything about their quality

Supplier

Hydraulic oil according to DIN 51 524 (DIN 51 517) ISO VG 46

ISO VG 68

ADDINOL

ADDINOL HLP 46

ADDINOL HLP 68

AGIP

AGIP OTE 46

AGIP OTE 68

ARAL

ARAL VITAM GF 46

ARAL VITAM GF 68

BP

ENERGOL HLP 46

ENERGOL HLP 68

CASTROL

CASTROL HYSPIN VG 46

CASTROL HYSPIN VG 68

CHEVRON

EP HYDRAULIC Oil 46

EP HYDRAULIC Oil 68

ELF

ELF OLNA 46

ELF OLNA 68

ESSO

ESSO NUTO H 46

ESSO NUTO H 68

MOBIL OIL

MOBIL D.T.E. 25

MOBIL D.T.E. 26

SHELL

SHELL TELLUS OEL 46

SHELL TELLUS OEL 68

TEXACO

TEXACO RANDO 46

TEXACO RANDO 68

WINTERSHALL

WIOLAN CA 46

WIOLAN CA 68

4610/e7-3-01-000

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Pre-lubrication A pump shut down for more than 30 days must have bearing pre-lubricated before start-up. Open connections on the bearing housing upper side and spray lube oil direct into the bearings (see sketch 7-1, sectional drawing). ATTENTION

Vent (Oil filling plug)

Oil drain plugs

Sketch 7-1 Bearing pre-lubrication

Oil level The center of the sight glass (if present) indicates the minimum oil level required in the bearing housing. During standstill of the pump the oil level is to settle higher; during operation the oil level sinks towards the centre of the sight glass. ATTENTION

Monitoring oil level. A sudden oil level drop can indicate a leak. Stop operation and inspect unit. The cause may also lie in a too high an adjusted oil level.

Oil replacement Warning: Lube oil can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturer. For oil replacement proceed as follows: 1. Shut down pump. 2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage bores and size see installation plan or dimension sheet.) 3. Remove screw plug, drain oil thoroughly. Tighten screw plug again securely. 4. Fill bearing bracket with fresh oil as described. Dispose of used oil according to statutory regulations. Do not put into waste water by any means.

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131

8.

OVERHAUL

8.1

Dismantling of the pump Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises.

Note: During the guarantee period, modifications, disassembly or repairs can only be worked out by our service personnel or with our written approval. When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts, gaskets, O-ring seals...) well beforehand to minimise the down time. When ordering spare parts it is essential to give an exact description of the part, its part number, the pump type and serial number (see the duty plate). References: Refer to specific drawings (section drawing(s), parts lists, installation plan). Note: These pumps should only be disassembled by qualified specialists with suitable tools and by strictly observing the instructions. All assembly works have to be carried out with the greatest possible care. Negligence leads to premature failure of the pump.

Preliminary work -

Close the suction and discharge valves and secure them against unauthorised opening.

-

Let hot pump parts cool down to ambient temperature before disassembly.

-

Isolate the driver to prevent start-up With electrical driver: Remove residual current (take away safety fuses). Have electrical connections disconnected by an electrician.

-

Drain the pump (position of drain screw see installation plan) The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to any endangering of operator(s) and environment. Observe legal provisions for disposal.

In case the pump delivered aggressive, toxic or otherwise dangerous media, it has to be flushed carefully, to be cleaned on the outside and to be decontaminated in the case of radioactivity. If the pump is sent to the manufacturer to be repaired, the cleaning/decontamination has to be carried out before transport. A certificate attesting that it is absolutely safe must be included. The service personnel will have to be careful however in spite of this, as even in the case of a thorough flushing and cleaning, residues of the fluid may leak out. -

Remove the coupling guard and separate the coupling halves (remove spacer).

-

Remove any instruments and ancillary pipes.

-

With oil lubrication: Drain off oil from bearing housings.

Dispose of used oil acc. to legal regulations. Never put it into the sewage system. Pay attention to hazardous situations during disassembly, i.e. take care to stand firm, secure assembly parts against dropping, support or prop loose parts etc. -

With mechanical shaft seals in Cartridge design: Loosen assembly bars of the cartridge mechanical seal at the seal cover, draw them into the groove of the shaft sleeve and fasten again.

-

Remove coupling half on pump drive side (see sketch 8.1-1), take off key (940...) To avoid damage to the bearings or to the shaft centering thread use a suitable puller and protect the shaft centering thread by a disc. The bearings must by no means be subjected to any pressure or shock.

Sketch 8.1-1

4610/e8-0-01-001 page 1

132

Dismantling of the internal block (cartridge) Remark: Maintenance, inspection and repair works on the bearings, shaft seals and hydraulic balance device does not require internal block removal (opening of barrel casing). If the internal block should be removed do not remove the bearings. -

Balance pipe: Remove the balance pipe (re-circulation line from discharge cover to suction tank or barrel casing suction side) and close the connections.

-

Note: The dismantling of the internal block from barrel casing can only be carried out with the required special tools. Follow separate description 8.4.

-

Transfer the dismantled internal block to assembly site and position it horizontally in such a way as the parts of the clamping tools and the delivery cover (163.01) are not supported.

Removal of bearing – non-drive side -

Remove screws (900.01) for the fastening of the fan cover (832.01) and take off fan cover. Take circlip (932.01) out of shaft groove by means of spring ring pliers, push fan (831.01) off the shaft and remove key (940...).

-

If present: Loosen grub screw (904...) of thrower (507.05) and push thrower off the shaft. Remove carefully any burrs caused by grub screw.

-

Remove hexagon socket screws (914.02) from bearing cover (360.02) and take off bearing cover.

-

Labyrinth seal (if present): Clean and lubricate the pump shaft and push carefully the bearing cover together with labyrinth seal (423...) off the shaft. If required: Push labyrinth seal (420...) out of bearing cover bore. Note: The labyrinth seal consists of two parts, a rotor and a stator, but is assembled as a single unit. Do not separate the rotor from the stator.

-

Remove shaft nut (920.16 or 920.15 depending on model). Shaft nut (920.16): Locking pins pressed against the shaft by the adjusting screws, are in the bearing fastening nut KMT (920.16). As the locking pins were fitted into the bearing nut by pressure fit, the bearing nut will still rest tightly on the shaft thread after loosening the adjusting screws. Light tapping on the shaft nut near the screw holes will loosen the locking pins a little so that the shaft nut can be screwed off easily. Shaft nut (920.15): Bend lockwasher tang out of bearing nut (920.15) and screw off bearing nut and take off lockwasher (931.01).

-

Take off oil ring (644.01) and push spacer sleeve (525...) off the shaft.

-

Arrest the shaft before drawing off the bearing bracket on non-drive side. To do so mount a holding device on the drive side to fasten the rotor to it by means of the shaft bore, see sketch 8.1-2. Draw off bearing bracket with puller: Push bearing bracket together with antifriction bearings evenly off the shaft. puller

Sketch 8.1-2

Arresting the rotor on drive side: Replace 2 fastening screws from bearing cover opposite to each other by the holding device and secure the rotor by the shaft centering thread. holding device

shaft

4610/e8-0-01-001 page 2

Bearing bracket non-drive side

Bearing bracket drive side

shaft

133

-

Remove doweling (tapered pins, 560...) on bearing bracket flange. Screw in (tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws 901...) on the bearing bracket flange.

-

Screw off hexagon socket screws (914.05) of the bearing bracket fastening, mount puller (see sketch) and draw off bearing bracket together with antifriction bearings (320.03).

-

Depending on design, push spacer sleeve (525.02) or inboard thrower (507.06) off the shaft.

-

Push spacer sleeve (525.02) together with labyrinth seal (423...) off the shaft or remove labyrinth seal from bearing housing bore.

-

Push thrower (507.06) off the shaft

-

Dismantle antifriction bearings from bearing housing.

Removal of shaft seal and hydraulic balance device -

Cartridge mechanical seal: Remove the fastening nuts (920.05) of the mechanical seal cover and draw the complete mechanical seal (Cartridge) out of the shaft sealing chamber. Be careful: Remaining medium will flow out. After loosening and moving the assembly bars out of shaft sleeve groove the mechanical seal can be disassembled into its single parts. WARNING: The mechanical seal cover is prestressed by internal springs.

-

Standard mechanical seal: Remove fastening nuts (920.05) at the seal cover (471.01) and take off seal cover together with the stationary components of the mechanical seal. Be careful: Remaining medium will flow out. Draw shaft sleeve (523.01) together with the rotating parts of the mechanical seal fastened to it off the shaft (the shaft sleeve is supplied with a groove to apply the tool).

-

Unscrew nuts (920.02) fastening the bearing lantern (344...), loosen by use of jack screws and remove bearing lantern.

-

Loosen shaft seal housing (441...) by use of jack screws and remove shaft seal housing. Be careful: Remaining medium will flow out.

-

Draw sleeve (520.01) off the shaft and remove split ring (501.01) from shaft groove. Remark: For removal of the split ring it may be required to push the balance drum towards drive side. Take off key (940.04).

-

Mount device and draw-off balance drum (603.01) and balance drum liner (605.01). See sketch 8.1-3. Take off key (940.02).

-

Delivery cover (163.01)

If the internal block has been dismantled: Remove split ring ( special tool 05) and distance shims ( tool 06). Remove carefully delivery cover (163.01).

Balance drum (603.01) Shaft

Balance drum liner (605.01)

Sketch 8.1-3

Removal of balance drum and balance drum liner

Removal of bearing – drive side - To disassemble the bearing bracket drive side remove holding device (mounted for dismantling the bearing on the non-drive side). WARNING: If the bearing bracket on the non-drive side has been removed. The rotor must not be moved in axial direction to avoid damaging of the shaft seal components. - If present: Loosen grub screw (904...) and pull outboard thrower (507.04) off the shaft. Remove carefully any burrs caused by grub screw. - Unscrew hexagon socket screws (914.02) from bearing cover (360.01) and take off bearing cover. 4610/e8-0-01-001 page 3

134

- Labyrinth seal (if present): Clean and lubricate the pump shaft and push carefully the bearing cover together with labyrinth seal (423...) of the shaft. If required: Push labyrinth seal (420...) out of bearing cover bore. Note: The labyrinth seal consists of two parts, a rotor and a stator, but is assembled as a single unit. Do not separate the rotor from the stator. - Bend lock washer tang out of bearing nut (920.17) and screw off bearing nut. Take off lockwasher (931.01) and oil ring (644.01). Push spacer sleeve (525...) off the shaft. - Remove doweling (tapered pins, 560...) on bearing bracket flange. Screw in (tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws 901...) on the bearing bracket flange. - Screw off hexagon socket screws (914.05) of the bearing bracket fastening. Loosen and remove carefully bearing bracket together with bearing (320...). Press out antifriction bearing outer race with rolling elements. - Draw distance sleeve (525.02) or inboard thrower (507.01) (depending on model) off the shaft, the antifriction bearing inner race will be taken along as well. If required use suitable puller.

Removal of shaft seal – drive side -

Cartridge mechanical seal: Remove the fastening nuts (920.05) of the mechanical seal cover and draw the complete mechanical seal (Cartridge) out of the shaft sealing chamber. Be careful: Remaining medium will flow out. After loosening and moving the assembly bars out of shaft sleeve groove the mechanical seal can be disassembled into its single parts. WARNING: The mechanical seal cover is prestressed by internal springs

-

Standard mechanical seal: Remove fastening nuts (920.05) at the seal cover (471.01) and take off seal cover together with the stationary components of the mechanical seal. Be careful: Remaining medium will flow out. Draw shaft sleeve (523.01) together with the rotating parts of the mechanical seal fastened to it off the shaft (the shaft sleeve is supplied with a groove to apply the tool).

Disassembly of the internal block Mark the stage casings, diffusers and impellers with the stage number during dismantling, as they must be refitted in the same place. Support the internal block adequately so that components of the pressure stages can be removed. -

Remove nuts (920...) from the tie bolts (905...).

-

Loosen and remove the casing part (130.01) together with diffuser last stage (177...) by carefully tapping with a rubber hammer and levering between the release pins. Be careful: Remaining medium will flow out.

-

Remove last diffuser (177.01) from casing part.

-

Slide the last stage impeller (230...) off the shaft, remove key (940.01)

-

Loosen and remove stage casing (108...) together with diffuser (171...). Be careful: Remaining medium will flow out.

-

Remove split ring (501.03), slide the impeller (230...) off the shaft, remove key (940.01).

-

Dismantle stage by stage in the same way up to the first stage casing (108...) has been removed. Support shaft adequately to prevent bending.

-

Withdraw carefully shaft (210.01) with first stage impeller (231...) out of diffuser device (170...). Slide impeller off the shaft and remove key.

-

Press diffusers (171...) out of the stage casings (108...)

-

If required (in case of wear): The impeller wear rings (503...) and the wear rings (502...) in the diffuser device / stage casings and the interstage bushes (541...) in the diffusers can be replaced.

After disassembly All pump parts should be cleaned and prepared for short term storage by applying a rust preventive to all machined surfaces which are not made of stainless steel. Recommended rust preventives are given under 3.2.3. Handle the pump shaft with care and where ever possible store shaft by hanging vertically to maintain straightness. Inspect all pump parts for wear or damage, see 8.2.

4610/e8-0-01-001 page 4

135

8.2

Inspection of wear parts

ATTENTION

Carry out all checks with the greatest possible care. Examine all parts for wear and remachine or replace as the case may be. Negligence will lead to a premature failure of the

pump.

Impellers Inspect impellers for wear or damage. Look for cavitation marks (pits) in the suction area (especially in the first stage impeller), erosion of vanes and cracks in the shroud. Smooth minor irregularities with a fine file or emery paper, replace impellers, if necessary.

Wear rings and clearances Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum (new) and the maximum (worn) diametrical clearances are given in the table below. Replace wear ring parts, when pump performance drops below acceptable system standard or the recommended maximum clearances have been reached or exceeded. Remark: Each clearance enlargement causes efficiency loss in pump. Clearance measurement: See sketch 8.2-1. Measure the clearance between corresponding sets of rotating and stationary parts. Use several measurement locations, than calculate the clearance as described below. Largest casing wear ring ID – smallest impeller OD = diametrical clearance

Sketch 8.2-1

Impeller- and stationary wear rings, interstage bushes Pump size GSG

100-300

125-330

150-360

200-400

SULZER standard clearance [mm] Minimum clearance 1st stage *

0,48

0,53

0,53

0,55

Maximum clearance *

0,72

0,79

0,79

0,82

Minimum clearance normal stage *

0,48

0,50

0,50

0,55

Maximum clearance *

0,72

0,75

0,75

0,82

SULZER extented clearance [mm] Minimum clearance 1st stage *

0,61

0,66

0,66

folgt

Maximum clearance *

0,91

0,99

0,99

folgt

Minimum clearance normal stage *

0,60

0,63

0,63

folgt

Maximum clearance *

0,90

0,94

0,94

folgt

* clearance in relation to diameter

Wear ring replacement Case wear rings: See sketch 8.2-2. Remove setscrews and press stationary wear rings out of their seats. Diffuser device: Insert a pulling tool or pry bar between wear ring and seat and apply pressure. Stage casings: Note that bushing is shouldered on one side. Use a suitable press. Installation: Be sure rings and seats are clean and free of burrs. Carefully tap new rings into place, chamfer towards inside, with a soft face mallet or with a press. Check that the ring contacts circumference (case shoulder). Drill and tap new locking screw holes half in case half in the wear ring. Fit and secure setscrews by peening.

4610/e8-0-01-001 page 5

Sketch 8.2-2

136

Impeller wear rings: (if present) See sketch 8.2-3. Remove impeller wear rings by removing setscrews and applying even heat to ring for easy removal. Perhaps grind off the old ring (take care not to damage the seat) and split with chisel. Installation: Ensure that new rings and seats are clean and free of burrs. o Heat wear ring in an electric oven or hot oil bath to approx. 100 C and install, chamfered inside edge to impeller. A press can be used. Check if installed ring touch the impeller shoulder circumference. Drill and tap new locking screw holes half in impeller half in the wear ring. Fit and secure setscrews by peening.

Sketch 8.2-3

Interstage bushes: See sketch 8.2-4. Remove interstage bushes by removing setscrews and tapping them out of their seats. A press can be used. Inspect seat and remove any burrs. Assemble new bushing. Drill and tap for setscrews. Fit and secure setscrews by peening.

Sketch 8.2-4

Balancing It is recommended that impellers are individually balanced on a balancing machine. Dynamic balancing to VDI 2060, ISO 1940, Q = < 2.5. The assembled rotor is not balanced as a unit, since the deflection of the rotor is different during balancing in air to the deflection under the influence of hydraulic axial and radial bearing forces in the close clearances within the pump.

Shaft Handle the shaft with care and support it evenly to maintain straightness. Avoid bumping, hitting or springing the shaft. Inspect shaft seats and shoulders for cleanliness, nicks and burrs; if necessary replace them. True running of the shaft Support shaft at bearing area (use V-blocks or rollers) and check for concentricity. The max. permissible run-out is given in the table below. If the runout is outside the permissible value, replace the shaft. Operating speed max. permissible run-out

d 3000 rpm

> 3000 up to 4000 rpm

0.025

0.020

Shaft seal Remark: The Cartridge mechanical seal should be renewed as a complete unit. For repairs the damaged seal cartridge should be shipped to the manufacturer or to one of the manufacturer’s service centers. Cartridge dismantling: After loosening and moving the assembly bars out of the shaft sleeve groove the mechanical seal can be disassembled into its single parts. WARNING: The mechanical seal cover is prestressed by internal springs. The front sides of the sealing rings (running faces) should show no sign of scoring. Renew stationary and rotating seal rings which are scored or crazed, as a unit, never replace only one ring. Check shaft sleeve for perfect surface quality, especially at the seat of the rotating unit; renew if necessary. Assembly: In case of re-assembly use new gaskets and O-ring seals. We recommend the use of new rotating and stationary seal rings. Assembly must be done very carefully and under conditions of extreme cleanliness. The seal ATTENTION parts must by no means be subjected to any pressure or shock (danger of break). Seal faces should not be lubricated with oil or grease as this may prevent introduction of the sealed fluid in operation, leading to overheating and failures. Remove protective films from new parts direct before assembly.

Bearing Antifriction bearings Rinse bearings with light oil. In case of major overhaul or damage, replace bearings. Remark: In case of renewed thrust bearings (angular ball bearings or tapered roller bearings): Use only paired bearings, never replace only one bearing of a unit. The bearing design number is given in the pump parts list.

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Lubricating ring Check surface quality of lubricating rings (inside diameter) and running sleeves for grooves and uneven wear. Measure inside and outside diameter circumference on several locations and check eccentricity (oval). See also sketch 8.2-1. Max. permissible diameter difference 0.3 mm. If the concentricity is outside the permissible value, replace the lubricating ring.

Balance drum / Balance drum liner Replace balance drum and balance drum liner, when pump performance drops below acceptable system standard or the recommended maximum clearances have been reached or exceeded. Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size (see also sketch 8.2-1). Replace balance drum and balance drum liner as a unit. Pump size GSG

100-300

125-330

150-360

200-400

SULZER standard clearance [mm] Minimum clearance *

0,28

0,30

0,32

0,35

Maximum clearance *

0,56

0,60

0,64

0,70

SULZER extented clearance [mm] Minimum clearance *

0,45

0,48

0,50

folgt

Maximum clearance *

0,90

0,96

1,00

folgt

* clearance in relation to diameter

Rotor concentricity check (shaft with rotating parts) Concentricity should be checked with the shaft in unloaded and loaded condition. Assemble the complete rotor. Instead of the last impeller insert a thread sleeve with SKF hydraulic nut HMV screwed on and a spacer sleeve. See sketch 8.2-5 . The additional parts required can be supplied by the manufacturer upon request..

balance drum

hydraulic nut

impeller

Sketch 8.2-5

Do not tighten the hydraulic nut. Support shaft at bearing area (use V-blocks or rollers). Check concentricity in unloaded condition. The measuring points are: diameter of impeller clearances, the extension of the hub on the rear of the impeller, the balance drum, the seat of mechanical seal and the coupling shaft end. See sketch 8.2-6. The max. permissible run-out depends on the operating speed and is given in the table: Operating speed

d 3000 rpm

> 3000 up to 4000 rpm

max. run-out

0.04 mm

0.03 mm

If the concentricity test has been satisfactory, the same check is to be carried out with the loaded rotor. Connect SKF hand lever oil pump to the hydraulic nut (fill oil reservoir) and by manual operation of the hand pump, axially load the parts rotating with the shaft. See also sketch 8.2-7. Oil pressure see table “Hydraulic clamping nut”.

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Before working with the high pressure oil injection kit the safety regulations have to be read and observed.

Hydraulic nut

Sketch 8.2-6 Repeat concentricity check on the same spots. If the gauge indicates an inadmissible run-out all surfaces which are at right angles to the axis of the shaft and which are used to absorb or transmit axial forces, such as shaft shoulder, impeller hubs, balance drum and sleeves have to be checked for squareness. The max. permissible variance in the vicinity of the shaft outer diameter (shaft shoulders, hubs, sleeves etc.) should not be more than 0.01 mm. If this value is exceeded, re-machine, e.g. turn on mandrel (without clamping) or grind with the minimum possible reduction in the hub and/or sleeve length. Repeat concentricity check as described above. Upon satisfactory completion of concentricity check, dismantle rotor. Mark impellers in sequence so that they can be refitted in the same order when assembling the pump. Remove the special components used for the concentricity and keep to use in future overhauls.

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Components of the hydraulic clamping device for true running test of rotor

Hydraulic clamping nut Pump size

Size

d

D

e

h

Oil pressure

Part 008 Drawing no.

Part 009 Drawing no.

100 – 300

19 A

M 95 x 2

162

43

5

245 bar

4-061420

4-088974

125 – 330

24 A

M 120x2

188

44

5

300 bar

3-086836

4-648082

150 – 360

24 A

M 120x2

188

44

5

340 bar

3-086836

4-089060

200 – 400

26 A

M 130x2

198

44

5

400 bar

3-086 835

4-089 058

000 Hydraulic clamping nut, make SKF type HMV 001 Union K-GEV 8L - G ¼

1.0718

002 Pipe 8 x 1.5 DIN 2391 - 130 lg.

1.0308 GBK

003 Union K-GEV 8L - G ¼

1.0718

004 Reducing socket 3/4 x 1/4

1.0718

005 Pump support SKF 101 352 3 006 Wika-pressure gauge 211.100.600 bar 007 Oil pump SKF 226 400

*

008 Sleeve

1.0503.05

009 Sleeve

1.0503.05

The additional parts required for the concentricity check can be supplied by the manufacturer upon request.

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8.3

Assembly of the pump

References: Refer to specific drawings (section drawing(s), parts lists, installation plan). These pumps should only be assembled by qualified specialists with suitable tools and by strictly observing the instructions. All assembly works have to be carried out with the greatest possible care. Negligence leads to premature failure of the pump.

Preliminary work -

Clean pump parts

-

Prepare lubricants (e.g. oil, Molykote, Never Seez)

-

Only use glycerine or "Klüber PROBA 270" paste for O-ring seals

-

Always renew seal rings and gaskets Pay attention to possibly hazardous situations during assembly, i. e. take care of a firm stand, secure assembly parts against dropping, support or prop loose parts etc.

Assembly of the internal block (Refer to match-marks during re-assembly) The assembly of the internal block has to made vertically. -

Place the diffuser device (170.01) with double flow impeller (231.25) vertically on supports so that shaft, impellers, diffusers and the components of the pressure stages can be pushed onto it. See sketch 8.3-1. Place O-ring (412.01) for sealing of the first stage casing.

-

Clean shaft, impeller bores and coat the contact surfaces slightly with lubricant. Insert key (940.01) for the first impeller and push impeller (231...) onto shaft stop.

-

Slide pre-assembled shaft (210...) with impeller vertical into the diffuser device (170.01) and support as required.

-

Insert diffuser (171...) into the first stage casing (108...) and mount stage casing - if necessary, knock with a rubber hammer. Place O-ring seal (412.01) for sealing of the next stage casing.

Shaft (210...)

Diffuser device (170.01)

-

Insert key (940.01) for next impeller and push on impeller (230...) from the non-drive side, insert split ring (501.03).

-

Insert diffuser (171...) into the next stage casing (108...) and mount stage casing. Place O-ring seal (412.01) for sealing of the next stage casing.

-

Insert key (940.01) into shaft groove and push on next impeller (230...).

-

Mount another pre-assembled stage casing (with diffuser) and fit O-ring seal.

-

Assemble remaining stages in the same way.

-

Slide casing part (130.01) with inserted last diffuser (177.01) on the spigot of the last stage casing (108...).

-

Fit discs (554.02) on the tie bolts (905.01). Lubricate threads and support surfaces of nuts (920.11) and screw on nuts. Clamp the whole hydraulic assembly together evenly and crosswise.

Supports

Sketch 8.3-1

Tightening torque see table 8.6.

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Fit discharge cover and secure with clamping tool -

Mount split ring (tool 05) on the casing part (130...) and place shims (tool 06). Lift the delivery cover (163.01) carefully over the shaft and slide into the spigot of the casing part. Clamp the discharge cover (163.01) with screws (use jack screw threads) against the internal block. See sketch 8.4-2. Remark: The delivery cover must be mounted in the correct position against the internal block (be sure balance connection is correct located).

Continue assembly horizontal -

Lift the internal block by crane and position it horizontally in such a way as the parts of the delivery cover and the clamping tools are not loaded. Support it appropriate.

Assemble balance device -

Insert key (940.02) into shaft. Place O-ring seal (412.08) into the balance drum (603.01) bore and push balance drum onto shaft.

-

Slide balance drum liner (605.01) with O-ring seal (412.07) into delivery cover (163...) bore, observe the position. Remark: Be sure cylindrical dowel pin (561.02) is correct located to engage in the hole of shaft seal housing (441...).

-

Insert key (940.04) into shaft and place split ring (501.01) in the shaft groove. Slide sleeve (520.01) with collar over it.

Assemble shaft seal housing and bearing bracket lantern -

Non-drive side: Fit seal (gasket or O-ring seal) on the spigot of the shaft seal housing (441...) and mount shaft seal housing on the delivery cover (163.01). Design with cooling: Place O-ring seals (412...) for sealing the cooling chamber. Remark: Allow the dowel pin (561...) preventing rotation of balance drum liner and the dowel pin in the delivery cover engage in the hole. Observe mounting position.

-

Mount bearing bracket lantern (344.01), observe the position of the dowel pin (561...). Lube threads and support surfaces for nuts, tighten evenly and crosswise. Tightening torque see table 8.6.

-

Drive side: Insert key (940.04) for the shaft sleeve (mechanical seal) and assemble shaft seal housing (441...) and bearing bracket lantern (344.01) as described for the non-drive side. Remark: Observe mounting position (dowel pin).

Assembly of the internal block into barrel casing -

Place seals (gaskets or O-ring seals) onto the sealing surfaces of diffuser device (170...) and discharge cover (163...). Mount assembly equipment for the internal block and transport the internal block to the assembly site (barrel casing).

For the assembly of internal block into barrel casing follow separate description. Refer to 8.4.

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Measurement and adjustment of the axial position of rotor Measurement is not necessary, if the installation length of the pump parts have not changed through remachining during repair, but it is essential, if new parts (shaft, impellers, stage casings) have been fitted, otherwise continue with paragraph "Rotor centering procedure". In order to achieve the most favourable hydraulic efficiency of the pump, the impellers and diffusers must be placed in the optimum position to each other. For this purpose and in order to avoid lateral distortion of the rotor, the theoretical axial position of the rotor is to be measured and set. The construction tolerances make it possible to keep the correction of the axial rotor position within very low limits. ATTENTION

Do not turn the rotor and do as less as possible move the rotor axial.

-

Assemble bearing bracket (330...) on both sides of the pump, screw on and tighten hexagon socket screws (914.05) evenly and crosswise.

-

Push rotor until stop in the direction of the non-drive side.

-

Non-drive side: Determine measurement „A“ (see sketch 8.3-2) from the support shoulder of the thrust bearing in the bearing bracket to the shaft shoulder with depth gauge.

-

The spacer sleeve (525.02) or the inboard thrower (507.06) must be longer than the measurement „A“ by the value „B“ given in the following table. Pump size

100-300

Taper roller bearing Dimension B =

6.5

Angular ball bearing Dimension B =

4

150-360

± 0.1

± 0.1

200-400

7

± 0.1

8

± 0.1

4

± 0.1

5

± 0.1

Note: New spacer sleeves (525.02) or throwers (507.06) are supplied with over size, they must be machined to the calculated dimensions. When repair work is done the nominal dimension can be gained by applying supplementary discs. Note: The spacer sleeve or thrower shoulders must be parallel to each other within 0.01 mm after machining.

Rotor pushed into final axial position towards non-drive side

A A+B

Re-machine shoulder

Rotor running position

Sketch 8.3-2 Measurement of the axial position of rotor

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-

On the drive-side: Check the length dimension of the distance sleeve (525.01) or the inboard thrower (507.01) (depending on design) while the rotor is moved to the non-drive side and correct if necessary. See sketch 8.3-3.

-

Measure with depth gauge dimension “C“ from support shoulder of the antifriction bearing outer race in the bearing bracket bore to the shaft shoulder in the shaft seal housing.

-

Measure the length of shaft seal sleeve “D” and thrower “E” and calculate the dimension “F” F = C – (D + E)

-

The calculated dimension “F” should correspond to the dimensions given in the following table. Pump size

100-300

150-360 4

result “F”

200-400

±1

5

Dimensions in mm

±1

Remark: Because of the big tolerance the spacer sleeve (525...) or thrower (507...) on the drive side has very rarely to be remachined. -

After measurement: Remove bearing housings on both sides of the pump.

Rotor pushed into final axial position towards non-drive side D

E F C

Rotor running position

Sketch 8.3-3

Rotor centering procedure The disassembly of the internal block requires that the rotating element radial center position be determined and adjusted, otherwise continue with paragraph „Assembly of shaft seal“. -

Drive side: Push shaft sleeve (mechanical seal) or “Dummy sleeve” with identical length onto shaft. Push distance sleeve (525...) or inboard thrower (507...) with nominal dimension onto shaft.

-

Mount bearing bracket (330...). Tighten fastening screws (914.05) of bearing bracket and loosen them once again, so that the bearing bracket can be shifted by the adjusting screws (901.03) which are at the bearing bracket flange.

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Horizontal adjustment -

Adjust bearing bracket by the lateral adjusting screws. See sketch 8.3-4. Measure between shaft and bearing bracket bore by means of an inside spring caliper until shaft is in the horizontal center. Tighten and secure lateral adjustment screws in such a way as to fix the bearing bracket in horizontal position and allow vertical movement. Execute the horizontal adjustment bearing bracket by turning the adjusting screws until shaft is horizontal center position of bearing bore

of the lateral set in bracket

=

Inside spring caliper

=

Adjusting screw

Adjusting screw

Shaft

Bearing bracket

Horizontal adjustment of the bearing bracket

Sketch 8.3-4

Vertical adjustment -

Attach a measuring gauge vertically near the bearing (the measuring pin has to be positioned at right angle to the shaft) to ascertain at the bearing area by what dimension the shaft can be lifted. Divide the result by two and note. See sketch 8.3-5 Measuring gauge Measure shaft vertical movement

T

Adjust shaft in center position 1

T /2

Shaft

Sketch 8.3-5 Vertical rotor adjustment

ATTENTION

Do not bend the shaft!

-

Mount antifriction bearing as described under “Assembly of bearings”.

-

Fit measuring gauge again, screw in lower adjustment screw (901.03) until shaft is lifted by the dimension noted before. Tighten bearing bracket fastening screws (914.05). Observe measuring gauge, the shaft position must not change. Secure adjustment screws with nuts (920.03).

-

Non-drive side: Push distance sleeve (525...) or inboard thrower (507...) with nominal dimension onto shaft. Mount bearing bracket (330.02) and adjust bearing bracket horizontal in the same way as described for the drive side.

-

Measure shaft vertical movement. Mount thrust bearing as described under “Assembly of bearings” and adjust bearing vertical as described for the drive side.

Check of free running state of the rotor Due to adjustment procedure and the manufacturing of the pump parts within given tolerances the rotor theoretically should be in center position, i.e. could usually be turned by hand. To do so, attach lathe carrier at coupling shaft end and check free running. -

Turn-on rotor and look for touching during running down.

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Causes and measures in case of touching of the rotor 1. Center position of the rotor not correctly adjusted, adjust once again (it may be necessary to adjust the rotor vertical over the center 60 % of T). 2. Renewed parts (stationary wear rings, impeller wear rings, interstage bushes...) are not in center or the running clearances are not correct. 3. Due incorrect assembly and uneven tightening of tie bolts, cause a deformation (bending) of the stage casing package, which is clamped together, may occur. This may cause a touching of the rotor parts at the stationary casing parts. With increasing stage number this will be more and more likely. If it is found that the rotor can only be turned under difficulty or not at all, disassemble the pump again and check exactly each pump part before re-assembly. ATTENTION -

Serious damage can be caused if the pump is started with off center rotor

If check of free –running is satisfactory dowel bearing housings in new position. Existing taper pin holes can be reaimed to the next size taper pin or, if required, drill new holes. Mark the old taper pin holes. Remove bearing housings on both sides of the pump and continue with paragraph „Assembly of shaft seals“.

Assembly of shaft seals Mount mechanical seals on non-drive side and drive side. Refer also to shaft seal drawing and manufacturer’s instruction. Cartridge mechanical seal design -

Mount rotating parts of shaft seal onto the shaft sleeve. If existing place sealing ring in the groove of the shaft sleeve bore.

-

Build in stationary elements of the mechanical seals into the mechanical seal cover(s) and push over shaft sleeve. Pre-stress the springs of the mechanical seal by pressing on the mechanical seal cover until the assembly bars can be pushed into the shaft sleeve groove.

-

Push complete pre-assembled mechanical seal (cartridge) into the sealing chamber (shaft seal housing)

-

Remark: Screw on fastening nuts (920.05) on the shaft seal cover but do not fasten yet.

Standard mechanical seal -

Mount rotating parts of the shaft seal on the shaft sleeve. Insert O-ring in the groove of the shaft sleeve bore and push shaft sleeve onto shaft.

-

Build stationary elements of the mechanical seal into mechanical seal cover. Fit O-ring seal and slide on seal cover with the pre-assembled stationary parts of the shaft seal, screw on nuts by hand but do not fasten yet.

Assembly of bearing bracket Mount baring bracket on drive side and non-drive side -

Depending on design mount distance sleeve (525...) or inboard thrower (507...). Distance sleeve (525...): Lubricate spacer sleeve surface (525.01) and push inboard labyrinth seal (423...) onto the spacer sleeve. Note: To avoid damage, press into place with the labyrinth seal rotor inside the stator. Slide spacer sleeve (525.01) in nominal dimension (together with labyrinth seal) into position on the shaft. Thrower (507...): Push inboard thrower (507...) in nominal dimension into position on the shaft.

-

Labyrinth seal: Lubricate bearing bracket bore and during assembly of bearing bracket push inboard labyrinth seal (423...) into bearing bracket bore. Note: Labyrinth seal stationary part with leakage groove or bore downwards.

-

Mount bearing bracket (330...). Screw on fasteners (914.05) finger tight, insert taper pins (560...) through bearing bracket flange into bearing lantern (344...). Support bearing bracket and seat taper pins, then properly tighten bearing bracket fasteners evenly and crosswise. Tightening torque see table 8.6.

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Assembly of bearing – non-drive side -

Drive side: Mount a holding device on the drive side to fasten the rotor to it by means of the shaft bore, see sketch 8.1-2. stamped

Angular ball bearing -

Heat angular ball bearings (320.02) in oil bath up to 80°C, mount bearings in X-arrangement (install bearings with the outer ring stamped outside). See sketch 8.3-6. Push inboard bearing onto shaft and into the bearing bracket bore. Apply pressure to inner race only. Fit spacer disc (551.01) and push outer bearing into bearing bracket bore, apply pressure to outer race only. ATTENTION

In case of renewed angular ball bearings: Use only paired bearings. Never replace only one bearing of a unit. The bearing design number is given in the pump parts list.

spacer disc (551.01)

Sketch 8.3-6

Taper roller bearing -

X-arrangement

Build in outer race of inboard taper roller bearing (320...) with bearing support ring into bearing bracket bore (make sure that one bore of the bearing support ring points downwards). Warm taper roller bearing o inner races with rolling elements in an oil bath to approx. 80-100 C and push them up to shaft stop. Fit outer race of outboard taper roller bearing. ATTENTION

In case of renewed taper roller bearings: Use only paired taper roller bearings, never replace only one bearing of a unit. The bearing design number is given in the pump parts list.

Continue bearing assembly -

Push spacer sleeve (525.05) onto shaft.

-

Screw on shaft nut (920.16 or 920.15 depending on model). Note: Before tightening of shaft nut remove holding device on the drive side bearing housing. Shaft nut (920.16): Apply lubricant to the contact face of the bearing nut. Screw on and tighten shaft nut (920.16). Secure shaft nut by tightening the adjusting screws. Shaft nut (920.15): Install lock washer (931.01) and shaft nut (920.15). Apply lubricant to the contact faces of the lockwasher and shaft nut. Tighten bearing nut and bend lockwasher tang into one of the shaft nut slots. ATTENTION

-

Do not over tighten bearing nut.

Fit lubricating ring (644.01) in the spacer sleeve groove. Insert O-ring (412.05) into the bearing bracket groove. Install bearing cover (360.02) and tighten bearing cover fasteners evenly and crosswise. Tightening torque see table 8.6. Note: During tightening the rotor reaches the final axial position.

-

Labyrinth seals (523.12 if present): On both sides of the bearing bracket. Lubricate shaft surface and bearing cover bore. Push labyrinth seal onto shaft and into bearing cover bore. Note: To avoid damage, press into place with the labyrinth seal rotor inside the stator. Mount stationary part of Labyrinth seal with leakage groove or bore downwards. Check correct seat of labyrinth seals.

-

Thrower (507... if present): Slide inboard thrower onto shaft. Adjust gap between thrower and bearing cover to 1 mm and tighten grub screw (904...).

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Assembly of bearing – drive side Roller bearing o

-

Heat roller bearing inner race in an oil bath to approx. 80-100 C and push it up to shaft stop. Build outer race of roller bearing (320.01) with rolling elements carefully into bearing bracket bore.

-

Install spacer sleeve (525.04), lock washer (931.02) and bearing nut (920.17). Apply lubricant to the contact faces of the lockwasher and bearing nut.

-

Tighten bearing nut. Bend lockwasher tang into the bearing nut slot. ATTENTION

-

Do not over tighten bearing nut.

Fit lubricating ring (644.01) in the spacer sleeve groove. Insert O-ring (412.05) into the bearing bracket groove. Install bearing cover (360.01) and tighten bearing cover fasteners evenly and crosswise. Tightening torque see table 8.6.

-

Labyrinth seals (523.11 if present): On both sides of the bearing bracket. Lubricate shaft surface and bearing cover bore. Push labyrinth seal onto shaft and into bearing cover bore. Note: To avoid damage, press into place with the labyrinth seal rotor inside the stator. Mount stationary part of Labyrinth seal with leakage groove or bore downwards. Check correct seat of labyrinth seals.

-

Thrower (507... if present): Slide inboard thrower onto shaft. Adjust gap between thrower and bearing cover to 1 mm and tighten grub screw (904...).

Check and correct the thrust bearing axial clearance (end play) ATTENTION -

To allow the forming oil films between bearing parts and for heat expansion, it is necessary to provide a correct bearing end play. The bearing end play must be checked after every disassembly of the thrust bearings.

Place clock gauge axially on the front of the shaft on the non-drive side; check axial clearance of the thrust bearing unit by axially moving the rotor into its final positions. See sketch 8.3-7. With taper roller bearing: tap lightly on the bearing bracket (non-drive side) with a rubber hammer to straighten twisted rolling elements. Move rotor into its final axial positions, use device as shown. Tighten hexagonal nut { (not too strongly), | loosen, read clock gauge, loosen {, tighten | and read nominal end play.

1

2

Nominal end play 0.04 to 0.06 mm

Sketch 8.3-7 -

If there is no noticeable clearance the bearing elements may be twisted (taper roller bearings), turn rotor slowly in both directions and measure once again.

-

If the measure axial clearance is smaller than 0.04 mm, the fault may be corrected by tightening the thrust bearing shaft nut (920...) more strongly. Correct mistake.

-

Remove device for bearing end play measurement. o

ATTENTION

If the taper roller bearing temperature after overhaul rises >90 C, as a first measure check bearing end play.

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Final assembly Shaft seal -

Cartridge mechanical seal: If present tighten clamping device (shaft/shaft sleeve). Tighten nuts (920...) of the mechanical seal cover evenly and crosswise. Loosen the assembly bars of the Cartridge mechanical seal at the seal cover, draw them out of the shaft sleeve groove and reattach them. Tightening torque see table 8.6.

-

Standard mechanical seal: Now fasten shaft seal covers on the non-drive side and drive side by tightening the fastening nuts (920.05) evenly and crosswise. Tightening torque see table 8.6.

Fan cooling -

Non-drive side bearing housing: Insert key (940.05) for fan (831.01) into shaft, slide on fan and place circlip (932.01) in shaft groove. Place fan cover (832.01) and fasten with cylindrical screws (900.01).

Mount coupling half -

Clean coupling bore and taper shaft extension, insert key that drives the coupling into shaft. A thin coating of oil on the shaft extension and hub bore is recommended, do not use molybdenum disulphide or similar products. ATTENTION

The bearings must by no means be subjected to any pressure or shock.

Fitting method: Push the cold coupling hub firmly on to the shaft fit. Fasten a dial gauge (the measuring pin has to be positioned axial to the coupling hub) to as certain by what dimension the coupling hub can be pushed on, see sketch 8.3-8. Set dial indicator to 0 position. Remove coupling and heat the coupling hub in an electric oven at a o o temperature of 140 C (280 F). No other method is acceptable. When sufficiently heated push the coupling hub with gloved hands into its fit on the shaft.

Sketch 8.3-8

Risk of burning, be carefully when handling hot parts. Use thick isolating gloves. Lube thread and support surface of coupling nut (920.34). Screw on and tighten the nut until the hub is axially moved to the correct interference fit. The required axial movement depends on shaft diameter and can be detected from the table besides. Let the coupling hub cool down and snug-tighten coupling nut (920.34). Axial movement for coupling hubs with taper 1:16

ATTENTION

Shaft diameter in mm

Movement in mm

65 (GSG 100-300)

1.040

70 (GSG 100-300)

1.120

71 (GSG 100-300)

1.136

75 (GSG 100-300)

1.200

The bearings must by no means be subjected to any pressure or shock.

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Ancillary equipment -

Connect ancillary pipework (balance pipe, seal circulation pipes...) and instruments (thermometer, constant level oiler, pressure gauges...) ATTENTION

Do not mix up connections. Carefully check piping system.

Driver -

Couple driver, check alignment of coupling (see 5.2).

-

Fit coupling guard. Electrical installations / connections for motors and controlling devices may only be carried out by qualified electricians. ATTENTION

For re-commissioning repeat all steps from paragraph 6.1.

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8.4

Disassembly and assembly of the internal block Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises.

Disassembly Remark: Proceed preliminary work as given in 8.1. The bearing housings must not removed for internal block removal (full cartridge design). ATTENTION

Internal block removal requires that the rotating element radial center position be checked and adjusted. See 8.3 “Rotor centering procedure”.

-

Drive side: Unscrew fastening nuts (920.26, 920.28) of tension ring (515.01) and tension ring. Be careful: Remaining medium will flow out.

-

Mount assembly equipment on drive side: See Sketch 8.4-1. Screw on support pipe (02) on the diffuser device (170...) by means of hexagon nuts (920.28). Fit screw into the center thread of the shaft and fasten the rotor in its axial position. Remark: Do not overtighten shaft center screw, this will cause in thrust bearing damage. Fasten roller trestle (01) at the lower casing studs (902.13) with hexagon nuts (920.26). Push roller trestle against support pipe and tighten fastening nuts.

-

Mount assembly equipment on non-drive side: Mount lateral rollers (03) on both sides of delivery cover. Fasten guide rails (04) right and left of barrel casing at the baseplate pedestals. ATTENTION

Be sure all fasteners are tightened and the assembly equipment is not damaged.

-

Non-drive side: Unscrew nuts (920.20) fastening the delivery cover (163.01). Loosen nuts crosswise. Fit and evenly tighten jackscrews on delivery cover (163...) to break the joints. Be careful: Remaining medium will flow out.

-

Carefully pull internal block out of barrel casing.

-

Mount clamping tools: Mount split ring (05) on the casing part (130...) as soon as the casing part (130...) is out of the barrel casing. Push shims (06) between delivery cover (163...) and casing part (130...) and clamp the split ring (05) against the delivery cover (163...) by means of the jack screw threads in the delivery cover. See sketch 8.4-2. Remark: If inserting of shims is not possible, loosen shaft center screw on drive side.

-

Push out internal block: Fit pipe extensions as required on the drive side and push the internal block fully out of barrel casing. See Sketch 8.4-2.

-

Lift internal block carefully by a crane and move pipe extension out of barrel casing. See Sketch 8.4-3. Disassemble pipe extensions and transport the internal block to a work shop.

-

Cover the barrel casing openings to prevent dirt intake.

Assembly -

Drive side: Assemble pipe extension in the required quantity.

-

Non-drive side: Screw in lateral rollers into thread holes on both sides of the discharge cover (163...).

-

Mount assembly equipment onto the barrel casing: Drive side roller trestle (01), non-drive side mount guide rails (04) onto baseplate pedestals.

-

Clean barrel casing and examine all seal surfaces, no irregularities or grooves are allowed.

-

Fit gaskets (410...) onto seal faces of the internal block (diffuser device 170... and delivery cover 163...).

-

Lift the internal block by a crane (with the pipe extension through the barrel casing) carefully onto the assembly equipment. See Sketch 8.4-3.

-

Push in internal block: Push internal block into barrel casing, remove pipe extensions on drive side as required. Stop and correct problem (or remove) if any binding occurs during installation (re-adjust guide rails or roller trestle).

-

Remove clamping tools: Remove split ring (05) and shims (06) when the internal block is pushed as far as possible into the barrel casing. See sketch 8.4-2.

-

Push internal block fully into barrel casing.

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151

-

Remove assembly equipment: Non-drive side, remove guide rails (04), unscrew lateral rollers (03) on the delivery cover (163...). Drive side, remove support pipe (02) and roller trestle (01).

-

Drive side: To slide internal block into its final axial position install tension ring (515...) without gasket. Fit and tighten hexagon nuts (920.28) evenly and crosswise. Remove tension ring, insert gasket (410.20) and re-install tension ring. Lubricate threads and support surfaces for hexagon nuts (920.26) and (920.28), tighten evenly and crosswise. Tightening torque see table 8.6.

-

Close barrel casing: (Non-drive side) Lubricate threads and support surfaces for discharge cover nuts (920.20), screw on nuts and tighten evenly and crosswise. Tightening torque see table 8.6. delivery cover nuts (920...)

shaft center screw

tension ring (515...)

support pipe (02)

internal block

roller trestle (01)

Sketch 8.4-1 split ring (05) shim (06) lateral rollers (03)

pipe extension

guide rails (04)

Baseplate pedestal

Sketch 8.4-2

rope suspension

Baseplate pedestal

Sketch 8.4-3

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8.5

Tools

Disassembly equipment for the thrust bearing housing Part no.

Part

1

1 Assembly device

2

4 Stud (thrust bearing removal)

3

Pump size GSG

100-300

125-330 150-360

200-400

Ø 330 x 25 M 12 x 200

M 16 x 210

4 Disc

A 13

A 17

4

4 Nut

M 12

M 16

5

1 Hexagon socket screw

6

1 Ball

M 20 x 1,5 x 180 Ø 12

Thrust bearing housing removal

Antifriction bearing

Disassembly equipment for the balance piston Part no.

Part

Pump size GSG

100-300

125-330 150-360

200-400

1

1 Assembly device

Ø 330 x 25

2

4 Stud (thrust bearing removal)

3

4 Disc

A 13

A 17

4

4 Nut

M 12

M 16

5

1 Hexagon socket screw

6

1 Ball

M 12 x 600

310x200x25

M 16 x 600

M 16 x 750

M 20 x 1,5 x 180 Ø 16

Balance drum (drum liner) removal

Balance drum

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Assembly equipment for the internal block (see also 8.4) Part No.

Drive side

No.

1

Support pipe

02

1

Fastening screws (for shaft center thread)

-

Pipe extension (Qty. according to number of stages)

4

Fastening screws (each)

1

Roller trestle

01

Non-drive side 2

Lateral rollers

03

2

Guide rails

04

(Size according to number of stages) Base pedestals

Fastening screws

Clamping tools (see also 8.4 and 8.4-2) Part No.

Internal block – discharge cover

No.

1

Split ring

05

2

Clamping screws with nuts

-

Fastening screws (Qty. according to size)

3

Shims

06

Rotor concentricity check (see also 8.2) Part No. Hydraulic nut SKF Type HMV

Pump size 100-300 125-330 150-360

200-400

1

1 Hydraulic nut

19 A

24 A

26 A

2

1 Thread sleeve

M95x2

M102x2

M130x2

3

1 Sleeve

1

3

2

Oil injection kit 729101B consisting of: 4 5 6 7

1 Oil injector 226400 1 Injector attachment 226402 1 High pressure pipe 227957 1 Connection nipple 228027 1 Pressure gauge 1077589 1 Tool case 729111B Tool case dimension: 340x310x95 mm Mass incl. tools: 10 kg Designation complete kit: 72901B (excluding pressure gauge 729101AB)

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4

5

6

154

8.6

Screw tightening torques Tightening torques (Nm) for Fastening Discharge cover

Fastening Tie bolts

Fastening Bearing bracket

Fastening Internal block

Part no.:

Part no.:

Part no.:

Part no.:

920.20

920.11

920.02

920.26

920.28

100 – 300

1460

60

200

140

40

125 – 330

folgt

40

800

550

165

150 – 360

2315

40

550

320

70

200 – 400

folgt

100

550

550

165

Pump size GSG

Tightening torques (Nm) for Fastening Mechanical seal cover

Fastening Bearing cover - DE

Fastening Bearing cover - NDE

Part no.:

Part no.:

Part no.:

920.05

914.02

914.05

100 – 300

100

40

100

125 – 330

320

145

145

150 – 360

320

145

280

200 – 400

320

145

280

Pump size GSG

Note: Tightening torques only valid, if thread and support surface for nuts (respectively screw head supports) are lubricated.

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Bolting sequence (Example)

Even loading Suggested torque values are recommended to produce properly stressed joints with a minimum probability of nuts, bolts or studs breaking or loosening. Avoid possible distortion by using correct tightening sequence during torque development.

•

’ —

12

Thread lube Lubricate threads and support surface for nuts with graphite and oil, molybdenum disulfide, or another anti-seize lubricant of comparable quality, except in instances where the lubricant is incompatible with fasteners application.

 “

”  11

˜ ‘

–

Torque development Tighten opposing fasteners in an alternating sequence when developing required torque. Lubricate and install fasteners finger-tight. Develop the required fastener torque in a minimum of three steps with a maximum of 33 % torque value on the initial pass.

Delivery cover nuts 920.20

Internal block tie bolt 905.01

Bearing lantern nuts 920.02 Bearing cover screws 914.05

Tension ring nuts 920.26 Tension ring nuts 920.28

• 

’ ”  – “ ‘

’





‘

Bearing lantern nuts 920.02

Bearing cover screws 914.02

Note: See also 5.2 for pump foot tightening torques

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Standard Torque Values All other fasteners with standard thread not covered by tables before should be tightened according to the fastener size and Class which is stamped on the fastener head. Look for a Class identification marking on the fastener, then refer to the appropriate column in the table. ATTENTION: The material in which the fastener is threaded must also be considered. If a Class 8.8 fastener is threaded into stainless steel material than the tightening torque for stainless Class 50 have always to be used. Material

Steel

Class Thread size M6 M8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36

5.6

8.8

Stainless A1, A2, A4 1.) 10.9

12.9

50

70

Nm

lbf.ft

Nm

lbf.ft

Nm

lbf.ft

Nm

lbf.ft

Nm

lbf.ft

Nm

lbf.ft

4 10 18 30 50 75 100 140 190 240 350 500 650 850

3 7 13 22 36 55 73 100 140 175 255 365 475 625

9 21 42 70 110 170 240 340 440 560 820 1100 1400 1900

6 15 30 50 80 125 175 250 320 410 600 810 1030 1400

13 31 58 100 160 240 340 460 630 800 1150 1600 2000 2600

9 22 42 73 115 175 250 340 460 590 850 1180 1470 1910

15 37 70 120 190 290 400 560 750 900 1400 1850 2500 3200

11 27 50 88 140 210 290 410 550 660 1030 1360 1840 2360

2.5 6 12 22 36 50 80 110 140 180 270 360 500 650

1.8 4.5 8.5 16 26 36 60 80 100 130 200 260 365 480

5.5 14 30 50 75 110 170 210 310 400 -

4 10 22 36 55 80 125 155 225 295 -

1.) Stainless threads are susceptible to "pick-up". This danger can be minimised through good lubrication with molybdenum disulphide. Typical marking on screws, studs and nuts Marking on screws Hexagon head screw

8.8

Hexagon socket screw

8.8

8.8

8.8

Mark 8.8

Marking on studs 8.8

Class

5.6

8.8

10.9

12.9

Index

5

8

10

12

Class

5.6

8.8

10.9

12.9

Studs can be marked both direct with her class or with a mark which indicate her class.

Marking on nuts 8.8

8.8

Nuts are market with her class or with an index which indicate her class.

Note: See also the Installation instruction for pump foot tightening torques.

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MOTOR MANUAL - NOT APPLICABLE -

158

MECH.SEAL MANUAL

159

EagleBurgmann India Pvt. Ltd. Plot No. 64, Survey No. 91/B, Ramtekadi Industrial Estate, Hadapsar, Pune – 411 013.

OPERATIONAL AND MAINTENANCE MANUAL FOR MECHANICAL SEAL PROJECT CUSTOMER P.O. NO EPIL REF

SR. NO

ITEM NO

DRAWING NO

API PLAN

EagleBurgmann India Pvt. Ltd.

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OPERATION & MAINTENANCE MANUAL INDEX SR NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 9.1 9.2 9.3 9.4 9.5 10.0 10.1 10.2 10.3 11.0 11.1 11.2

DESCRIPTION PAGE NO INSTALLATION CHECK LIST 1- 2 GENERAL ABOUT API PLAN - (CHECK AS APPLICABLE) 3-4 GENEARL PRECAUTIONS FOR INSTALLATION OF SEAL 5 SEAL INSTALLATION PROCEDURE FOR BETWEEN BEARING 6-7 (DOUBLE ENDED) PUMPS SEAL INSTALLATION PROCEDURE FOR BACK –PULL OUT PUMPS 8-9 PRECAUTIONS TO BE TAKEN BEFORE ROTATION 10 SEAL REMOVAL PROCEDURE 10 CIRCULATION REQUIREMENT FOR MECH. SEAL 11-14 BRIEF ABOUT MECH. SEAL 15 TYPE – A ARRANGEMENT – 1 15 TYPE – C ARRANGEMENT – 1 15 TYPE – A ARRANGEMENT – 2 15-16 TYPE – A ARRANGEMENT – 3 16 TYPE – C ARRANGEMENT – 2 & 3 16 MAINTENANCE 17 PREVENTIVE MAINTENANCE 17 SHUT DOWN MAINTENANCE 18 BREAK DOWN MAINTENANCE 18 WARNING SYSTEM MAINTENANCE 18 PRECAUTIONS DURING INSTALLATION 19 INSTALLATION OF WARNING SYSTEM 19

NOTE: THIS IS A COMBINED OPERATIONAL & MAINTENANCE MANUAL FOR STANDARD BALANCED TYPE MECHANICAL SEALS SUPPLIED FOR REFINERY, FERTILISER, PETROCHEMICAL & CHEMICAL INDUSTRIES AS PER API 682 AND API 610 PLEASE OMIT THE PORTION/PARAGRAPHS WHICH ARE NOT APPLICABLE FOR ORDERED SEALS. REFER COVERING PAGE FOR APPLICABLE SEAL TYPE / FLUSH.

EagleBurgmann India Pvt. Ltd.

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OPERATION & MAINTENANCE MANUAL 1.0 INSTALLATION CHECK LIST 1.1 PLEASE CHECK & ENSURE FOLLOWING BEFORE INSTALLATION OF MECH SEAL End play Radial movement / shaft whip Shaft run out Stuffing box square ness or perpendicularity Concentricity of stuffing box bore Connection of Flushing Plan as per Drawing Avaibility of B. fluid as per data sheet

: : : :

0.1 mm maximum 0.08 mm maximum 0.08 mm maximum 0.015 mm per 30 mm maximum

:

0.13 mm maximum Conformance Conformance

1.2 THE FOLLOWING PROBLEMS MAY ARISE IF THE ABOVE ARE NOT IN LIMIT:

1. Shaft / sleeve fretting. 2. Over / under compression of seal. 3. Chattering / chipping of carbon. 4. Pump vibration. 5. Excessive wear, fretting of shaft / sleeve. 6. Excessive wear of mating faces. 7. Wobbling of seal faces. 8 Erratic face wear. 9 Throttle bush, throat bush and impeller wear ring or inter stage bush seizing.

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OPERATION & MAINTENANCE MANUAL

EagleBurgmann India Pvt. Ltd.

2

163

OPERATION & MAINTENANCE MANUAL 2.0 APPLICABLE API PLANS

EagleBurgmann India Pvt. Ltd.

3

164

OPERATION & MAINTENANCE MANUAL 2.0 APPLICABLE API PLANS

EagleBurgmann India Pvt. Ltd.

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165

OPERATION & MAINTENANCE MANUAL 3.0 GENERAL PRECAUTIONS PRIOR TO SEAL INSTALLATION The mechanical seal is a precision manufactured product and should be handled with utmost care. The seal faces are lapped to a high degree of flatness and should be protected from any damage, scratch or chipping till they are installed. •

DO NOT REMOVE THE SEALS FROM PACKAGE TILL YOU ARE READY TO INSTALL ON THE EQUIPMENT.

•

CLEANLINESS IS UTMOST IMPORTANT. All working surfaces should be cleaned thoroughly. Lapped faces should be covered with soft tissue paper and rested on clean soft pads to avoid scratches.

•

Do not use hammer while fitting the seals/sleeves/glands.

•

Use genuine spares allocated to individual applications/equipment.

•

Ensure glands conform to the spigot or bore dimensions and PCD of the stuffing box for correct fit with out distortions.

•

Ensure seal G.A. drawing is available for seal installation.

•

Remove high spots, major scratches, waviness on the stuffing box sealing face to avoid distortions on the glands to achieve leak proof joint.

•

Do not apply oil to the surfaces where grafoil packing are used.

EagleBurgmann India Pvt. Ltd.

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166

OPERATION & MAINTENANCE MANUAL 4.0 SEAL INSTALLATION PROCEDURE- BETWEEN BEARINGS PUMPS These instructions are applicable for horizontally split, double bearing centrifugal pumps. Other pump types may require different assembly procedures. 4.1 PREPARATION Remove the bearings and bearing housings, and disassemble the pump as far, as is necessary to remove the old packing or seals, glands and shaft sleeves. Verify shaft/sleeve diameters meet the tolerances and surface finish shown on the assembly drawing. If the seal assemblies are to be mounted on a shaft sleeve, these sleeves must be gasket to the shaft and leak tight. To avoid damage to O-rings and packing during assembly, chamfer shaft and sleeve ends and shoulders 10 degree x .125”/3 mm (fig.1), and remove all sharp edges from keyways and grooves. Carefully clean the stuffing box bores and faces. Verify stuffing box bore diameters comply with the dimension shown on the installation drawing. If stuffing boxes are split, ensure gaskets extend flush with the stuffing box faces, and halves are in alignment. Reassemble the sleeves, bearing housings and bearings, and adjust the shaft to its actual operating location. Verify shaft end ply does not exceed the pump manufacturer’s limit, usually .005”/umm, and shaft rubout does not exceed .001” per inch/0.001 mm per mm (TIRE) of shaft diameter (figs 2 & 3). Verify stuffing box face perpendicularity to the shaft (fig.), and shaft concentricity to the stuffing box (fig.) do not exceed .001” per inch/. 001mm per mm (TIR) of diameter. Again disassemble the bearings and bearing housings. Wipe the shaft/sleeve clean and apply a lubricant, which is compatible with the sealed fluid and the gasket materials. 4.2 ASSEMBLY Take the complete cartridge from their packages. Do not disassemble or alter the units. First centre line the shaft, for desired clearance required for impeller. Start installation on “NONDRIVE END” side of the pump. Apply lightly grease on gasket / ‘O’ ring of the gland to prevent them to fall off. Gently insert assembly of the cartridge on the shaft and let it rest flat on stuffing box face. Ensure the ‘O’ ring / gasket on gland face is intact and in position and be careful not to damage the O ring or packing inside the cartridge sleeve. While inserting the cartridge ensure the studs engage the gland holes, and orientation of flushing holes are maintained as per drawing. EagleBurgmann India Pvt. Ltd.

6

167

OPERATION & MAINTENANCE MANUAL Assemble the gland bolts finger tight. Continue tightening alternatively until secure. Do not distort the gland by over tightening. Do not tighten socket set screws for clamping shaft and sleeve. Leave them loose only. IMPORTANT: While sliding up the gland and seal sleeve assembly, ensure the sleeve slides forward easily to avoid the seals getting over compressed and damaged. In similar manner install the seal on drive end side of the pump. Reassemble the bearing housings and bearings, and complete all required axial adjustments to the pump rotating assembly. If the cartridge sleeve packing is grafoil, tighten the socket head cap screws evenly to compress the grafoil packing onto the pump shaft/sleeve. Leave the eccentric washers in place to maintain the axial position of the cartridge sleeve. If the assembly drawing calls for holes or dimples to be drilled under the cartridge sleeve set screws, remove the set screws and mark their location. Unbolt the cartridge gland and loosen the socket head cap screws, remove the bearings, bearing housings, and cartridge assemblies. Drill the shaft/sleeve in the positions marked. Repeat steps 2-5. Tighten the cartridge sleeve set screws evenly. (If the shaft/sleeve has been drilled, ensure that the set screws align with the appropriate drilled holes). Remove the shipping clips, or slide out the set plates 180-degree to clear the slot in the cartridge sleeve. Completely reassemble the pump, frequently turning the shaft by hand to check for free rotation. If the shaft will not turn, the seal has been improperly set. Refer to assembly drawing and/or pump manual for piping connections and coupling alignment (fig.). Proceed as indicated.

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OPERATION & MAINTENANCE MANUAL 5.0 SEAL INSTALLATION PROCEDURE ON BACK PULL-OUT PUMPS These instructions are applicable for back pullout, overhung centrifugal pumps. Other pump types may require different assembly procedures. 5.1 PREPARATION 1. Disassemble the pump as far, as is necessary to remove the old packing or seal, gland and shaft sleeve. 2. Verify that the shaft /sleeve diameter meets the tolerances and surface finish shown on the assembly drawing. 3. If the seal assembly is to be mounted on a shaft sleeve, this sleeve must be gasketed to the shaft and Leak tight. 4. To avoid damage to O-rings and packing during assembly, chamfer shaft and sleeve ends and shoulders 10 degree x 0.125"/3 mm (fig.1), and remove all sharp edges from keyways and grooves. 5. Check the condition of the pump bearings and replace them if necessary. Verify shaft end ply does not exceed the pump manufacturer's limit, usually 0.005"/ 0.1 mm, and shaft run out does not exceed 0.001" per inch/ 0.001 mm per mm (TIR) of shaft diameter (figs. 2 & 3). 6. Carefully clean the stuffing box bore and face. Verify that the stuffing box bore diameter complies with the dimension shown on the installation drawing. 7. Reassemble the stuffing box housing, complete with shims and/or gaskets. Verify stuffing box face perpendicularity to the shaft (fig.4), and shaft concentricity to the stuffing box (fig.5) do not exceed 0.001" per inch/ 0. 001 mm per mm (TIR) of diameter. 8.

Again disassemble the stuffing box housing. Wipe the shaft/sleeve clean and apply a lubricant, which is compatible with the sealed fluid and the gasket materials.

5.2 ASSEMBLY 1.

Take the complete cartridge from its package. Do not disassemble or alter the unit.

2.

Apply lightly grease on gasket / ‘O’ ring of the gland to prevent them to fall off. Gently insert assembly of the cartridge on the shaft and let it rest flat on stuffing box face. Ensure the ‘O’ ring / gasket on gland face is intact and in position and be careful not to damage the O ring or packing inside the cartridge sleeve. While inserting the cartridge ensure the studs engage the gland holes, and orientation of flushing holes are maintained as per drawing. Assemble the gland bolts finger tight. Continue tightening alternatively until secure. Do not distort the gland by over tightening. Do not tighten socket set screws for clamping shaft and sleeve. Leave them loose only.

EagleBurgmann India Pvt. Ltd.

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169

OPERATION & MAINTENANCE MANUAL IMPORTANT: While sliding up the gland and seal sleeve assembly, ensure the sleeve slides forward easily to avoid the seals getting over compressed and damaged. 3.

Reassemble the stuffing box housing and the impeller.

4.

If the cartridge sleeve packing is grafoil, tighten the socket head cap screws evenly to compress the grafoil packing onto the pump shaft/sleeve. Leave the eccentric washers in place to maintain the axial position of the cartridge sleeve.

5.

If the assembly drawing calls for holes or dimples to be drilled under the cartridge sleeve set screws, remove the setscrews and mark their location. Unbolt the cartridge gland and loosen the socket head cap screws, remove the impeller, stuffing box housing and cartridge assembly. Drill the shaft/sleeve in the positions marked. Repeat steps 2-5.

6.

Tighten the cartridge sleeve set screws evenly. If the shaft/sleeve has been drilled, ensure that the setscrews align with the appropriate drilled holes.

7

Remove the shipping clips, or slide out the set plate 180 degrees to clear the slot in the cartridge sleeve.

8.

Completely reassemble the pump, frequently turning the shaft by hand to check for free rotation. If the shaft will not turn, the seal has been improperly set.

9.

Refer to assembly drawing and/or pump manual for piping connections and coupling alignment (fig. 6). Proceed as indicated.

EagleBurgmann India Pvt. Ltd.

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OPERATION & MAINTENANCE MANUAL 6.0 PRECAUTIONS TO BE TAKEN BEFORE ROTATION Ensure that product circulation pipelines are connected to the seal chamber properly, as per the API PLANS mentioned in the respective SEAL DRAWINGS. Set plates must be in clear-off position to avoid rubbing against the rotating parts. Ensure the seal area is flooded so that product is all around the seal. DRY RUNNING WILL CAUSE OVER HEATING AND MAY DAMAGE THE MATING FACES AND SECONDARY PACKING. The direction of rotation for pump should be proper as per pump manufacturer's manual. Ensure the socket set screws holding sleeve to the shaft are tight and applied with LOCTITE GR.241 or 242. Ensure the fixing bolts for gland and stuffing box are tight. 7.0 SEAL REMOVAL PROCEDURE While removing the seals from the pump following precautions are necessary. Before any action to be taken for removal, FIRST SLIDE BACK THE SET PLATES AND SECURE THEM IN THE SLEEVE /D-COLLAR GROOVE FIRMLY. Flush /neutralize the seal area, if it necessary, due to hazardous / toxic / flammable / corrosive nature of the product. Remove the couplings and gently slide out the seal without any damages. Seals removed in undamaged condition will retain the evidences on failed parts. These evidences can be useful in trouble-shooting of the seals.

EagleBurgmann India Pvt. Ltd.

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171

OPERATION & MAINTENANCE MANUAL 8.0 CIRCULATION REQUIREMENTS FOR MECHANICAL SEALS Mechanical seals while running generate heat. Efficient performance and longer life of mechanical seal is related to the rate of removal of the generated heat. Circulation plans used for this purpose also give other benefits like prevention of sedimentation near the seal faces. Various circulating plans according to API standard and their contribution to extend the seal life is given below. API PLAN 11 The product circulates from the discharge flange to the seal land, through the orifice. This plan is normally used for clean fluids. API PLAN 61 Vent connection is always plugged for safety. Drain connections can be open or connected to the tank to Carry the media leakage to the safe place, when, media is non-hygienic, flammable, explosive, and hazardous. API PLAN 23 This plan is used usually for hot water duty and hot hydrocarbon duty. Stuffing box jacket cooling with water and throat bush are mandatory to make this plan successful. The product in the seal cavity is circulated through the heat exchanger by pumping ring located in the seal cavity and cooled product from heat exchanger is circulated back to the seal cavity. Thus heat exchanger operates at low duty conditions, as compared to API PLAN 21, which improves the reliability of heat exchanger, as well reduces the cost of water utility, required for cooling. API PLANS 62 External quench fluid is circulated through connections located at atmospheric side of the seal to prevent contact of the product with atmosphere. This plan is recommended for products which solidify /crystallize in presence of atmosphere and also for safety from hazardous / toxic / corrosive flammable / explosive / cryogenic duties. ADVANTAGES 1. It cools the seal faces externally. 2. Prevents solidification / crystallization of the product between the faces. 3. Keeps the area below seal area clean and prevents seal hang-ups which normally are caused due to presence of solidified /crystallized product under seal area. 4. Safety to the environment. API PLAN 32 This plan is used to inject an externally sourced & clean, cool fluid in to the seal cavity. The flush goes from the seal cavity to the impeller area & then to the process stream. This plan is used when the product is extremely dirty, or slurry in nature, where API plan 31 can not be used. The external flush pressure must be at least 1.0 TO 1.5 kg/cm2 higher than Max. seal chamber pressure. To control the flow of external fluid mixing in to the process, either close clearance labyrinth / throat bush or lip seal is used, at the throat area of the stuffing box. EagleBurgmann India Pvt. Ltd.

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172

OPERATION & MAINTENANCE MANUAL API PLAN 52 This plan is used for services where no leakage to the atmosphere is tolerated. For such applications, to reduce hazards to the atmosphere, tandem seals are offered. API plan 52 consists of double mechanical seals, with buffer fluid between them. The buffer fluid is contained in the overhead reservoir, which is vented to the vent system, thus maintaining buffer fluid close to the atmospheric pressure. Inner seal leakage will be the media, in to the buffer fluid. BUFFER LIQUID SELECTION 1) Specific gravity of the buffer fluid should be higher than media, to avoid leakage of the media, through out board seal to the atmosphere. Moreover detection of media is possible at earlier stage. 2) Buffer fluid should be compatible with media, to avoid buffer fluid getting converted to gel or sludge, when media leaks into buffer fluid. 3) The viscosity of the buffer fluid should be less than 500 cst at the minimum temperature, to which it is exposed. 4) The buffer fluid should not freeze at the site ambient temperature. 5) Flash point of the buffer fluid should be higher than service temperature, for media having, if oxygen is present. Various controls are provided to identify abnormalities created in mechanical seal and to take preventive measures or shutdown measures prior to catastrophic failure. Level control switch, pressure switch, pressure relief valve are the instruments provided to identify various abnormalities. For better circulation of buffer liquid, pumping ring is used in secondary seal area. The buffer liquid is circulated across seal faces, and goes back to the tank (close circulation). API PLAN 53M In general API Plan 53M system operates at an exactly similar way as the API plan 53 barrier fluid reservoir, however with one main difference. The nitrogen pressurization of the Plan 53 barrier vessel is replaced by the use of an accumulator. Accumulator: The bladder accumulator connects of a fluid section and a gas section, with the bladder acting as a gas proof screen. The fluid around the bladder is connected with the system circuit, so that the bladder accumulator draws in fluid when the pressure drops, the compressed gas expands and forces stored fluid into the circuit.

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OPERATION & MAINTENANCE MANUAL FLUID CONTROL SYSTEMS Before the API Plan 53M is taken into operation the bladder should first be pressurized with nitrogen i.e. it should be done before the system is actually filled and pressurized with barrier fluid. The bladder as balloon, will then be blown up and completely fill the accumulator body through the process opening, risking damage to the bladder. This will be prevented by means of a protective device such as poppet valve. After pre-charging the bladder with nitrogen the system will be filled and pressurized with barrier fluid by means of a so called topping up or make-up unit. This unit will fill the system by approximately 2 to 7 bars in excess of the minimum barrier pressure. In this way the bladder is pressed together allowing barrier fluid to enter the accumulator body. In this way barrier fluid is stored in the accumulator body under dynamic condition. As the very moment the barrier fluid leaks over the seals into the process the systems loses barrier fluid i.e. also loses pressure. The bladder of the accumulator will immediately expand in reaction to the minor loss of pressure, thus replenishing the loss of barrier fluid. GENERAL NOTE FOR ACCUMULATOR 1.

Use nitrogen only.

2.

All Accumulators are supplied un-precharged. Prior to commissioning in the fluid control system accumulator has to be lubricated with the barrier fluid and precharged with nitrogen to 26 kg/cm.sq. Follow nitrogen precharging and lubrication procedure.

3.

A check of Accumulator precharge must be made after the initial installation or after any form of servicing has been carried out. It is recommended that a routine check of precharge pressure be carried out every 2 months.

4.

Before dismantling the accumulator from the system or attempting for accumulator servicing fluid pressure must be reduced to zero by exhausting the fluid to the reservoir.

5.

Check accumulator name plate for working pressure.

6.

Use a regulator valve when the accumulator shell rated pressure is less than the gas pressure in the nitrogen cylinder. Precharge pressure must never be less than 30% of the max. operating pressure.

7. 8.

Accumulator mounted vertical (Gas valve on top) with proper clamps and brackets buffer rings for maximum efficiency and life.

9.

The space necessary for filling the testing equipment is 200 MM around the gas valve.

10.

No welding or mechanical process must be carried out on the accumulator shell and valves. EagleBurgmann India Pvt. Ltd. 13

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OPERATION & MAINTENANCE MANUAL 11.

Before the system is pressurized it has to bleed. For this the bleed plug in the connection fitting has to be used until the fluid emerges.

LUBRICATION OF SHELL BORE & BLADDER PRIOR TO PRECHARGE Remove the Gas Valve. Slack off Locknut 6 mm. Ensure that the bladder is free to move 6mm. Crack open accumulator isolating valve, start the pump (hand pump). Fill the Accumulator with fluid until it overflows. Shut the isolating valve and stop the pump. Tighten the lock nut using two spanners. Ensure that the bladder does not rotate. Replace the gas valve. Open the bleed valve immediately precharge (follow precharging procedure). FOR NITROGEN PRECHARGING / OPERATION & MAINTENANCE OF BLADDER ACCUMULATOR REFER TO THE SEPARATE MANUAL OF MANUFACTURER.

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OPERATION & MAINTENANCE MANUAL 9.0 BRIEF ABOUT THE SEAL 9.1 SEAL: API 682 TYPE ‘A’ ARRANGEMENT 1 The seal is multi-coil spring balance type. The seal face is made of blister resistant carbon graphite. O-ring is used as secondary packing, which is uniformly loaded by multi-coil springs through the compression ring. The seal face is driven by drive pin in the collar engaged in the seal face slots, giving positive drive. The cartridge construction makes easy installation and avoids complex measurements which are normally done incase of non-cartridge seal installations.

9.2 SEAL: API 682 TYPE ‘C’ ARRANGEMENT 1 The seal arrangement uses single seal of type LY9 welded metal bellows construction. The cartridge arrangement of seals is pre-assembled with precision in the factory. Dispatched in cartridge form, the seal is easy to install without complex measurements, as normally done in case of conventional non-cartridge seals. The seal type LY9 uses stationary welded metal bellows. Seal face in CARBON is press fitted in low expansion shell, thus avoiding face distortions. CARBON Vs SiC face forms most suitable, wear resistant pair for the application. Secondary seals in grafoil are most suitable for high temperature duty. Inherent pressure balance, elimination of hang-ups (usually this problem is more in case of spring loaded pusher type seals), and all secondary packing sealing in static, are the superior features of these seals. The seal face contact is maintained by minimum and uniform load, which reduces wear of the seal face, allowing it to perform for longer period. Stationary mounted seal, ensures positive contact of the seal faces in presence of solids/slurry contained in media. The face alignment/tracking is better when seal sizes are bigger. This minimizes weapage across the seal face and reduces the chance of coke build-up. For better performance of seals, equipment parameters should be maintained within limits specified in this manual. Supporting systems like jacket cooling, steam quenching is essential to provide better working environment, to the mechanical seal. 9.3 SEAL: API 682 TYPE A ARRANGEMENT 2 EPIL has offered tandem seal arrangement of seals to suit customer's requirement. Tandem Seals are offered normally if the media is hazardous, flammable, and if temperatures are cryogenic. Inboard seal primary is pusher type balanced LL9D type seal, having multiple coil spring design, most suitable for low specific gravity liquids. Spring retainer called collar contain multiple small size springs to load seal faces adequately through compression ring. Collar has drive pins, which engage in seal ring slots giving positive drive to the seal face. Outboard seal is LL9D type with balanced and pusher type features. Description of seal is same as described EagleBurgmann India Pvt. Ltd.

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OPERATION & MAINTENANCE MANUAL above. Pumping ring is integral part of the outboard seal collar, to enhance the flow of buffer fluid in the secondary seal area. The cartridge construction allows easy installation and avoids complex measurements which otherwise are required to be done in case of non-cartridge seals. Media is circulated through discharge flange to inboard seal area (see API plan 11). API plan 52 circulates compatible buffer fluid, thus lubricates secondary seal and prevents hazardous media from escaping to the atmosphere. 9.4 SEAL: API 682 TYPE A – ARRANGRMENT -3 Generally known as Dual seal arrangement is offered when media is hazardous, cryogenic or having no lubrication properties. In arrangement 3 seal area is pressurized at least 1 to 1.5 Kg /cm.sq.higher than stuffing box pressure. For this purpose external clean Fluid is pressurized by the inert gas in the reservoir (API 53 or 53M) & is circulated across the seal area with the help of pumping ring .Alternately external fluid is circulated from other pump unit with controlled flow & pressure , across the seal area (API 54). Inboard mating ring, is normally clamped, to avoid face separation /damage to the seal faces , in situations when the barrier fluid pressure varies and make seal suitable to work in this condition as per API 682 norms. External compatible media is circulated in Dual seal area at minimum to 1.5 kg/cm2 bars more than maximum stuffing box pressure with the help of API plan 53 or 53M or 54. 9.5 SEAL: API 682 TYPE ‘C’ ARRANGEMENT 2&3 The seal arrangement uses double seal of type LY9DTZTT welded metal bellows construction. The cartridge arrangement of seals is pre-assembled with precision in the factory. Dispatched in cartridge form, the seal is easy to install without complex measurements, as normally done in case of conventional non-cartridge seals. The seal type LY9DTZTT uses stationary welded metal bellows. Seal face in CARBON is press fitted in low expansion shell, thus avoiding face distortions. CARBON Vs SiC face forms most suitable, wear resistant pair for the application. Secondary seals in grafoil are most suitable for high temperature duty. Inherent pressure balance, elimination of hang-ups (usually this problem is more in case of spring loaded pusher type seals), and all secondary packing sealing in static, are the superior features of these seals. The seal face contact is maintained by minimum and uniform load, which reduces wear of the seal face, allowing it to perform for longer period. Stationary mounted seal, ensures positive contact of the seal faces in presence of solids/slurry contained in media. The face alignment/tracking is better when seal sizes are bigger. This minimizes weapage across the seal face and reduces the chance of coke build-up. For better performance of seals, equipment parameters should be maintained within limits specified in this manual. Supporting systems like jacket cooling, steam quenching is essential to provide better working environment, to the mechanical seal.

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OPERATION & MAINTENANCE MANUAL 10.0 MAINTENANCE Generally maintenance may be classified as (a) preventive maintenance, (b) shut down maintenance and (c) break down maintenance. 10.1 PREVENTIVE MAINTENANCE For preventive maintenance, the seal on its own does not have to be maintained as after the installation of seal one does not have any approach to the seal. But for satisfactory working of the seal, its auxiliary system i.e. circulation and quenching system has to be maintained properly. A periodic check of the circulation/flushing, flow-rate and inlet temperature to the seal is very important. Monitoring of these is very essential as failure or wide fluctuations of these may result in the failure of seal necessitating immediate shut down of the pump. Vibrations on the pump should not exceed 8 mm/sec. any time. Whenever higher vibrations are noticed, primary cause should be established. Regular checks should be carried out for alignment of couplings. If vibrations are frequent, basic source of vibrations must be identified, rectified to avoid its recurrence. Possible sources of vibrations are repetitive misalignment of couplings, cavitation, suction loss, bearing failures, imbalance of rotating parts, pipe stresses etc. Following must be monitored for satisfactory working of the seal : API PLAN 11 1. Monitor flow rate of the media. Control orifice area. 2. Check the temperature and ensure that it is well with in the capabilities of the elastomers. API PLAN 61 Vent connection is always plugged for safety. Drain connections can be open or connected to the tank to carry the media leakage to the safe place, when, media is non-hygienic, flammable, explosive, and hazardous. API PLAN 52 If the circulation system is equipped with level switch, pressure switches and pressure relief valve: When level switch indicates low alarm, fill up the liquid to normal level. Analyze the drop in buffer liquid level; observe pipeline leakage and secondary seal leakage. When level switch indicates high alarm, reduce level by draining the buffer liquid, bring the level to normal and observe again. Check the primary seal leakage. When pressure switch indicates low alarm, primary seal leakage started. Plan for shut down, depending upon leakage. When pressure switch indicates high alarm, check if primary seal has failed. This requires shut down, depending upon leakage. Mainly check the levels of buffer liquid whether at constant level, or dropped or increased. EagleBurgmann India Pvt. Ltd.

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OPERATION & MAINTENANCE MANUAL 10.2 SHUT DOWN MAINTENANCE OF PUMPS (Shut down taken because of pump or plant overhauling). FOR MAINTENANCE OF THE SEAL, remove seal from pump. Clean all parts and examine them. If face or faces are not excessively worn out, lap faces. If lapping facility not available then fit seal with new faces and send used faces for lapping to seal manufacturer. If faces are excessively worn-out or damaged, then replace them with new spare and order new spares as stand-by. Change all elastomers. Re-using used elastomers is calling for early failure of seal. Sometimes maintenance plant staff used old elastomers and it does work but it is not recommended practice as sometimes seal leaks immediately at restart causing more panic and loss of money in attending the pump. 10.3 BREAK DOWN MAINTENANCE If seal failure causes pump shutdown then break down site maintenance becomes necessary. Be fore re- installing, the case of seal failure should be diagnosed and rectified.

11.0 BRIEF ABOUT THE WARNING SYSTEM In order to ensure no emissions are mixed with in the atmosphere the EMISSION CONTAINMENT SEAL area must be vented to the flare or vapour recovery system. Other wise pressure will build up in the barrier area and emissions across the inner and outer seals will eventually equalize. The piping arrangement shown in the drawing no. A3A LD45/ A/ R0 allows for automatic venting of the barrier area at 1 to 2 p.s.i. over the vapor recovery system pressure. By preventing the pressure building in the barrier area, all emissions across the inner seal will be vented out o the vapor recovery system, rather than to the atmosphere. The system is equipped with pressure gauge and pressure switch. The orifice allows to detect even small amount of emissions with the help of pressure gauge and pressure gauge. The pressure switch indicates or gives an alarm if the pressure build up is more than its set pressure. Although nitrogen purging is not necessary for emission containment seal, to reduce emissions much below the allowable limit Nitrogen at 5 to 10 p.s.i. can be used. For extremely hazardous, explosive media like propane, ethylene oxide etc. nitrogen purging helps to reduce emissions, thereby eliminating possibilities of fire hazards.

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OPERATION & MAINTENANCE MANUAL 11.1 PRECAUTIONS DURING THE ASSEMBLY OF THE WARNING SYSTEM. 1. Avoid undue stresses at the piping joints and joints for the instruments and valves. 2. Ensure the direction of arrow for inline check valve is towards flare or vapour recovery system. 3. Block valve should always remain open to allow V.H.A.P. vapours to got to the flare or vapour recovery system. 11.2 INSTALLATION PROCEDURE FOR THE WARNING SYSTEM 1. The warning system supplied by EBIPL is a preassembled unit, with accessories mentioned above. 2. Connect the flushing line connections for primary seals of the drive end and non-drive end seals. Ensure the differential pressure between the N.D.E. and D.E. stuffing boxes is atleast 2 to 3 kgf/sq.cm. 3. Connection V1 is for vent and is on the vertical axis at the top most position of the gland plates 1 of both N.D.E and D.E and is used for venting out the leaked vapours to the flare or vapour recovery system. Connect the alarm system without pressure switch and pipe with the help of double ferrule type fitting. Supplied in loose condition. 4. Ensure while assembling the warning system undue stresses do not come at the pipe joints as well as on the gland plate 2. 5. Take steel angle or I beam and drill holes at position to match with that of pressure switch suitably. Fix or weld the angle or I beam to the base frame of the pump at distance convenient to available space from the pump centre line. 6. Fix the pressure switch vertically on the angle or I beam already erected. Connect pressure switch to the block and bleed valve with the help of double ferrule as shown in the warning system drawing A3A LD45/A/R0. Avoid undue stresses on the pipe joints and on the pressure switch, block and bleed valve during assembly. 7. Connect block valve to the flare or vapour recovery system. This completes the installation procedure of the warning system.

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Installation, Operation & Maintenance Instructions These instructions are for the fitting, operation and maintenance of the coupling as used in rotating equipment and will help to avoid danger and increase reliability. The information required may change with other types of equipment or installation arrangements. These instructions must be read in conjunction with the instruction manuals for both the driver and driven machinery.. If the coupling is to be used for an application other than that originally intended or outside the recommended performance limits, John Crane must be contacted before its installation and use. Any warranty may be affected by improper handling, installation, or use of this coupling. Contact John Crane for information as to exclusive product warranty and limitations of liability If questions or problems arise, contact your local John Crane representative or the original equipment manufacturer as appropriate. ATTENTION John Crane couplings are precision products and must be handled appropriately. Take particular care to avoid damage to spigots, mating faces, hub bores, keyways and membranes. Do not excessively compress the coupling membranes during assembly. Refer to Table 1 for compression limits. (X) These instructions are written for standard catalogue products, generally designed in accordance with the drawing shown. ATTENTION

These instructions are provided to familiarise the user with the coupling and its designated use. These instructions must be read and applied whenever work is carried out on the coupling and must be kept available for future reference. Reference

Description

1

Transmission Unit

2

Driver Hub

3

Driven Hub

4

Hub Bolts

5

Guard Ring Spacer

7

Membrane Pack

8

Drive Bolt Assembly



6



Foreword

Figure 1



!

where there is an obligation or prohibition concerning the avoidance of risk. where there is an obligation or prohibition concerning harm.





ATTENTION





If the coupling is not to be used immediately, it should be stored away from direct heat in its original packing.



Storage

The following designations are used in the installation instructions to highlight instructions of particular importance. IMPORTANT is used for items of particular concern when using the coupling.

Safety Instructions

All documentation supplied with the coupling should be retained for future reference.

Spares When requesting spares always quote the full designation of the coupling The following spares can be purchased from John Crane. 1. Set of hub bolts (4) (please specify standard or/and large hubs)

1. A factory assembled transmission unit, comprising 2 off guard rings (5), 1 – off spacer (6), 2 off membrane packs (7) plus fasteners and fixings(8)

2. Hubs, bored to your requirement or unbored (2, 3)

2. Driver hub

4. Membrane pack including drive bolts and guard ring assemblies (5, 7, 8)







The usual extent of supply comprises







3. Complete transmission unit, balanced or unbalanced (1)



3. Driven hub 

4. 2 sets of bolts (4) to assemble the transmission unit to the two hub flanges 





IMPORTANT

If a general arrangement drawing is supplied with the coupling then all data indicated on that drawing takes precedence over information included in these instructions. Taper Bore with Keyed Drive

Remove coupling from packaging and carefully inspect for signs of damage. Pay particular attention to the hub bores and the spigot/recess location features, which should be free from burrs and other damage.

1. Fit the hub onto the shaft without the key(s). Lightly hammer the hub with a soft faced mallet to ensure metal to metal contact takes place. 

Installation



2. Measure the distance from the end of the shaft to the face of the hub using a depth micrometer. 

3. Securely mount a dial gauge onto the inboard hub flange and set to zero. 4. If necessary remove the hub and fit the key(s) which should be a tight sliding fit in the keyway with a small clearance at the top of the key. 5. Refit the hub and draw up the shaft to the correct axial position indicated by the dial gauge. The hub may have to be heated to achieve the required interference. See Figure 2. Note that the hub face may not be flush with the shaft end when taper bores are used. 





Prior to installing the coupling, ensure that the machinery is made safe. Half-couplings must be adequately supported during installation to avoid accidental damage should they slip. Ensure the hub bore and mating shaft are clean.

!



INSTALLATION OF HUBS

Parallel Bore with Keyed Drive The hub is usually installed with the hub face and shaft end flush. 

1. Measure the shaft diameter and hub bore to confirm the correct fit. 

2. For clearance fits, install the key(s) into the shaft keyway and with a little lubrication on the shaft, slide the hub onto the shaft. The key should be a tight sliding fit in the keyway with a small clearance at the top of the key. Secure the hub to the shaft in the correct axial position with one or more grub screws. 

3. John Crane recommends a light interference fit for most applications and it may be necessary to apply heat to assist fitting of such hubs. A warm oil bath will usually be adequate. DO NOT use spot heat or exceed 175 degrees centigrade as this may cause distortion. A thermal heat stick can be used to estimate the temperature before quickly sliding the hub onto the shaft. A suitable stop will ensure the correct axial position is located.

Figure 2

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Installation (continued) Taper Hubs Mounted by Oil Injection

Installation, Operation & Maintenance Instructions Unbored Hubs John Crane recommends a light interference fit for keyed hubs and shafts [e.g. a K7/m6 fit]. The finished bore size can be calculated from the measured shaft diameter.

2. Thoroughly clean all contact surfaces and smear the tapered surfaces with oil.

When setting up the hub to machine the bore use the hub location recess and face as datum surfaces, as shown in Figure 3.





1. Ensure that fillets and corner radii of mating surfaces, oil distribution and drainage grooves are well rounded and free from burrs.



3. Fit the hub onto the shaft. 

4. Fit the oil injection equipment, axial stop and mounting tools. Consult the arrangement drawing and the oil injection system suppliers’ instructions. Fit and secure the axial ram or hydraulic nut BEFORE injecting oil between the components.





!

The hub face should be set such that the maximum run out does not exceed 0.00008mm per mm of hub flange diameter or 0.025 mm TIR, whichever is greater.

6. By means of the mounting tools, position the hub in the correct axial position, injecting oil during this operation.

Adapters





5. Inject oil between the components until the required mounting pressure is reached, or it leaks out at the ends of the mating surfaces.

The hub location recess should be set so the maximum run out does not exceed 0.00008mm per mm of recess diameter or 0.012 mm TIR, whichever is greater.



7. Release the oil pressure. 

8. Remove the mounting tool and oil injection equipment. 

9. Assemble the locking washer and lock nut to shaft end if applicable.

For machines having an integral flanged shaft, the flange may be machined to suit the bolting configuration of the coupling transmission unit. Alternatively, the coupling may be supplied with a customised flange adapter. Refer to the specific general arrangement drawing for location and mounting details. 5. Recheck the DBSE after the shafts have been aligned.

Align the centre lines of the DRIVING and DRIVEN machine shafts as follows:

6. Axial shims (together with a shim carrier in some cases) may be supplied on applications where it is difficult to accurately set a predetermined shaft end separation [DBSE]. This is often the case where one or both of the hubs are taper bored. Where this feature is supplied, the thickness of shims [plus carrier if applicable] are added to the free length of the transmission unit so that the combined length is equal to the measured distance between the hub flange faces, making any allowance for known shaft movements. Note it is best to measure the transmission unit when it is in a gagged condition.







IMPORTANT

DBSE should be measured between the inner face of the hubs and should not be taken as the length of the transmission unit at its outer periphery. DBSE may not be equal to the precise distance between shaft ends. In particularly, the faces of taper bored hubs may not be flush with the shaft end. Refer to Figure 4.



4. Align the shaft centre lines both horizontally and vertically by aligning the hub flanges. JOHN CRANE recommends the reverse periphery method for accurate alignment. This can be done using dial gauges or with the John Crane LASE-A-LIGN™ shaft alignment system kit kit. Further details are available from John Crane on request.



IMPORTANT





3. With one machine firmly bolted down, set the distance between shaft ends (DBSE) according to the drawing or catalogue dimension.





2. Check for any soft foot and correct before commencing alignment.





1. Move the equipment into position



Shaft Alignment

The misalignment tolerances quoted in literature and on drawings, allow for dynamic conditions and variations. For the best service from the coupling, John Crane recommend that installed misalignment is no more than 10% of the maximum allowable misalignment, allowance being made for any anticipated movements which will occur during operation (eg. Thermal movements on hot pumps).

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Installation, Operation & Maintenance Instructions Installation Of The Transmission Unit ensuring the spigots enter their recesses squarely. Bolt-threads should be lubricated with oil and tightened in a “diametrically opposite” sequence to the torque values shown in Table 1.



1. Check spigot and recess locations on the hubs and transmission unit for damage

Hub tightening torque values apply to oil lubricated threads. Maximum angular misalignment = 0.33 degrees up to 3600rpm. 0.25 degrees above 3600rpm.

Always remove the compression bolts as soon as the transmission unit is in position, before fully tightening the hub bolts.

 

IMPORTANT 

6. Rotate the machinery two or three times slowly to ensure it moves freely. 



2. It may be necessary to compress the transmission unit whilst sliding it between the hubs. Facilities are provided to make this easier. The spacer flanges are drilled (4 holes in each flange) to allow compression bolts (ref. 9) to be threaded into the guard ring. Tightening evenly will compress the transmission unit until clearance between the hub spigots and length of the transmission unit is achieved, allowing installation. (see Figure 5). Minimum gap of X should not be less than the values shown in Table 1, unless indicated otherwise on the general arrangement drawing.

5. Measure dimension ‘A (see Figure 1) on the transmission unit. Check against the minimum and maximum value in Table 1. 

The transmission unit must be adequately supported during installation to avoid accidental damage should it slip.





!



3. Align the hub/transmission unit flanges if they have been match marked. 

4. Fit the hub bolts and tighten these evenly to locate the transmission unit,

TABLE A1

Bolt Size

Large Hub Tightening Torque Nm

Min gap X mm

Coupling Max Axial Deflection +/- mm

Dim’n ‘A’ (Min) mm

Dim’n ‘A’ (Max) mm

Dim’n ‘B’ mm

Hub Jacking Bolt Size

35

M12

120

9.1

1.4

10.1

65

M12

120

9.4

1.7

10.9

10.3

82

M6

11.2

102

750

M12

120

M14

180

10.1

1.9

M6

11.6

11.9

120

1050

M12

120

M14

180

10.7

M6

2.2

12.3

12.7

136

1500

M14

180

M16

280

M6

11.9

2.4

13.8

14.2

153

2000

M16

280

M16

M8

280

13.4

2.7

15.4

15.8

171

2600

M16

280

M8

-

-

14.6

3.0

16.7

17.2

183

3350

M14

M8

180

-

-

15.3

3.2

17.7

18.2

205

4250

M8

M14

180

-

-

16.1

3.5

18.6

19.2

220

M8

6010

M16

280

-

-

17.3

3.9

20.1

20.7

250

M8

8500

M16

280

-

-

19.8

4.4

23.0

23.7

276

M8

9013

M16

280

-

-

23.1

5.0

26.7

27.5

320

M8

9017

M16

280

-

-

25.2

5.5

29.2

30.0

348

M16

9021

M16

280

-

-

28.1

6.0

32.4

33.4

378

M16

9036

M16

280

-

-

34.3

7.1

39.4

40.5

460

M16

9049

M16

280

-

-

37.7

7.9

43.4

44.7

507

M16

!





Operation, Inspection And Maintenance Before starting the machinery, ensure that all necessary safety procedures are being observed and coupling guards are fitted.

Routine examination should include a periodic check on the tightness of fasteners and visual inspection of transmission components for signs of fatigue or wear.

!





If the coupled machinery is disturbed at any time, shaft alignment should be re checked. Alignment checking is recommended if a deterioration of installation alignment during service is suspected. Maintenance work must only be carried out by suitably qualified personnel when the equipment is stationary and has been made safe.

be identified and corrected before replacing the coupling. It is possible to repair the coupling by fitting a replacement disc pack assembly or replacing the entire transmission unit. To replace the transmission unit, remove the hub bolts and then withdraw the transmission unit using the compression bolts feature in the spacer as appropriate. It may be necessary to use the jacking holes provided in each hub to push the spigot off the guard ring. (See Table 1).

!

Transmission unit must be adequately supported during removal to avoid accidental damage should it slip.

ATTENTION



M10



M8

500

Large Hub



300

Standard Hub



Bolt Size

Standard Hub Tightening Torque Nm

Coupling Size

When repairing John Crane’s flexible membrane couplings, only John Crane approved parts should be used.

Failures are rare and can generally be attributed to excessive misalignment or / and severe torsional overload. In all cases of coupling failure, the cause should

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Installation, Operation & Maintenance Instructions This section refers to couplings which bear the CE and ATEX* required markings: CE / ATEX marking

C) Ambient temperature is (-55°C < Ta < 90ºC) When the ambient temp. is specified, ‘T3’ is replaced by the following ‘T’ mark (**) according to table1.

All couplings which comply with CE and ATEX legislation will be marked as shown. This will be etched on the spacer element of the transmission unit. Note:

A) Ambient temperature is standard (40ºC max)

‘XX’ is the year of manufacture and will change. For example for year 2016; XX = 16. CE and EX marks must meet requirements of Annex II in Reg. (EC) No. 765/2008 and Annex II in Dir. 84/47/EEC respectively. Where Metastream metal membrane couplings from John Crane are required for use in higher ambient temperatures, John Crane UK Ltd certifies that the equipment complies with the temperature classification range listed below table 1; and in all other respects complies with the type certificates. Operation in aggressive atmospheres

Operation in Aggressive Atmospheres The following components contain non-metallic materials. Confirm compatibility or provide suitable protection if the coupling is to operate in an aggressive atmosphere.





• The hub electrical insulation (if supplied option) – reinforced thermosetting plastic. • Limited end float bearings (if supplied option) – PTFE based plastic. Temperature Classification of Metastream Couplings



Metastream T, L and H series couplings, using the disk type flexible elements, are covered by type examination certificate Sira 02ATEX9403. Metastream M series couplings, using the diaphragm type flexible elements, are covered by type examination certificate Sira 02ATEX9404.

B) Ambient temperature is (-55°C < Ta < 150ºC) OR Ambient temperature is unspecified, the equipment is not suitable for mining applications, Group I, Category 2.

Metastream metal membrane couplings from John Crane, supplied in conformance with Directive 2014/34/EU, have to meet the classifications specified in table 1 when used in accordance with instructions and information supplied.

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Installation, Operation & Maintenance Instructions

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Installation, Operation & Maintenance Instructions

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Installation, Operation & Maintenance Instructions

Tel: 1-847-967-2400 Fax: 1-847-967-3915

Tel: 44-1753-224000 Fax: 44-1753-224224

Tel: 55-11-3371-2500 Fax: 55-11-3371-2599

Tel: 971-481-27800 Fax: 971-488-62830

Tel: 65-6518-1800 Fax: 65-6518-1803











Asia Pacific Singapore



Middle East & Africa United Arab Emirates



Latin America Brazil



Europe United Kingdom



North America United States of America

If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use. In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling products made from PTFE. Old and new PTFE products must not be incinerated. ISO 9001 and ISO 14001 Certified, details available on request. Revised 08/16

www.johncrane.com

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©2016 John Crane

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PLAN 53B SEAL SYSTEM MANUAL

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Operating manual

Buffer System (SPO) SPO9050/M438-D1

 These instructions are intended for the assembly, operating and monitoring personnel.  This manual must be kept available on site.  Read this manual diligently and follow all instructions.  We definitely recommend you contact EagleBurgmann should anything be unclear.  The product named on the title page will be called system in the following.  The designation non-EagleBurgmann equipment refers to all non-EagleBurgmann components, see equipment list and drawing  Use this documentation only in conjunction with the documents stated in "System Information" in order to avoid mistakes.

EagleBurgmann Germany GmbH & Co. KG Äußere Sauerlacher Straße 6-10 | D-82515 Wolfratshausen | Tel.: +49 (0)8171 23 0 | Fax: +49 (0)8171 23 12 14 [email protected] | www.eagleburgmann.com

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Manufacturer and address EagleBurgmann Germany GmbH & Co. KG Stammhaus - Fachbereich Versorgungssysteme Äußere Sauerlacher Straße 6-10 D - 82515 Wolfratshausen Tel.: +49 (0) 81 71 - 23 0 Fax: +49 (0) 81 71 - 23 19 29

Dealer http://www.eagleburgmann.com  EagleBurgmann International  Country (distribution locations and Service Center)

Service-Center http://www.eagleburgmann.com  EagleBurgmann International  Country (distribution locations and Service Center)

Creation Date: Supply Systems Department: Documentation & Standardization Department:

08.05.2017 Andreas Haindl Tom Witjes

Country of origin of the system Germany

Version and date of document EBG_31.05.2016 // 24.04.2017

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Table of Contents 1.

Safety ....................................................................................... 5 1.1.

1.1.1.

Operator-specific safety instructions and hazard analysis results................................................................................ 5

1.1.2.

Product-specific safety instructions .................................... 6

1.1.3.

Operating-specific safety instructions ................................ 7

1.2.

Personal, material, environmental damage and notes .............. 8

1.3.

Standards and directives .......................................................... 9

1.4.

Warranty and liability ................................................................ 9

2.

System information..................................................................10 2.1.

Intended use ...........................................................................10

2.2.

Operating data and limits on use .............................................10

2.3.

Materials .................................................................................10

2.4.

Notes on explosion protection .................................................11

2.5.

Findings from the general risk assessment..............................11

2.6.

Other applicable documents and drawings ..............................12

3.

Transportation .........................................................................13 3.1.

Packaging ...............................................................................13

3.2.

Delivery ...................................................................................13

4.

Storage ...................................................................................14

5.

Description and function ..........................................................15 5.1.

Description of system ..............................................................15

5.2.

Description of components ......................................................15

5.3.

Emissions ................................................................................16

6.

Assembly, and disassembly ....................................................17 6.1.

Space required ........................................................................17

6.2.

Accessories .............................................................................17

6.3.

Montage ..................................................................................18

6.4.

Disassembly ............................................................................19

7.

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General safety notes ................................................................ 5

Start up and shut down............................................................21 7.1.

Requirements ..........................................................................21

7.2.

Start up ...................................................................................21

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7.3. 8.

Shutting down .........................................................................24 Operation ................................................................................25

8.1. 9.

Notes for the end user .............................................................25 Servicing .................................................................................26

9.1.

Cleaning ..................................................................................26

9.2.

Maintenance............................................................................26

9.3.

Repair .....................................................................................27

10.

Faults ......................................................................................28

10.1. Fault table ...............................................................................29 11.

Disposal ..................................................................................30

12.

Customer service ....................................................................31

12.1. Spare parts..............................................................................31 12.2. Accessories .............................................................................31 12.3. Queries and orders..................................................................31 13.

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Copyright .................................................................................32

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Safety

1.

Safety

1.1.

General safety notes

1.1.1. Operator-specific safety instructions and hazard analysis results  EagleBurgmann systems are manufactured to a high quality and have high operational reliability. However, the system is a potential source of risk if it is not operated correctly or is used improperly.

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

The regulations applicable at the location as well as the accident prevention requirements must be complied with at all times.



Unauthorized modifications and changes that adversely affect the safety of the system are not permitted.



The operator holds the responsibility for accident-free operation.



Within the scope of his safety concept the operator is requested to check what effects failure or damage to the system would have on the environment, and which additional prevention measures are necessary to protect people or the environment.



The operator must prevent the system from being misused or operated improperly.



To avoid the risk of burns and personal injuries due to contact with hot surfaces, the operator must affix appropriate insulation and/or warning signs to the system.



Safety and warning signs may not be removed and must be kept in a legible condition.



The maximum permissible operating pressure of the system and other components in a closed supply circuit must not be exceeded, regardless if caused by incorrect handling or through procedures. Appropriate measures must be taken which comply with the regulations applicable at the location.



Work on the system is principally only permitted on a depressurized machine during standstill and with disconnected supply voltage. Secure the device to prevent unauthorized reactivation.



For the sake of clarity, the operator is recommended to incorporate this document into his generally applicable company regulations.



The operating instructions of the operator must be observed and complied with.



The system can be lifted by the points shown in the drawing.



The operator must ensure that the system is installed in the predisposed installation point of the plant.

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Safety

1.1.2. Product-specific safety instructions  Any person within the operator's company involved in the installation, removal, operation, start-up, and maintenance of the system must have read and understood this operating manual, and the safety notes in particular. We recommend that the operator confirm that this is the case.

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

How the system is incorporated into the higher level system will determine whether it is safe to operate. The technician with responsibility for the overall system is also responsible for matching the system to the higher level system.



Only competent, authorized, trained and instructed personnel may install, commission, maintain or remove EagleBurgmann systems. EagleBurgmann offers the corresponding seminars to obtain the required skills.



Responsibilities for the applicable tasks should be clearly assigned and obeyed to prevent confusing competencies regarding safety.



The personnel must wear safety clothing, safety gloves and safety glasses and respiratory protection, if necessary, that is appropriate to the work to be done.



This documentation must be accessible to the personnel at all times.



The system’s switching logic must be matched to the individual seal and must be implemented and tested by the operator.



The operator must interpret the test results and select the resulting status values for the seal (function, fault, danger) so that the seal is guaranteed to work at all times and to minimize the response time in the event of a fault.

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Safety

1.1.3. Operating-specific safety instructions  Systems that are operated with hazardous substances must be free of hazardous substances during maintenance work to eliminate risks to people or the environment.

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

Depending on the medium and/or sealing gas (e.g. separating gas) to be sealed, you must comply with the hazardous substance ordinance, the relevant regulations on handling hazardous substances (e.g. safety data sheets as defined in directive 91/155/EEC, national regulations, etc.) and the accident prevention regulations. If the utilized medium to be sealed is subject to a hazardous substance ordinance, then all regulations for handling hazardous substances must be observed.



The gas concentration in the atmosphere should be measured at regular intervals, as required, while working on the system.



When installing the units, check the local grounding and potential requirements and power system conditions before connecting any cables. The operator must take suitable measures if critical potential differences are identified. Any ground connections used must be regularly tested for effectiveness (resistance to ground).



When nitrogen is used in enclosed spaces and pits, the nitrogen concentration can rise very quickly. Danger of suffocation.



Comply with the third-party manufacturer’s regulations and documentation for non-EagleBurgmann devices.



Any mode of operation that adversely affects the operational safety of the system is not permitted.



All valves must be secured against unauthorized operation.

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1.2.

Safety

Personal, material, environmental damage and notes A list of notes used in the document along with an explanation is supplied in the following:

Situation resulting in death or severe injuries if not avoided.

Type and source of danger Possible consequences - Action - Action

DANGER

Situation which can result in death or severe injuries if not avoided.

Type and source of danger Possible consequences - Action - Action

WARNING

Situation which can result in light injuries if not avoided.

Type and source of danger Possible consequences - Action - Action

CAUTION

Situation which can cause material or environmental damage if not avoided.

Additional note or information.

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Material or environmental damage

Note

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1.3.

Safety

Standards and directives The system has been built according to currently valid technical standards and is safe to operate. The basic health and safety requirements of the applicable laws, standards and directives were applied during the development and execution of the system. All information pertaining to safety in this documentation refers to the valid national laws and ordinances of the European Union. The generally applicable regulations on accident prevention and on environmental protection must be observed in addition to the safety instructions given in this manual.

1.4.

Warranty and liability The General Terms and Conditions apply to all systems of EagleBurgmann Germany GmbH&Co. KG at: www.eagleburgmann.com Warranty and liability claims for personal or material damage is excluded if ascribable to one or several of the following causes: 

Improper use of the system.



Improper transport, storage, assembly, disassembly, start-up, shut down, operation, and maintenance of the system.



Constructive changes to the system without written approval from the manufacturer.



Disregarding the General Safety Instructions, Notes on Personal and Material Damage, and the supplemental notes and information.



Improper repair.



Using spare and wearing parts as well as operating materials and cleaning agents other than approved by the manufacturer.

EagleBurgmann Germany GmbH & Co. KG shall only assume warranty and liability for material and manufacturing defects.

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System information

2.

System information

2.1.

Intended use The system is intended solely for use in the specified application. Any other or more extensive usage will be regarded as incorrect usage and the manufacturer shall not be liable for any damage caused. Any usage not conforming to the conditions stipulated under “Operating limits and Limits on use” below will be regarded as incorrect usage. The risk associated with such improper usage shall be borne solely by the operator. Operation under other conditions or in another location must be agreed with EagleBurgmann and documented.

2.2.

Operating data and limits on use System: Max operating temperature: Max operating pressure: Design temperature: Design pressure Additional info: Medium

0 °C… +80 °C 50 bar (g) ----ULSD

See the equipment list, data sheets and drawing for further information.

2.3.

Materials The materials used to construct the system are varied to suit the application and are specific to the order. They can be referred to from the drawing and the documentation.

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2.4.

System information

Notes on explosion protection

Findings from the risk assessment

2.5.



The system must be grounded by the end user to avoid electrostatic sources of ignition.



Brush discharge is possible due to paint coating thicknesses (> 0.2 mm). For this reason, use only category IIA and IIB substances to avoid electrostatic sources of ignition.



To recognize hazards and take any appropriate measures, the customer must comply with the minimum requirements for safety and the health protection of employees as well as with the operator responsibilities.



A manufacturer's declaration will be issued as needed if the system will be operated in a potentially explosive atmosphere. The customer can use to this as reference for his higher level review.

Findings from the general risk assessment

The end user must ensure that the listed risks are known and that appropriate measures have been taken to prevent them. Although an individual risk assessment was carried out during development and construction, not all dangers can be eliminated because they occur in the various product life cycles and cannot be prevented by the manufacturer. When handling this system the customer must take the following into account:

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

Transportation and set-up: The muscular and skeletal system can be overstrained due to the forced postures from working and the lifting and carrying of heavy loads.



Sharp edges and crushing: Joining the system to the higher level system or connections can be a source of risk to people due to positioning and swinging movements and/or lack of freedom of movement. Hands or other extremities could becrushed as a result.

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2.6.

System information 

Electric shock: Faulty assembly, incorrect connections, defective parts, etc. can expose the personnel to the risk of electric shock during the test run and during operation. Risk to people and components due to live parts of the housing and/or electrostatic discharge.



Hot surfaces: Hot/cold surfaces, e.g. pipelines, containers or electrical components, could become a danger to people during operation.



Allergic reactions/poisoning: Components of the utilized media can damage the human immune system or trigger allergic reactions.



Combination of hazards: Misjudgements during faults, maintenance work or system operation can lead to hazardous situations that are not foreseeable.

Other applicable documents and drawings

Not available for all systems



Assembly drawing:

SPO9050/M438-D1



P&ID:

FA-SPO01-001-075



Equipment list / data sheets:

EL-SPO01-001-075



Terminal diagram:



Operating instructions for individual devices:



Test run report:



Certifications: Use this documentation only in conjunction with the other applicable documents stated above in order to avoid mistakes. The latest version of the assembly drawing, in the original scale, is definitive for construction, and for use in conjunction with this document. If required, request drawings of the components from EagleBurgmann.

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3.

Transportation

Transportation If the system is equipped with measuring devices, vibration and impact during transportation must be avoided. Always lift the transport crates at the indicated points. The factory fits the inlet and outlet openings with protective plugs to protect the interior from corrosion and prevent the discharge of residual fluid.

3.1.

Packaging Unless otherwise contractually agreed, the packaging used conforms to the "HPE" packaging guidelines issued by the "Bundesverband Holzmittel, Paletten, Exportverpackung e.V." and "VDMA".

The pictograms and handling instructions on the packaging should be followed.

3.2.

Delivery EagleBurgmann supplies the system and all components (e.g. measuring devices, if available) fully assembled, purged, unpressurized and tested for leaks and function. Before installation, check the system for visible signs of damage to assemblies or devices. Obvious defects should be documented with photographs to simplify subsequent clarification.

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4.

Storage

Storage If the unit will be stored for a few weeks or even months, it must be kept indoors in a dry place protected against dust and from the weather. Even when stored indoors, the system should be covered with a tarpaulin to protect against dust. Long-term storage of the system is not permissible. 

The storage location must be suitable for the weight of the system.



There must be sufficient space available for maintenance and/or repairs.



The storage location must be free of vibrations and other impacts.



All equipment components must be stored upright on a flat surface.



Electrical equipment should also be prepared for storage in accordance with the manufacturer’s instructions where applicable.



The system must be protected against freezing.



Corrosion protection measures must be taken for the exposed metal parts when stored for longer than six months.



Adequate ventilation should be provided.



The temperature must be kept constant:



Relative humidity: < 65 %



Temperature: +15 °C to +25°C



Protection must be provided against direct heat sources (sun and heaters) and UV radiation (sun, halogen and fluorescent lamps and arc welding).



The presence or creation of ozone (arc welding, mercury vapor lamps, high voltage devices and electric motors) must be prevented to avoid the risk of elastomer embrittlement. EagleBurgmann will not accept liability for damage caused by improper storage.

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5.

Description and function

Description and function EagleBurgmann supply systems are complete supply units for mechanical seals. A seal can only be guaranteed to function correctly if a sufficient volume of medium, and with the necessary pressure, is available at any given time. EagleBurgmann systems are required to supply (pressure, temperature and flow) multiple mechanical seals in back-to-back, face-to-face, or tandem arrangement. A double mechanical seal with barrier can only work reliably if the barrier pressure is higher at any given time than the pressure in the chamber to be sealed.

5.1.

Description of system The cooling effect of the EagleBurgmann system depends strongly on the quench fluid (buffer fluid) circulation in the buffer fluid circuit as well as the ambient temperature. When the system is installed correctly, the Thermosiphon effect (natural circulation) will start automatically. Suitable circulating devices (pumping screw in the mechanical seal or external circulating pump) substantially improve the cooling effect due to increased circulation. The liquid stored in an EagleBurgmann accumulator can supply a mechanical seal with pressure and buffer fluid for a limited time. Pressurization and refilling of the buffer system occurs through a locally available supply system. The refill intervals depend on the degree of seal leakage.

5.2.

Description of components Descriptions of how all the possible components work are given below. Not all of these components are necessarily present in this system, however:

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4

The liquid stored in the accumulator (It.no. 1) maintains the buffer pressure for a limited period in the event of a fault (power failure, faulty pump, etc.) and serves as damper for pressure fluctuations.

5

Heat exchanger (It.no. 9) for cooling the buffer fluid.

6

Thermometer for visually checking the temperature.

9

Pressure gauge (It.no. 3) for visually checking the pressure.

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Description and function

11

Transmitter (It.no. 2) for digital monitoring of the temperature and/or pressure. With optional visual monitoring.

29

Instrument shut-off valve (It.no. 6) used to shut off and vent an instrument.

30

Non-return valve (It.no. 8) prevents a medium from flowing back.

31 32 33 37

5.3.

Base frame (It.no. 13) supports and connects all the components and is used for equipotential bonding. Connecting pipes between the components. Pipe filter (It.no. 10) for cleaning the medium. Refer to the equipment list for the filter mesh size. Valve (It.no. 4; 5) used for isolation, draining or venting a line section.

Emissions A seal is a dynamic system which cannot be leak-free for physical and technical reasons. The leakage rate is influenced, among other things, by the seal design, the production tolerances, the operating conditions, and the running quality of the machine. If the buffer pressure drops below the pressure in the sealing chamber, the medium to be sealed can access the sealing gap and contaminate the flushing and buffer medium. Components which can come into contact with the leakage must be corrosion resistant or protected accordingly.

Risk of suffocation in closed rooms due to increased nitrogen concentration. Unconsciousness and suffocation followed by death. - Ensure the ventilation of rooms. - Regularly check the nitrogen concentration. - Wear personal protective equipment.

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6.

Assembly and disassembly

Assembly and disassembly The General Safety Instructions must be observed. Assembly drawing and flow chart must be to hand during the assembly and disassembly. It is absolutely mandatory to not apply force during the assembly and disassembly. All work on the system must be executed extremely carefully and under the cleanest possible conditions. The operator is responsible for the proper assembly and disassembly.

6.1.

Space required You will find the main dimensions and connection dimensions in the assembly drawing (size when completed for filter inserts and other components, for example, must be taken into consideration by the operator).

6.2.

Accessories The following tools and accessories must be prepared for the assembly and disassembly:

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

Allen key



Open-end or ring wrench



Torque wrench



Loctite (LOCTITE Corporation) or SWAK (Swagelok Company) for thread locking/ sealing paste



Cellulose cloths for cleaning



Collection tanks for pipelines and components to be drained

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6.3.

Assembly and disassembly

Assembly

The system must be installed so as to allow easy access for operation, monitoring and servicing. The installation site must be clean, level and easy to access, if possible. The installation site must be suitable for the weight of the system. Given the size of the system, it may be necessary for the end user to check the stress analysis relating to wind and working loads. All further pipelines must be earthed at regular intervals in accordance with end user specifications. The system must be aligned analogous to the drawing. Transfer points must be tightened and maintained in accordance with manufacturer's specifications.

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

The system must be assembled so that the inlet of the system is 1 – 2 m above the supply outlet of the seal to permit natural circulation of the liquid. The distance may be shorter if also using a pump.



The system must be firmly attached to the ground.



Pipelines in the system should be made of stainless steel with minimum dimensions of Ø 18 x 1.5 mm. Refer to the drawing and the flow diagram for the exact connection sizes. The individual pipe sections are normally connected through screwed joints. Thoroughly clean the pipe sections entirely with compressed air before assembly.



Install venting devices at the highest points in the pipe system if the layout of the pipes does not preclude the possibility of air pockets.



Drain connections must be installed at the lowest points of the piping system.

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6.4.

Assembly and disassembly 

Install the cooling water pipes to the system so that the maximum operating pressure of the cooling coil is not exceeded. Always follow the regulations applicable at the installation site. It must be possible to regulate the cooling water flow rate.



Pipe sections should be as short as possible and create optimum flow conditions. Run pipes so that they rise steadily and thus avoid air pockets. Only use pipe bends for turns and ball valves for shut-offs.



Pipes should be fixed at regular intervals (no more than 2 m) using sound-proofed pipe clamps so that screwed joints and valves are free of vibration and other mechanical forces.



Relative movement between the system and mechanical seal (linear expansion / vibration) should be taken into account when laying the pipes.



If available: Connect electrical components to suitable facilities with due regard to the applicable connected loads of the thirdparty manufacturer (e.g. control room). The function, fault and alarm logic must be determined and defined by the end user.



Switch off the complete system.



Disconnect the electrical connection of the system.



Allow the medium to cool off.

Disassembly

The medium must be collected and disposed of properly. The medium should never reach the drainage system and seep into the ground. 

Depressurize the system and drain the medium. For that purpose, install a connecting pipe at the "DRAIN" (if available) outlet to the collection tank. As soon as the system is depressurized and the line is connected to the container the drain ball valve (if available) can be opened. Next, the ball valve of the "VENT" ventilation (if available) can be opened cautiously until the medium has drained completely. Risk of suffocation in closed rooms due to increased nitrogen concentration.

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Assembly and disassembly WARNING

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Unconsciousness and suffocation followed by death. - Ensure the ventilation of rooms. - Regularly check the nitrogen concentration. - Wear personal protective equipment.



Purge and clean the system with a suitable medium.



Close all valves to prevent residual leakage of the medium during movement and the invasion of dirt.



Dismantle pipelines.



Dismantle the system from the plant.

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7.

Start up and shut down

Start up and shut down Slowly open the valves required for operation, see chapter 2.6. Never tighten or loosen screwed joints under pressure. Depressurize the system first.

The manufacturer’s instructions apply for all non-EagleBurgmann devices. Before final commissioning it must be ensured that all of the instructions contained in these operating instructions regarding risk prevention, safeguards, safety measures and assembly have been heeded.

7.1.

Requirements Do not start up until: 

The entire pipeline system has been installed and checked.



The electrical installation work has been carried out correctly and checked.



The priming pressure has been set in the accumulator.



If storage tank available, it has been filled with fresh buffer fluid up to the "MAX" mark, Normally, the priming pressure is set as follows: Pressure to be sealed x 0.9 Maximum permitted operating pressure of accumulator < priming pressure x 4 Comply with the specifications on the flow diagram!

7.2.

Start up

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

Switch on the electrical power supply.



Open or close all valves as indicated in the flow diagram.



If PCV or PDCV available: Adjust the setpoints according to the equipment list, the data sheets or the flow diagram. 21

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Start up and shut down 

If available: Open the "VENT" ventilation valve at the system. The medium must be collected and disposed of properly. The medium should never reach the drainage system and seep into the ground.

The prescribed viscosity depends on the product and must be coordinated with EagleBurgmann. 

Use an external filling device to fill the system with fresh and clean medium. To fill the system, the filling device must be connected to the system at the "FILL" input. Repeat the venting process until non-bubbling fluid emerges at the end of the pipe of the "VENT" ventilation valves.



After venting the system, check the priming pressure of the accumulator and recharge the accumulator as necessary. Always use a suitable filling and testing device (as specified by the manufacturer) to fill and test the accumulator. In the first week the priming pressure must be checked at least twice using the filling and testing device. If there is no loss of nitrogen, a further test should be conducted after four months. If this further test detects no change in pressure, then an annual check of the priming pressure will be sufficient. Only for systems of the SPA product series: Operate at the lowest buffer pressure setting for at least 10 minutes. This will vent the pipes.



If heat exchanger/cooling coil available: The required cooling water quantity of the heat exchanger/cooling coil must be available and must flow in and out of the system without problems. The required operating values of the seal must be considered when setting the system. You absolutely must consult with EagleBurgmann in case of any deviations.



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Set the buffer pressure:

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Start up and shut down 



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Once the required buffer pressure is attained and the equipment is vented, set all valves according to the flow diagram. Set the alarm values as per flow diagram, equipment list or data sheet. The specified values must be compared to the seal drawing; you absolutely must consult with EagleBurgmann in case of any deviations. Set the buffer pressure: If the LOW alarm is reached during operation, new buffer medium must be refilled by means of the connected refill unit until the initial buffer pressure value is reached.



Set the buffer pressure to a constant level of approximately 10 %, but not less than 2 bar above the highest operating pressure of the mechanical seal. If the pressure fluctuates on the side to be sealed, allow for an adequate margin for error between this pressure and the buffer pressure. See also the mechanical seal operating manual.



Open the cooling water pipe and adjust the mass flow rate to keep the temperature normal in the quench circuit of the seal (approximately 30 - 50°C)



Once all drain and vent valves are closed and the buffer pressure has the required level, the system may then be put into operation.

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7.3.

Start up and shut down

Shutting down 

Switch off the equipment.



Switch off the system.



Allow the medium to cool off. For short-term shutdowns (approx. 1 to 2 months) it is better to leave the buffer fluid in the equipment. For longer periods of shutdown it may reasonable instead to drain the buffer fluid and preserve the assembly. Consultation with EagleBurgmann is absolutely required. The medium must be collected and disposed of properly. The medium should never reach the drainage system and seep into the ground.

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

Depressurize the system.



Drain the medium. We recommend installing a connecting pipe to the "DRAIN" outlet, if available, to the collection tank. As soon as the pipe is connected to the container, the ball valve can be opened slowly. When the high pressure in the equipment has been reduced, you may carefully open the ball valve of the "VENT" ventilation until the medium has drained completely.



Close all valves.

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8.

Operation

Operation The manufacturer’s instructions apply for all non-EagleBurgmann devices.

8.1.

Notes for the end user  Valves between the system and seal must always be open. For operation at low temperatures, we advise preheating the barrier medium in the storage tank to at least +10°C to avoid overloading the pump motor. It is also sensible to provide trace heating for the buffer fluid lines.

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

The end user must consider and implement the health safety requirements applicable at the site of installation as well as the product-specific safety and inspection measures, including the recurring tests. Regular functional checks of the monitoring devices.



Compliance with EagleBurgmann's maintenance instructions.



Compliance with the maintenance instructions of third-party manufacturers.



Documentation of all work.



Pressure of quench fluid (buffer medium) higher than the pressure to be sealed before the mechanical seal.



The nitrogen priming pressure of the accumulator must be reset whenever a new component is installed, or after every repair.



In the first week the priming pressure should be checked at least twice using the filling and testing device. If there is no loss of nitrogen, a further test should be conducted after 4 months. If this further test detects no change in pressure, then an annual check of the priming pressure will be sufficient.



The buffer medium can also be refilled during operation while pressurized.

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9.

Servicing

Servicing

The manufacturer’s instructions apply for all non-EagleBurgmann devices.

9.1.

Cleaning The cleaning intervals depend on the degree of contamination. After maintenance and cleaning, we recommend purging the system to clean the pipelines.

9.2.

Maintenance If operated properly, the system is maintenance free. Wearing parts must be replaced as necessary. Carry out semi-annual inspections of the overall system following the General Safety Instructions. Defects (e.g. leaks and loosened pipe fastenings) must be rectified immediately. An Inspection should include checks of the system and all individual components.

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

Leakage checking of the system



If barrier medium available: Check of pressure and temperature of barrier medium. Change entire medium; for the first time after 50 operating hours, then every 3,000 operating hours (it will be necessary to fully vent the system). For deviating operator requirements the intervals can be considered for as long as they do not exceed >3,000 operating hours.



If heat exchanger/cooling coil available: Check flow rate of the cooling medium.



If pipe filters are available and cleanable: Clean the filter cartridge and filter casing after the first 50 operating hours, then monthly to quarterly, depending on the degree of contamination.

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SPO9050/M438-D1

Servicing The operator can extend the intervals if the degree of contamination.

9.3.



If storage tank available: Check the fill level and top up, if necessary, initially during start-up, then every day or every week (depending on the losses).



If accumulator is available: Check the priming pressure. Pressure as described under As-delivered State. Always use a suitable filling and testing device (as specified by the manufacturer) to fill and test the accumulator.

Repair

If there are compelling reasons to repair the system on site, repairs must be carried out by the operator's own trained personnel or by the EagleBurgmann service staff following the General Safety Instructions. Only complete system components should be replaced.

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SPO9050/M438-D1

Faults

10. Faults The manufacturer’s instructions apply for all non-EagleBurgmann devices. Uninterrupted operation is to be expected if used correctly as intended, if the limiting values are observed, if the wearing parts are checked regularly and if the specified notes are observed. In the event of a fault, proceed as follows: 

Identify the type of fault (if possible).



Document the fault (if possible).



Shut off the system as for the shutdown.



Rectify fault. Only start up the system after all causes of fault have been rectified and the system is in a faultless condition. For faults that cannot be rectified or unclear identification of the cause of fault, immediately contact either your local EagleBurgmann dealer, an EagleBurgmann Service Center, or the EagleBurgmann Head Office..

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SPO9050/M438-D1

Faults

10.1. Fault table If the system contains the following components, the following faults are possible. Nr.

1

3

4

Component/TAG number

Event

Pressure gauge

Indicated pressure is sinking

Pressure transmitter Pressure gauge

Description

Actions

Pressure drop in the system Without buffer pressure, damage to the seal is possible.

Refill the system. Check the buffer or intake pressure. It may be necessary to reset the buffer pressure. Check seal and replace as necessary.

Buffer pressure set incorrectly.

Reduce pressure until the pressure gauge displays the required pressure.

HIGH Alarm

Pressure rise in the system

Check buffer pressure and reduce pressure as necessary. Check seal and replace as necessary.

No indication

Thermometer defective

Check device and replace as necessary.

Temperature exceeds permissible operating temperature of the system

Check cooling (heat exchanger), check seal and replace as necessary.

LOW Alarm Indicated pressure is rising, or is too high

5

6

9

10

Pressure transmitter Thermometer

Thermometer

Temperature too high HIGH Alarm

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SPO9050/M438-D1

Disposal

11. Disposal The correct disposal of the system, leakage, waste and hazardous waste is the task of the operator. Contaminated systems must be disposed of under compliance with the local regulations. The manufacturer’s instructions apply for all non-EagleBurgmann devices.

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Customer service

12. Customer service The EagleBurgmann Customer Service offers an extensive service package: From advice, engineering, standardization, assembly, starting up, damage analysis to seal-related seminars. You will find more information in diverse EagleBurgmann publications and at: www.eagleburgmann.com

12.1. Spare parts

Use only EagleBurgmann spare parts or approved non-EagleBurgmann parts, otherwise there is a risk that the system will not operate correctly, representing a hazard to people and the environment.

Use only EagleBurgmann spare parts or approved non-EagleBurgmann parts otherwise the EagleBurgmann warranty will expire.

12.2. Accessories Accessories can be obtained from the EagleBurgmann dealers, the EagleBurgmann Service Center, or the EagleBurgmann Head Office.

12.3. Queries and orders For all queries and orders, contact the EagleBurgmann Head Office and provide the following information:

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

Manufacturer-Commission number 2250031553



Drawing no.

SPO9050/M438-D1



Diagram number

FA-SPO01-001-075



Equipment list / data sheets

EL-SPO01-001-075



Individual part-Item number



Material



Number of parts as per drawing

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SPO9050/M438-D1

Copyright

13. Copyright EagleBurgmann Germany GmbH & Co. KG has the copyright in this manual and reserves the right to make technical modifications to improve the system, even if such modifications are not included in this manual. It may, however, be used by purchasers, planners and operators of the system for the purposes of creating their own documentation. No claims of any nature may be derived from such usage The original document was written in German. All other languages were translated from the original language.

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221

Instruction Manual for Bladder Accumulators

GB

Instruction Manual Bladder Accumulators Betriebsanleitung Blasenspeicher

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1RWLFHG·LQVWUXFWLRQ Accumulateurs a vessie

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222

RUS

QHP 10/6/15

Product Information For Gas-loaded Bladder accumulators 5 Protective Cap 3 Gas Valve Assembly 4 Locknut 6 Nameplate 2 ‘O’ Ring 1 Bladder Assembly 7 Accumulator Shell

9 Anti Extrusion Ring 10 ‘O’ Ring 11 PTFE Ring 12 Locking Ring 14 Bleed Plug 13 Bonded Seal 8 Fluid Port Assembly

1. General Bladder accumulators are pressure vessels as defined in the pressure equipment directive 97/23/EC. They are closed vessels which are designed and built to store fluid under pressure. Bladder accumulators are hydraulic accumulators with a nitrogen filled bladder for use in hydraulic systems. Hydraulic accumulators are specifically designed to store and then discharge fluid under pressure. The regulations for commissioning and operating hydraulic accumulators which are in force at the place of installation must be observed. The plant operator is exclusively responsible for ensuring compliance with these regulations. The certificate of conformity and other documents supplied with the accumulator should be carefully stored at the place of

GB

installation for subsequent recurrent testing. Extensive maintenance and repair instructions are available for work which may be carried out on the accumulator after initial installation and commissioning, e.g. repair work. These can be sent to customers on request. WARNING All work on hydraulic and pneumatic connections to the accumulator shall only be carried out by suitably trained staff. Improper installation or handling can lead to serious accidents. Before any work is carried out on hydraulic equipment, the hydraulic system must be de-pressurized including gas pre-charge. Gases under pressure After discharging and/or completely draining the accumulator (e.g. to depressurise the hydraulic system before work is carried out), the accumulator can build up an amount of pressure again when the lines are later shut off on the fluid side. This problem must be taken into account generally and in particular before carrying out work on hydraulic systems which include connected hydraulic accumulators. All fluid-side lines connected to the accumulator must therefore be depressurised and after that the lines must remain open. Only then may the appropriate work (e.g. disassembly of the accumulator) be carried out. On no account must any welding, soldering or mechanical work be carried out on the accumulator.

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DANGER of explosion if welding or soldering is carried out! Danger of bursting, and loss of operating permission if unauthorized mechanical work is carried out on the accumulator. Hydraulic accumulators must only be filled with oxygen free dry nitrogen N2 (99.995%). Do not use other gases: Danger of explosion! CAUTION: The accumulator shell can become hot. Risk of burns. 2. Storage 2.1 Complete Accumulators All accumulators must be stored in clean, dry and cool conditions away from direct sunlight. Recommendations for short term storage: Provided the accumulators are stored in clean, dry and cool conditions away from direct sun light they can be left in their original packing for several weeks without deterioration. Recommendations for long term storage Instructions (Mineral Oil) All accumulators are supplied without nitrogen pre-charge unless a pre-charge pressure is specified with the order. Accumulator should be pre-charged to approximately 2 to 3 Bar with oxygen free dry nitrogen. The fluid port should be capped with a suitable pressure plug after pre-charge. Refer to pre-charging procedure under 4.0 Commissioning. Recommendations for long term storage Instructions (Water Glycol fluids) Precautions must be taken when the accumulator system fluids are of low

viscosity e.g. Glycol based. The following steps should be followed: * Exhaust nitrogen pre-charge, replace gas * valve cap, and stem protective cap. * With the accumulator inverted, fluid port * uppermost, fill with system fluid until level * with the top of the fluid port connection. It * is important to check that the system fluid * is safe to use – if not a suitable compatible * fluid should be used. * Once full fit a suitable pressure plug into * the fluid port connection. The accumulator is now ready for long term storage. Long term storage shall not exceed one year. 2.2 Spare Bladders Full technical specifications can be provided for all bladder components, these are available on request. Elastomeric material classification and their shelf life expectancy are detailed in BS ISO 2230. If bladders are not stored correctly they will be susceptible to attack from ozone, heat or rotational electrical equipment. Cracking will be visible within 12 months. Ideal conditions for storage - Stored in a black plastic sealed bag, in a - box, away from direct sunlight, heat or - rotational electrical equipment. - Storage temperature +15°c to +25°c - Stored inflated using Nitrogen gas, to its - natural shape. (No more than 1 x normal - shape)

GB

NOTE: Both complete accumulators and spare bladder storage instructions are only a recommendation. Where severe conditions may be encountered and recommendations cannot be met, please contact our Technical Department for advice.

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2.2.1 Spare Bladders Inspection prior to use - Remove all packaging, do not use sharp - instruments - Inflate bladder to approximately 1.5 x - normal shape - Visually examine all surfaces for cracking, - mechanical damage, such as cuts, tears or, - abraded areas, seams should be checked - for any deterioration. - Immerse in water and examine for leaks or - perforations. 3. Installation and safety equipment 3.1 Inspection prior to use All accumulators should be inspected on receipt for any damage which may have occurred during transit. Read all instructions thoroughly before beginning any type of work. Check all threaded parts for tightness e.g. protective cap, gas valve locknut, fluid port, locking ring, bleed screw, adapters and fittings if applicable. WARNING: Check that the maximum working pressure of the accumulator is not less than the maximum working pressure of the system to which it is being fitted (see 7. Markings section)

GB

3.2 Recommendations for installation Full comprehensive recommendations for installation can be requested from our technical department. CAUTION If the accumulator was in storage prior to fitting to the hydraulic system, the following is advised: Ensure the accumulator contains lubricating fluid prior to pre-charging (see 4. Commissioning)

After short term storage: accumulator must be pre-charged with correct nitrogen pressure prior to fitting to hydraulic system. After long term storage (Mineral Oil): Accumulator gas pre-charge pressure must be discharged, all fluid pressure must be vented prior to removing the pressure plug. Accumulator can then be pre-charged to the required pressure. After long term storage (Water Glycol fluids): Ensure gas pre-charge pressure is vented and the accumulator is drained of excess system fluid. The accumulator can then be pre-charged to the required pressure. 3.3 Safety equipment It is essential that the accumulator is protected from over pressurisation. (Isolation valve, pressure release device between accumulator and isolation valve, burst disc assembly to relieve nitrogen pressure, or excess temperature protection equipment) Overpressure protection devices are available on request from QHP Accumulators perform at their most efficient in the vertical position with the gas valve uppermost. Mounting should take into account any possibility of loading which may be caused by adverse weather or seismic events. Accumulators should be mounted to eliminate any movement in the event of system pipework rupture or to create abnormal stresses on the system pipework. Accumulators should be protected from damage by vehicles or traffic, e.g. fork lift trucks. It will be necessary to check the gas pre-charge pressure at regular intervals (see 5. Maintenance) Consideration must therefore be given to following:

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- The provision of a safety valve block or - isolation valve between the accumulator - and the fluid pressure line to enable - isolation of the fluid pressure. - Location of the accumulator gas valve with - regard to accidental damage and fitting of - pre-charging equipment. - Provision and location of an additional - warning label stating “pre-charge with - nitrogen gas at …bar”. QHP are able to provide a comprehensive range of mounting clamps and brackets, safety blocks or isolation valves, and burst discs. Contact our Sales Department for details 4. Commissioning Important All accumulators are supplied without nitrogen pre-charge unless a pre-charge pressure is specified with the order. Prior to fitting to the hydraulic system all accumulators must be pre-charged with nitrogen. Failure to do so will result in the bladder failing. WARNING: Never use oxygen or air – this could cause an explosion! Only use oxygen free dry nitrogen gas N2 (99.995%) WARNING: Check the accumulator label or marking to ensure that the maximum working pressure of the accumulator is equal to or greater that the system working pressure. Always use a nitrogen regulator valve when the maximum working pressure of the accumulator is lower than the gas pressure in the nitrogen cylinder.

The pre-charge pressure is dependent on the operating conditions. For advice contact our Technical Department. Note pre-charge pressure lower than 20% of the maximum working pressure may cause bladder failure. Ensure the accumulator contains lubricating fluid prior to pre-charging. It is normal practice to use system fluid for this purpose, usually 10% of the accumulator capacity being sufficient volume. 4.1 Pre-charging procedure A

E C

I H

D G

F B

3

WARNING: Only suitably trained and competent personnel shall carry out any pre-charging. NEVER LEAVE PRE-CHARGING EQUIPMENT UNATTENDED DURING USE. The following procedure must be followed to ensure safe pre-charging of the accumulators. All pre-charging equipment should be supplied by QHP – see catalogue for details. • Release pressure from the fluid side of the • bladder accumulator. • Remove protective cap (5) and if fitted gas • valve sealing cap on assembly (3) • Attach nitrogen regulator (A) to nitrogen • bottle (B) • Ensure hand-wheel (E) on charging set (C) is • fully retracted, including pin. • Fit charging set assembly (C) to accumulator • gas valve (3) • Connect charging hose (D) between nitrogen • regulator (A) and charging set assembly (C)

GB

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• Check bleed (F) is fully closed. • Set nitrogen bottle gas regulator (A) to 25 • psi. NOTE: The Nitrogen Pressure Regulator Valve shall have two gauges, one for the high pressure (upstream) and one for the reduced pressure (downstream). To avoid overcharging due to incorrect setting, the pressure-reducing device shall have a maximum set pressure not exceeding the maximum allowable pressure PS of the accumulator. To avoid overcharging by malfunction, the pressure-reducing device shall be equipped with a relief device limiting the downstream pressure. CAUTION: Initial pre-charge above 25 psig will cause the bladder to burst! • Slowly turn hand-wheel (E) clockwise one to • one and a half turns to depress the gas valve • core. • Open nitrogen cylinder valve (G) using bottle • key (H), gas pressure will be indicated on the • right hand gauge of the regulator. • Turn regulator handle (I) clockwise until gas • pressure register on the left hand gauge. This • pressure should be 10% higher than the • required pre-charge pressure. • Allow the gas pre-charge pressure to • stabilize, adjust if required. • Check gas pre-charge pressure on charging • set assembly (C). When this is equal to the • pressure on the pressure regulator, close • nitrogen bottle valve (G). • If the pressure is too high, it can be reduced • via the bleed (F) • Turn handle (E) on charging set anticlockwise • to seal gas valve (3). • Open bleed valve (F) to vent gas from • charging valve (3).

GB

• Remove charging assembly (C) and • connecting hose (D) from the accumulator. • Check accumulator gas valve for leaks using • leak detection spray or soapy water. • Replace sealing cap and protective cap The accumulator is now ready to be put into service. 5. Maintenance of the accumulator In order to ensure long and trouble free operation, the following maintenance procedure must be carried out regularly: - Test the nitrogen pre-charge pressure. - Check valve and protection devices for - correct operation, - Check that connections are tight and - leak free, - Check the mounting supports - Visually inspect accumulator 5.1 Pre-charge check frequency It is recommended that the following testing frequency be maintained: - After installation - One week after installation - Eight weeks after installation - If no nitrogen loss is detected, the test - frequency can be: - Once per year. NOTE Continuous operation at high operating temperature requires more frequent testing 6. Re-certification In the United Kingdom most accumulators fall within the requirements of the Pressure System Safety Regulations 2000 (PSSR) and the Pressure Equipment Directive (PED97/23/EC) Key points include: • Requirements to determine the safe • operating limits of the accumulator and

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• records to show that these are not exceeded • by the system pressure. • Preparation of written scheme of • accumulators above 250 bar/litres. • Establish a maintenance procedure, carry • out regular examinations. If you require assistance in ensuring that you meet the requirements of the regulations please contact our Sale Department. QHP operates trained accumulator re-certification centres around the UK who can assist you on the above. Please contact our Sales Department for details.

- identification number of notified body - (if applicable)

7. Markings Nameplates Metal labels are attached to all standard QHP bladder accumulators and show the following essential user information. * Name and address of Manufacture / Supplier * Model number * Maximum working pressure (MWP) * Accumulator volume * Date of manufacture * Warning and safety information Essential information required by the applicable design code is permanently stamped on the domed end of the accumulator shell. Typical information / Marking shown below

GB

- CE marking in accordance with the Pressure - Equipment Directive 97/23/EC - date of Manufacture, (Month/Year) - manufacturer’s serial number - manufacturer’s name/symbol - total shell volume in litres - allowable temperature range in degree - Celsius - maximum allowable pressure PS - test pressure PT

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Produktinformationen Für mit Gas gefüllte Blasenspeicher 5 Schutzkappe 3 Gasventilbaugruppe 4 Sicherungsmutter 6 Fabrikschild 2 O-Ring 1 Blasenbaugruppe 7 Speichergehäuse

9 Antiextrusionsring 10 O-Ring 11 PTFE-Ring 12 Sicherungsring 14 Entlüftungschraube 13 Verbundabdichtung 8 Flüssigkeitsanschluss

1. Allgemeine Hinweise Blasenspeicher sind Druckbehälter im Sinne der Druckgeräterichtlinie 97/23/EG. Sie sind geschlossene Behälter, die zur Aufnahme von unter Druck stehenden Fluiden ausgelegt und gebaut sind. Blasenspeicher sind HydroSpeicher mit einer mit Stickstoff gefüllten Blase zum Gebrauch in hydraulischen Anlagen. Hydro-Speicher sind ausschließlich dazu bestimmt, Druckflüssigkeiten aufzunehmen und wieder abzugeben. Für Hydro-Speicher sind die am Aufstellungsort geltenden Vorschriften vor Inbetriebnahme und während des Betriebes zu beachten. Der Betreiber ist für die bestimmungsgemäße Einhaltung dieser Vorschriften ausschließlich verantwortlich. Die mit dem Blasenspeicher gelieferte Konformitätserklärung sowie sonstige beigefügte Dokumente, sind am Aufstellungsort für die Aufstellungsprüfung und eventuell wiederkehrende Prüfungen, sorgfältig aufzubewahren. Werden außer der

D

Aufstellung und Inbetriebnahme auch andere Arbeiten, z. B. Reparaturen, an Blasenspeichern durchgeführt, so halten wir hierfür umfangreiche Wartungs- und Reparaturanleitungen bereit. Diese werden Ihnen auf Wunsch zugesendet. WARNUNG Alle Arbeiten an den hydraulischen und pneumatischen Anschlüssen des Blasenspeichers dürfen nur von dafür ausgebildeten Fachkräften durchgeführt werden. Bei unsachgemäßem Montieren und Handhaben können schwere Unfälle verursacht werden. Vor Arbeiten an Hydraulikanlagen, einschließlich Gasvorfüllung, ist das Hydrauliksystem drucklos zu machen. Gase unter Druck Hydro-Speicher können nach dem Entladen bzw. vollständigem Entleeren (z.B. drucklos machen vor Arbeiten am Hydrauliksystem) durch ein nachträgliches Absperren der Leitungen auf der Flüssigkeitsseite wieder Druck aufbauen. Dieses Problem ist generell und insbesondere vor Arbeiten an Hydrauliksystemen mit angeschlossenen Hydro-Speichern zu berücksichtigen. Daher sind alle flüssigkeitsseitigen, an den Hydro- Speicher angeschlossenen Leitungen drucklos zu machen und danach nicht mehr zu verschließen. Erst dann dürfen entsprechende Arbeiten (z.B. Demontage des Speichers) durchgeführt werden. Am Blasenspeicher sind keine Schweiß-, Lötoder mechanischen Arbeiten vorzunehmen. Explosionsgefahr bei Schweiß- und Lötarbeiten! Berstgefahr und Verlust der Betriebserlaubnis bei unbefugten mechanischen Arbeiten am Blasenspeicher.

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Hydro-Speicher dürfen nur mit sauerstofffreiem Stickstoffgas N2 gefüllt werden (99.995%). Keine anderen Gase verwenden! Explosionsgefahr! ACHTUNG: Der Speicherkörper kann heiß werden. Verbrennungsgefahr. 2. Lagerung 2.1 Komplette Speicher Alle Speicher müssen in einer sauberen, trockenen und kühlen Umgebung vor direkter Sonneneinstrahlung geschützt aufbewahrt werden. Empfehlungen für die Kurzzeitlagerung: Wenn die Speicher in einer sauberen, trockenen und kühlen Umgebung vor direkter Sonneneinstrahlung geschützt aufbewahrt werden, können sie ohne Leistungsverminderung mehrere Wochen lang in ihrer Originalverpackung gelagert werden. Empfehlungen für die Langzeitlagerung (Mineralöl) Alle Speicher werden ohne Stickstoff-Vorfüllung geliefert, es sei denn, in der Bestellung ist ein Vorfülldruck angegeben. Speicher sollten auf circa 2 bis 3 Bar mit sauerstofffreiem Stickstoff vorgefüllt werden. Der Flüssigkeitsanschluss muss nach der Vorfüllung mit einem geeigneten Druckstopfen versehen werden. Weitere Informationen dazu sind in Abschnitt 4.0 (Inbetriebnahme) zu finden. Empfehlungen für die Langzeitlagerung (Wasser-Glykol-Gemische) Es sind bestimmte Vorsichtsmaßnahmen zu treffen, wenn die Speicherflüssigkeiten eine niedrige Viskosität besitzen, z. B. bei Flüssigkeiten auf Glykolbasis. In diesem Fall sind die folgenden Schritte zu befolgen: * Lassen Sie die Stickstoff-Vorfüllung ab,

* bringen Sie die Gasventilkappe wieder an * und setzen Sie die Schutzkappe auf. * Füllen Sie die den umgedrehten Speicher * (Flüssigkeitsanschluss ganz oben) mit * Systemflüssigkeit, bis diese die Oberseite * des Flüssigkeitsanschlusses erreicht hat. * Es ist wichtig zu überprüfen, dass die * Systemflüssigkeit anwendungssicher ist. * Sollte dies nicht der Fall sein, muss eine * andere geeignete Flüssigkeit verwendet * werden. * Bringen Sie nach dem Befüllen einen * geeigneten Druckstopfen im * Flüssigkeitsanschluss an. Der Speicher ist jetzt für die Langzeitlagerung bereit. Die Langzeitlagerung soll ein Jahr nicht überschreiten. 2.2 Ersatzblasen Vollständige technische Angaben zu allen Speicherblasenteilen sind auf Anfrage erhältlich. Eine Klassifikation der Elastomerwerkstoffe und deren Haltbarkeitsdauer sind in BS ISO 2230 enthalten. Bei unsachgemäßer Lagerung können die Blasen durch Ozon, Hitze oder rotierende elektrische Ausrüstungen beschädigt werden. Risse werden innerhalb von 12 Monaten sichtbar.

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Ideale Lagerbedingungen - Lagerung in einem schwarzen, versiegelten - Plastiksack, in einer Kiste, vor direkter - Sonneneinstrahlung, Hitze oder rotierenden - elektrischen Ausrüstungen geschützt. - Lagertemperatur +15°C bis +25°C - Lagerung mit Stickstoffgas gefüllt, in - natürlicher Form (nicht mehr als 1 x die - normale Form) HINWEIS: Diese Anleitungen zur Lagerung kompletter Speicher und Ersatzblasen sind lediglich Empfehlungen.

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Wenn bei schwierigen Lagerbedingungen die Empfehlungen nicht eingehalten werden können, wenden Sie sich zur Beratung bitte an unsere Technikabteilung. 2.2.1 Prüfung von Ersatzblasen vor dem Gebrauch - Alle Verpackungsmaterialien entfernen, - keine scharfen Gegenstände verwenden. - Blase bis auf das ca. 1,5-fache der normalen - Größe füllen. - Alle Oberflächen visuell auf Risse, - mechanische Schäden wie Schnitte, - Schlitze, Abriebstellen überprüfen, Nähte - auf Verschleiß überprüfen. - In Wasser eintauchen und auf - Undichtigkeiten oder Perforationen prüfen. 3. Montage- und Sicherheitsausrüstungen 3.1 Prüfung vor dem Gebrauch Alle Speicher bei Lieferung auf eventuelle Transportschäden untersuchen. Alle Anleitungen vor Beginn jeglicher Arbeit sorgfältig durchlesen. Alle Verschraubungsteile, z. B. Schutzkappe, Gasventil-Sicherungsmutter, Flüssigkeitsanschluss, Sicherungsring, Entlüftungsschraube und ggf. Adapter und Armaturen, auf festen Sitz prüfen.

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WARNUNG: Sicherstellen, dass der maximal zulässige Betriebsdruck des Blasenspeichers nicht unterhalb des maximal zulässigen Betriebsdrucks des Systems liegt, an das der Speicher angeschlossen ist. Hierzu die Markierungen in Abschnitt (7) beachten. 3.2 Installationsempfehlungen Vollständige und umfassende Empfehlungen zur Installation können von unserer Technikabteilung angefordert werden.

10

ACHTUNG: Wenn der Speicher vor der Montage des Hydrauliksystems gelagert worden ist, werden die folgenden Schritte empfohlen: Vor der Vorfüllung sicherstellen, dass der Speicher

Schmierflüssigkeit enthält (siehe 4. Inbetriebnahme) Nach der Kurzzeitlagerung: Vor dem Anschluss an das Hydrauliksystem muss der Speicher mit dem korrekten Stickstoffdruck vorgefüllt werden. Nach der Langzeitlagerung (Mineralöl): Der Gasvorfülldruck des Speichers muss entladen und der gesamte Flüssigkeitsdruck vor dem Entfernen des Druckstopfens abgelassen werden. Der Speicher kann dann auf den erforderlichen Druck vorgefüllt werden. Nach der Langzeitlagerung (Wasser-Glykol-Mischungen): Sicherstellen, dass der Gasvorfülldruck abgelassen und die überschüssige Systemflüssigkeit aus dem Speicher entfernt wird. Der Speicher kann dann auf den erforderlichen Druck vorgefüllt werden. 3.3 Sicherheitsausrüstung Die Speicher sind unter allen Umständen gegen Überdruck zu schützen. (Absperrarmatur, Druckentlastungsvorrichtung zwischen Speicher und Absperrarmatur, Berstscheibenbaugruppe zur Verringerung des Stickstoffdrucks oder Sicherheitseinrichtung gegen Temperaturüberschreiten) Überdruckschutzvorrichtungen sind auf Anfrage von QHP erhältlich. Die Speicher arbeiten am effektivsten in vertikaler Einbauposition mit dem Gasventil oben. Die Einbauposition ist so zu wählen, dass mögliche Belastungen auf Grund ungünstiger Witterungsbedingungen oder seismischer Erschütterungen vermieden werden. Die Speicher sind so zu einzubauen, dass jegliche Bewegungen bei Brüchen des Leitungssystems ausgeschlossen sind und das Leitungssystem keinen außergewöhnlichen Belastungen ausgesetzt wird. Die Speicher sind vor Beschädigungen durch

231

vorbeifahrende Fahrzeuge, z. B. Gabelstapler, zu schützen. Der Gasvorfülldruck ist in regelmäßigen Abständen zu überprüfen (siehe (5) Wartung). Dabei ist Folgendes zu beachten:

Systembetriebsdruck.

- Zwischen dem Speicher und der - Flüssigkeitsdruckleitung muss ein - Sicherheitsventilblock oder ein Trennventil - vorgesehen werden, um eine Isolierung des - Flüssigkeitsdrucks zu ermöglichen. - Bei der Positionierung des Gasventils des - Speichers sind eventuelle unbeabsichtigte - Beschädigungen und der Einbau von - Vorfüllvorrichtungen zu berücksichtigen. - Anbringen eines zusätzlichen - Warnhinweises: „Stickstoffgasvorfüllung auf - ...bar“.

Der Vorfülldruck ist von den Einsatzbedingungen abhängig. Wenden Sie sich zwecks Beratung an unsere Technikabteilung. Ein Vorfülldruck unter 20 % des maximal zulässigen Betriebsdrucks führt möglicherweise zu einer Fehlfunktion der Blase.

QHP bietet eine umfangreiche Auswahl an Haltern und Klemmen, Sicherheitsblöcken oder Trennventilen, und Berstscheiben Kontaktieren Sie unseren Vertrieb für weitere Einzelheiten. 4. Inbetriebnahme Wichtig Alle Speicher werden ohne Stickstoff-Vorfüllung geliefert, es sei denn, in der Bestellung ist ein Vorfülldruck angegeben. Vor dem Anschluss an das Hydrauliksystem müssen alle Speicher mit Stickstoff gefüllt werden. Wird dies unterlassen, kommt es zur Fehlfunktion der Blase. WARNUNG: Verwenden Sie niemals Sauerstoff oder Luft – dies kann eine Explosion verursachen! Verwenden Sie nur sauerstofffreies Stickstoffgas N2 (99.995%). WARNUNG: Das Etikett oder die Kennzeichnung des Speichers überprüfen, um sicherzustellen, dass der maximal zulässige Betriebsdruck des Blasenspeichers gleich oder höher ist als der maximal zulässige

Grundsätzlich ein Stickstoff-Regelventil verwenden, wenn der maximal zulässige Betriebsdruck des Speichers über dem Gasdruck im Stickstoffzylinder liegt.

Vor dem Vorfüllen überprüfen, ob sich Schmierflüssigkeit im Speicher befindet. In der Regel wird hierzu Systemflüssigkeit verwendet, wobei eine Menge von 10 % des effektiven Speichervolumens ausreichend ist. 4.1 Vorgehensweise beim Vorfüllen: A

E C

I H

D G

F B

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WARNUNG: Die Vorfüllung darf nur von ausreichend geschultem und kompetentem Personal durchführt werden. DIE VORFÜLLAUSRÜSTUNG WÄHREND DER VERWENDUNG NIE UNBAUFSICHTIGT LASSEN. Zum sicheren Vorfüllen von Speichern ist wie folgt vorzugehen. Alle Vorfüllvorrichtungen sollten über QHP bezogen werden. Nähere Angaben finden Sie in unserem Katalog. • Druck von der Flüssigkeitsseite des • Blasenspeichers ablassen. • Schutzkappe (5) und, falls vorhanden, • Verschlussdeckel (3) des Gasventils an der

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• Baugruppe abnehmen. • Stickstoff-Regelventil (A) an die • Stickstoffflasche (B) anschließen. • Sicherstellen, dass das Handrad (E) an der • Füllvorrichtung (C), einschließlich Stift, • vollständig zurückgezogen ist. • Füllvorrichtung (C) an das Gasventil (3) des • Speichers anschließen. • Füllschlauch (D) zwischen demStickstoff• Regelventil (A) und der Füllvorrichtung (C) • anschließen. • Sicherstellen, dass die Entlüftungsschraube • (F) vollständig geschlossen ist. Stickstoffflaschen-Gasregler (A) auf 25 psi einstellen. HINWEIS: Das Stickstoff-Druckregelventil hat zwei Druckmesser: einen für den hohen Druck (stromauf) und einen für den reduzierten Druck (stromab). Um eine Überlastung durch eine inkorrekte Einstellung zu verhindern, muss der Druckminderer einen maximalen Einstelldruck haben, der den maximal zulässigen Druck PS des Speichers nicht übersteigt. Um eine Überlastung durch Fehlfunktion zu verhindern, muss der Druckminderer mit einer Entlastungsvorrichtung ausgestattet sein, die den Ausgangsdruck begrenzt.

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ACHTUNG: Eine anfängliche Vorfüllung über 25 psi führt zum Bersten der Blase! • Das Handrad (E) langsam um eine bis • eineinhalb Drehungen im Uhrzeigersinn • drehen, um den Gasventileinsatz • herunterzudrücken. • Ventil des Stickstoffzylinders (G) mithilfe • des Schraubenschlüssels (H) an der Flasche • öffnen. Der Gasdruck wird auf der Anzeige • rechts vom Regulierventil angegeben. • Den Griff am Regulierventil (I) im

• Uhrzeigersinn drehen, bis auf der Anzeige • links ein Gasdruck angegeben wird. Dieser • Druck muss 10 % über dem erforderten • Vorfülldruck liegen. • Der Gasvorfülldruck muss sich stabilisieren. • Falls nötig einstellen. • Den Gasvorfülldruck anhand der • Füllvorrichtung (C) prüfen. Das Ventil an • der Stickstoffflasche (G) schließen, wenn • dieser Druck dem Druck am Regulierventil • entspricht. • Wenn der Druck zu hoch ist, kann er durch • die Entlüftungsschraube (F) reduziert • werden. • Das Handrad (E) an der Füllvorrichtung • gegen den Uhrzeigersinn drehen, um das • Gasventil (3) zu schließen. • Die Entlüftungsschraube (F) aufdrehen und • Gas aus dem Füllventil (3) ablassen. • Die Füllvorrichtung (C) und den • Anschlussschlauch (D) vom Speicher • abnehmen. • Das Gasventil des Speichers auf undichte • Stellen prüfen. Hierzu Lecksuchspray oder • Seifenwasser verwenden. • Den Verschlussdeckel und die Schutzkappe • wieder anbringen. Der Speicher ist jetzt betriebsbereit. 5. Wartung des Speichers Um jedoch einen langen und störungsfreien Betrieb zu gewährleisten, sind folgende Wartungsarbeiten in regelmäßigen Abständen durchzuführen: - Vorfülldruck des Stickstoffs prüfen. - Ventil und Schutzvorrichtungen auf korrekte - Funktion prüfen. - Anschlüsse auf festen Sitz und Leckagen - prüfen. - Befestigungselemente prüfen. - Speicher visuell überprüfen. 5.1 Prüfintervalle für die Vorfüllung

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Es wird empfohlen, nachfolgende Prüfintervalle einzuhalten: - Nach jedem Einbau. - Eine Woche nach Einbau. - Acht Wochen nach Einbau. - Ist kein merklicher Gasverlust aufgetreten, - können die zukünftigen Prüfintervalle - einmal jährlich erfolgen. HINWEIS: Dauereinsatz bei hohen Betriebstemperaturen erfordert kürzere Prüfintervalle. 6. Rezertifizierung In Großbritannien unterliegen die meisten Speicher den Anforderungen der Pressure System Safety Regulations 2000 (PSSR) und der Druckgeräterichtlinie 97/23/EG. Wesentliche Punkte sind: • Anforderungen zur Bestimmung der • sicheren Betriebsgrenzen des Speichers • und Aufzeichnungen zum Nachweis, dass • diese nicht vom Systemdruck überschritten • werden. • Erstellen eines schriftlichen Plans von • Speichern über 250 bar/Liter. • Ein Wartungsverfahren einsetzen, • Sicherheitskontrollen und regelmäßige • Überprüfungen durchführen. Wenn Sie Unterstützung bei der Erfüllung der Anforderungen dieser Richtlinien benötigen, wenden Sie sich an unsere Verkaufsabteilung. QHP betreibt qualifizierte Rezertifizierungsstellen für Speicher an verschiedenen Standorten in Großbritannien, die Sie bei der Rezertifizierung unterstützen können. Bitte wenden Sie sich für weitere Informationen an unsere Verkaufsabteilung.

enthalten die folgenden wichtigen Informationen für Benutzer. * Name und Adresse des * Herstellers/Modellnummer * Maximal zulässiger Betriebsdruck (MWP) * Speichervolumen * Datum der Herstellung * Warnungen und Sicherheitsinformationen Nach dem geltenden Ausführungsnormen erforderliche wichtige Informationen sind permanent auf das Kuppelende des Speicherkörpers aufgestanzt. Typische Informationen/Kennzeichnung: - CE-Kennzeichnung gemäß der - Druckgeräterichtlinie 97/23/EG - Herstellungsdatum (Monat/Jahr) - Seriennummer des Herstellers - Name/Symbol des Herstellers - Gesamtvolumen in Litern - Zugelassener Temperaturbereich in Grad - Celsius - Maximal zulässiger Betriebsdruck PS - Prüfdruck PT - Kennnummer der benannten Stelle (falls -zutreffend)

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7. Kennzeichnungen Fabrikschilder Metallschilder sind an allen StandardBlasenspeichern von QHP befestigt und

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Información del producto Para acumuladores de vejiga cargados con gas 5 Tapón protector 3 Conjunto de la válvula de gas 4 Tuerca de retención 6 Placa de identificación 2 Junta tórica 1 Conjunto de la vejiga 7 Cuerpo del acumulador

9 Anillo antiextrusión 10 Junta tórica 11 Anillo PTFE 12 Anillo de bloqueo 14 Tornillo de purga 13 Cierre hermético 8 Conjunto de la boca de entrada del fluido

1. Información general Los acumuladores de vejiga son aparatos a presión que cumplen las especificaciones de la directiva 97/23/CEE para aparatos a presión. Estos son depósitos cerrados que se han diseñado y construido para acumular fluidos sometidos a presión. Los acumuladores de vejiga son dispositivos hidráulicos que tienen una vejiga llena de nitrógeno y que se usan en equipos hidráulicos. Los acumuladores hidráulicos tienen como finalidad almacenar y posteriormente vaciar fluidos bajo presión. Antes de la puesta en servicio de los acumuladores hidráulicos y durante su utilización deben tenerse en cuenta las normas vigentes en el lugar de instalación. La responsabilidad final de la correcta utilización y el debido cumplimiento de estas normas recaerán sobre el operador de la máquina. El certificado de conformidad que se suministra con los acumuladores de vejiga y,

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en caso necesario, la documentación proporcionada, deberán mantenerse en el lugar de instalación como ayuda para las pruebas necesarias y los eventuales controles periódicos. Dado que podría ser necesario realizar trabajos distintos a la instalación y el mantenimiento (p. ej., reparaciones) en el acumulador a vejiga, disponemos también de instrucciones específicas para estas tareas. Éstas le serán enviadas cuando lo solicite. ADVERTENCIA Todos los trabajos en las conexiones hidráulicas y neumáticas del acumulador de vejiga deben ser realizados únicamente por personal técnico especializado. Un montaje y utilización incorrectos pueden ocasionar accidentes graves. Antes de realizar cualquier tipo de trabajo con un equipo hidráulico, el sistema hidráulico debe despresurizarse, incluido el gas de precarga. Gas presurizado Después de descargar o vaciar completamente los acumuladores (por ej., despresurizar el sistema hidráulico antes de efectuar cualquier trabajo), puede existir recargamiento de presión al cerrar posteriormente las líneas de la tubería en el lado del fluido. Este comportamiento es general y debe tenerse en cuenta sobre todo antes de efectuar trabajos en sistemas hidráulicos que tengan agregados acumuladores hidráulicos. Por ello, deben despresurizarse todas las líneas de tubería conectadas al acumulador en el lado del fluido, que no se han de cerrar. Solo después de esto podrá realizarse el trabajo requerido (por ej., desmontar el acumulador). No realice trabajos de soldadura ni mecánicos en el acumulador de vejiga.

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Peligro de explosión durante la soldadura Riesgo de ruptura y pérdida del permiso para la utilización si se realizan en el acumulador trabajos mecánicos no autorizados. Los acumuladores hidráulicos se han de llenar solamente con nitrógeno seco libre de oxígeno, N2 (99.995%). No utilice otros gases: ¡peligro de explosión! ATENCIÓN El cuerpo del acumulador puede calentarse. Peligro de quemaduras. 2. Almacenamiento 2.1 Acumuladores al completo Todos los acumuladores deben almacenarse en un lugar limpio, seco y fresco, y no deben estar expuestos a la luz solar. Recomendaciones para el almacenamiento de corto plazo: Siempre y cuando los acumuladores se almacenen en un lugar que esté limpio, seco, fresco y fuera del alcance de la luz solar, pueden dejarse dentro de su embalaje original durante varias semanas sin que sufran deterioro alguno. Recomendaciones para un almacenamiento de largo plazo. Instrucciones (aceite mineral) Todos los acumuladores se entregan sin precarga de nitrógeno, salvo que se especifique en el pedido presión de precarga. Los acumuladores deberán cargarse previamente hasta un nivel de nitrógeno sin oxígeno de 2 a 3 bares aproximadamente. La boca de entrada del fluido debe taparse con un tapón de presión adecuado después de la carga. Consulte los procedimientos de precarga del apartado 4.0 Puesta en funcionamiento. Recomendaciones para el almacenamiento de largo plazo. Instrucciones (fluidos con agua glicolada)

Deben tomarse las debidas precauciones en el caso de que los fluidos del sistema del acumulador tengan un nivel bajo de viscosidad, por ejemplo, los fluidos a base de glicol. Deberán seguirse los pasos siguientes: * Vacíe la precarga de nitrógeno, coloque de * nuevo el tapón de la válvula de gas y el del * vástago protector. * Con el acumulador en posición invertida y * la boca de entrada del fluido en la parte de * arriba, llénelo con el fluido del sistema * hasta que esté nivelado con la parte * superior de la conexión de la boca de * entrada del fluido. Es importante * comprobar que se puede usar el fluido del * sistema de forma segura; en caso contrario, * se deberá utilizar el fluido compatible * adecuado. * Una vez que esté lleno, coloque un tapón * de presión adecuado dentro de la conexión * de la boca de entrada del fluido. El acumulador ya está listo para su almacenamiento de largo plazo. El periodo * de almacenamiento de largo plazo no debe exceder un año. 2.2 Vejigas de repuesto Pueden solicitarse las especificaciones completas de cada uno de los componentes de la vejiga. La clasificación del material elastomérico y su vida útil se detallan en BS ISO 2230.

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Si las vejigas no se almacenan correctamente, podrán dañarse por causa del ozono, el calor o los equipos eléctricos rotacionales. Se podrá observar agrietamiento en un periodo de 12 meses. Condiciones idóneas para el almacenamiento - Deben almacenarse en una bolsa negra de - plástico herméticamente cerrada, dentro de - una caja alejada de la luz solar directa, del - calor y de equipos eléctricos rotacionales. - La temperatura de almacenamiento debe

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- oscilar entre los +15 °C y los +25 °C - Deben almacenarse infladas, utilizando gas - nitrógeno, en su forma natural. (No más de - 1 vez su forma normal) NOTA: Las instrucciones de los acumuladores completos y de las vejigas de repuesto son sólo recomendaciones. En caso de que las condiciones sean adversas y no se puedan seguir las recomendaciones, por favor póngase en contacto con nuestro departamento técnico para recibir asesoramiento. 2.2.1 Inspección de las vejigas de repuesto antes de su uso - Retire todo el embalaje, no utilice - instrumentos afilados. - Infle la vejiga hasta aproximadamente 1,5 - veces su forma normal. - Realice un examen visual de todas las - superficies para determinar si hay grietas, - daños mecánicos como cortes, desgarros o - áreas desgastadas, y compruebe las juntas - en busca de cualquier señal de deterioro. - Sumerja las vejigas en agua para comprobar - que no existen fugas ni perforaciones. 3. Equipo de instalación y seguridad 3.1 Inspección antes del uso Todos los acumuladores deben inspeccionarse cuando se reciban para comprobar que no han sufrido daños durante el transporte. Lea todas las instrucciones con detenimiento antes de comenzar cualquier tipo de trabajo. Hay que comprobar que todas las piezas roscadas estén bien apretadas, por ejemplo, los tapones de protección, la tuerca de retención de la válvula de gas, la boca de entrada del fluido, el anillo de sujeción, el tornillo de purga y los adaptadores y accesorios, si los hay.

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ADVERTENCIA: La presión máxima de trabajo del acumulador no ha de ser menor a la presión máxima de trabajo del sistema al

que se conecta (consulte el apartado 7. Marcado). 3.2 Recomendaciones para la instalación Puede solicitar recomendaciones completas para la instalación a nuestro departamento técnico. ATENCIÓN Si el acumulador estaba almacenado antes de fijarlo al sistema hidráulico, se aconseja lo siguiente: compruebe que el acumulador contiene fluido lubricante antes de la precarga (consulte el aparatado 4. Puesta en funcionamiento) Después de un almacenamiento de corto plazo: el acumulador debe cargarse previamente con la presión de nitrógeno correcta antes de la fijación al sistema hidráulico. Después del almacenamiento de largo plazo (aceite mineral): se debe eliminar la presión del gas de precarga del acumulador, junto con toda la presión de fluido, antes de retirar el tapón de presión. Seguidamente, el acumulador puede cargarse con la presión adecuada. Después del almacenamiento de largo plazo (fluidos de agua glicolada): Asegúrese de que la presión del gas de precarga se ha eliminado y se ha drenado todo exceso de fluido del sistema en el acumulador. El acumulador podrá entonces cargarse con el nivel de presión adecuado. 3.3 Equipo de seguridad Es vital proteger al acumulador de una sobrepresurización. (válvula de aislamiento, dispositivo de descarga entre el acumulador hidráulico y la válvula de aislamiento, montaje de disco de ruptura para reducir la presión del nitrógeno, o un dispositivo de seguridad contra el exceso de temperatura). Puede solicitar dispositivos de protección

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contra la sobrepresión a QHP. Los acumuladores funcionan mejor en posición vertical con la válvula de gas en la parte superior. El montaje del acumulador debe tener en cuenta la posibilidad de cargas debidas al mal tiempo o a movimientos sísmicos. Los acumuladores se deben montar de forma que no haya movimiento en caso de que se produzca una rotura de las conducciones del sistema y evitando provocar presiones anómalas en éstas. Se deben proteger los acumuladores de posibles daños provocados por el tráfico de vehículos, como por ejemplo, carretillas elevadoras. Es necesario comprobar la presión de precarga de gas a intervalos regulares (véase el apartado 5. Mantenimiento). Por lo tanto, se debe prestar especial atención a las siguientes cuestiones: - La provisión de un bloque de válvula de - seguridad o válvula de aislamiento entre el - acumulador y la línea de fluido bajo presión - para permitir aislar la presión del fluido. - La ubicación de la válvula de gas del - acumulador teniendo en cuenta la - posibilidad de daños accidentales y la - conexión del equipo de precarga. - La provisión y ubicación de una etiqueta de - advertencia adicional que indique "Precarga - de nitrógeno a .... bares". QHP puede proporcionar una amplia gama de soportes y abrazaderas de montaje, bloques de seguridad o válvulas de aislamiento y discos de ruptura. Póngase en contacto con nuestro departamento de ventas para más detalles. 4. Puesta en funcionamiento Importante Todos los acumuladores se suministran sin precarga de nitrógeno, a menos que se haya especificado una presión de precarga en el pedido. Antes de efectuar la conexión al

sistema hidráulico, todos los acumuladores se deben haber cargado previamente con nitrógeno. Si esto no se lleva a cabo, la vejiga fallará. ADVERTENCIA: No utilice nunca oxígeno ni aire, ya que podría causar una explosión. Utilice únicamente gas nitrógeno seco sin contenido de oxígeno N2 (99.995%). ADVERTENCIA: Compruebe la etiqueta del acumulador o el marcado para asegurarse de que la presión máxima de trabajo del acumulador es igual o superior a la presión máxima de trabajo del sistema. Utilice siempre una válvula reguladora de nitrógeno cuando la presión máxima de trabajo del acumulador sea superior a la presión del gas en el cilindro de nitrógeno. La presión de precarga depende de las condiciones de funcionamiento. Nuestro departamento técnico puede proporcionar asesoramiento al respecto. Hay que tener en cuenta que una presión de precarga inferior al 20 % de la presión máxima de trabajo puede causar fallos en la vejiga. Asegúrese que el acumulador contiene fluido lubricante antes de realizar la precarga. Es muy habitual utilizar el fluido del sistema con este propósito, generalmente basta con un 10 % de la capacidad del acumulador.

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4.1 Procedimiento de precarga: A

E C

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D G

F B

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ADVERTENCIA: La precarga solo podrán realizarla aquellos

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miembros del personal competentes y con la capacitación adecuada. NO DEJE NUNCA DESATENDIDO EL EQUIPO DE PRECARGA MIENTRAS ESTÉ EN USO. Se debe seguir el procedimiento siguiente para garantizar que la precarga del acumulador se realiza de forma segura. Todo el equipo de precarga debe ser suministrado por QHP. Consulte nuestro catálogo para obtener más información. • Reduzca la presión de la vejiga del • acumulador en el lado del fluido. • Extraiga el tapón de protección (5) y, si lo • hubiera, el tapón de sellado de la válvula • de gas (3) durante el montaje. • Conecte el regulador de nitrógeno (A) al • cilindro de nitrógeno (B). • Compruebe que el volante (E) del conjunto • de carga (C) está completamente retraído, • incluido el pasador. • Conecte el conjunto de carga (C) a la • válvula de gas del acumulador (3). • Conecte la manguera de carga (D) entre el • regulador de nitrógeno (A) y el conjunto de • carga (C). • Compruebe que la válvula de purga (F) está • completamente cerrada. Gradúe el regulador de nitrógeno (A) a 25 psi. NOTA: La válvula del regulador de presión de nitrógeno tendrá dos medidores, uno para la presión alta (aguas arriba) y otro para la presión baja (aguas abajo). Para evitar la sobrecarga debida a un ajuste incorrecto, el dispositivo reductor de presión tendrá una presión máxima establecida inferior a la presión máxima permitida PS del acumulador. Para evitar la sobrecarga por el mal funcionamiento, el dispositivo reductor de presión contará con un dispositivo de reducción que limitará la presión aguas abajo.

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ATENCIÓN: Una precarga inicial por encima de 25 psig hará explotar la vejiga. • Gire lentamente el volante de mano (E) en • el sentido de las manecillas del reloj una • vuelta o vuelta y media para despresurizar • la espiga de soplado de la válvula de gas. • Abra la válvula de cilindro de nitrógeno (G) • con la llave (H); en el manómetro derecho • del regulador se indicará la presión del gas. • Gire la empuñadura del regulador (I) en el • sentido de las manecillas del reloj hasta • que se muestre presión del gas en el • manómetro izquierdo. Esta presión debe • ser un 10 % superior a la presión de • precarga requerida. • Deje que se estabilice la presión del gas de • precarga; ajústelo en caso necesario. • Compruebe la presión de precarga del gas • en el conjunto de carga (C). Cuando sea • igual a la presión del regulador de presión, • cierre la válvula del cilindro de nitrógeno (G). • Si la presión es demasiado alta, puede • reducirse mediante el purgado (F). • Gire la empuñadura (E) del conjunto de • carga en sentido contrario a las manecillas • del reloj para cerrar la válvula de gas (3). • Abra la válvula de purga (F) para purgar el • gas de la válvula de carga (3). • Retire el conjunto de carga (C) y la • manguera de conexión (D) del acumulador. • Compruebe que la válvula de gas del • acumulador no tenga fugas utilizando un • pulverizador para detectar fugas o agua • jabonosa. • Vuelva a colocar el tapón de sellado y el • tapón de protección . El acumulador está ya listo para su uso. 5. Mantenimiento del acumulador Para garantizar un funcionamiento duradero y sin problemas del equipo, deberán realizarse los siguientes trabajos a intervalos regulares:

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- Prueba de la presión de precarga con - nitrógeno. - Comprobación del correcto funcionamiento - de válvulas y dispositivos de protección. - Comprobación del apriete de las conexiones - y de que no existen fugas. - Comprobación de los elementos de fijación. - Inspección visual del acumulador. 5.1 Intervalos de comprobación de precarga Se recomienda realizar las pruebas en los intervalos siguientes: - Después de cada instalación - Una semana después de la instalación - Ocho semanas después de la instalación - Si no se ha observado ninguna pérdida de - nitrógeno, pueden realizarse en lo sucesivo - los controles: - Una vez por año NOTA Si se utiliza la unidad de forma prolongada con alta temperatura, los intervalos de control han de ser más cortos. 6. Recertificación En el Reino Unido, la mayoría de los acumuladores deben ajustarse a los requisitos establecidos dentro de la Normativa de Seguridad sobre Sistemas de Presión 2000 (PSSR) y la Directiva de de Equipos de Presión (PED97/23/EC) Entre los puntos clave se encuentran: • Requisitos para determinar los límites • dentro de los cuales es seguro operar un • acumulador y un registro donde se muestre • que el sistema de presión no los ha excedido. • La preparación de un programa por escrito • sobre acumuladores por encima de los 250 • bares/litros. • Establecimiento de un proceso de • mantenimiento, realización de pruebas • periódicas y de seguridad.

En caso de necesitar ayuda para comprobar que se cumplen los requisitos especificados por la normativa, por favor contacte con nuestro departamento de ventas. QHP cuenta con centros capacitados para recertificaciones de acumuladores en todo el Reino Unido que pueden ayudarle a este respecto. Si desea más información, puede ponerse en contacto con nuestro departamento de ventas. 7. Marcado Placas de identificación Todos los acumuladores de vejiga estándar de QHP llevan incorporadas etiquetas metálicas donde se muestra la siguiente información esencial para el usuario • Nombre y dirección del fabricante/Número • de modelo del proveedor • Presión máxima de funcionamiento (MWP) • Volumen del acumulador • Fecha de fabricación • Información de advertencias y seguridad La información esencial necesaria para el código de diseño pertinente se encuentra estampada en el extremo cóncavo del cuerpo del acumulador. Información típica/El marcado se muestra más abajo - Maracado CE según la Directiva de Equipos de Presión 97/23/EC - Fecha de fabricación, (mes/año) - Número de serie del fabricante - Nombre del fabricante/símbolo - Volume total del cuerpo en litros - Rango de temperatura permitido en gados - Celsius - Presión maxima permitida PS - Prueba de presión PT - Número de identificación del organism - notificado (si procede)

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Informations sur le produit Accumulateurs à vessie hydrauliques 5 Capuchon de protection 3 Soupape de gaz 4 Contre-écrou 6 Plaque signalétique 2 Joint torique 1 Vessie 7 Corps de l’accumulateur

9 Bague antiextrusion 10 Joint torique 11 Anneau en PTFE 12 Rondelle-frein 14 Bouchon de purge 13 Bague composite 8 Bouche hydraulique

1. Généralités Les accumulateurs à vessie sont des réservoirs sous pression tels que définis par la directive 97/23/CE relative aux équipements sous pression. Ces accumulateurs sont des réservoirs fermés qui sont conçus et construits pour contenir des fluides sous pression. Les accumulateurs à vessie sont des accumulateurs hydrauliques avec un réservoir rempli d’azote pour utilisation dans les circuits hydrauliques. Les accumulateurs hydrauliques sont spécialement conçus pour absorber puis restituer des fluides sous pression. Les règlements de mise en service et d’utilisation des accumulateurs hydrauliques, en vigueur sur le lieu d’installation, doivent être observés. L’exploitant du système est exclusivement responsable d’assurer la conformité à ces règlements. Le certificat de conformité et toute autre documentation fournie avec l’accumulateur doivent être soigneusement conservés sur le lieu de l’installation pour

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d’éventuels essais ultérieurs. Des instructions détaillées sur l’entretien et la réparation sont disponibles pour les travaux qui peuvent être réalisés sur l’accumulateur après l’installation initiale et la mise en service, comme des travaux de réparation. Ces instructions peuvent être envoyées aux clients sur demande. AVERTISSEMENT Tous les travaux sur les connexions hydrauliques et pneumatiques de l’accumulateur doivent être effectués uniquement par des ouvriers qualifiés. Une installation ou une manipulation incorrecte peut provoquer des accidents graves. Avant d’entreprendre un travail quelconque sur l’équipement hydraulique, le circuit hydraulique doit être purgé de toute pression, y compris de la précharge. Gas sous pression Après une décharge et/ou une purge complète (ex. : décompression avant une intervention sur le système hydraulique), l’accumulateur peut accumuler à nouveau une pression suite à un isolement ultérieur des conduites côté fluide. Ce problème doit être pris en compte de manière générale, et en particulier avant des interventions sur les circuits hydrauliques comprenant des accumulateurs hydrauliques raccordés. Pour cette raison, toutes les conduites côté fluide raccordées sur l’accumulateur doivent être purgées et doivent ensuite restées ouvertes. Les interventions appropriées (ex. : démontage de l‘accumulateur) peuvent être réalisées seulement ensuite. Il est interdit d’effectuer des soudures, des brasages ou des travaux mécaniques sur l’accumulateur.

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Risque d’explosion en cas de soudure ou de brasage ! Risque d’éclatement et perte d’autorisation d’exploitation, en cas de travaux mécaniques non autorisés sur l’accumulateur. Les accumulateurs hydrauliques doivent être remplis uniquement avec de l’azote sec libre d’oxygène N2 (99.995%). N‘utilisez pas d’autres gaz : Risque d’explosion! ATTENTION : Le corps de l’accumulateur peut devenir chaud. Risque de brûlures. 2. Stockage 2.1 Accumulateurs complets Tous les accumulateurs doivent être stockés dans un endroit propre, sec, frais et à l’abri de la lumière directe du soleil. Recommandations pour le stockage de courte durée : Pour autant que les accumulateurs soient placés dans un environnement propre, sec, frais et à l’abri de la lumière directe du soleil, ils peuvent rester dans leur emballage d’origine pendant plusieurs semaines sans détérioration. Recommandations pour un stockage de longue durée (fluide de type huile minérale) Tous les accumulateurs sont fournis sans précharge en azote, à moins qu’une pression de gonflage ne soit spécifiée au moment de la commande. L’accumulateur doit recevoir une précharge d’azote libre d’oxygène d’environ 2 à 3 bars. La bouche hydraulique doit être obturée au moyen d’un bouchon approprié après la précharge d’azote. Consultez la procédure de précharge à la section 4.0 Mise en service. Recommandations pour le stockage de longue durée (eau glycolée) Des précautions doivent être prises lorsque les fluides du circuit hydraulique ont une faible

viscosité, ce qui est le cas par exemple de l’eau glycolée. Les mesures suivantes doivent être prises: * Videz la vessie de son azote, refermez la * soupape de gaz et posez le capuchon de * protection. * Renversez l’accumulateur, la bouche étant * tournée vers le haut, remplissez le système * de fluide jusqu’à ce qu’il soit au niveau de * la bouche hydraulique. Il est important de * s’assurer que le fluide du système peut être * utilisé sans risque ; dans le cas contraire, * utilisez un fluide compatible approprié. * Une fois l’accumulateur rempli, un bouchon * de pression approprié doit être inséré dans * la bouche hydraulique. L’accumulateur est maintenant prêt pour un stockage de longue durée, qui ne doit cependant pas dépasser un an. 2.2 Vessies de rechange Les spécifications techniques complètes de tous les composants de la vessie peuvent être fournies sur demande. Le classement des matériaux élastomères et leur durée de conservation prévue sont précisés dans la norme BS ISO 2230. Si les vessies ne sont pas stockées correctement, elles seront exposées à des attaques sous l’effet de la présence d’ozone, de la température, ou de machines électriques tournantes. Des fêlures apparaîtront en moins de 12 mois. Conditions de stockage idéales - Rangez l’accumulateur dans un sac noir en - plastique fermé, dans une boîte, à l’abri de - la lumière du soleil, de la chaleur ou de tout - équipement électrique tournant. - La température de stockage doit se situer - dans la fourchette de +15°C à +25°C - Au stockage, la vessie doit être remplie - d’azote et épouser sa forme naturelle (sans - dépasser sa forme naturelle)

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REMARQUE: les instructions sur le stockage de l’accumulateur complet et de la vessie de rechange constituent uniquement des recommandations. Dans des environnements difficiles où ces recommandations ne peuvent pas être respectées, veuillez consulter notre service technique. 2.2.1 Inspection des vessies de rechange avant l’usage - Retirez la totalité de l’emballage et n’utilisez - pas d’instrument tranchant - Gonflez la vessie à environ 1,5 fois sa forme - normale - Recherchez visuellement tous signes de - fêlure et de dommages mécaniques, tels que - coupures, déchirures ou abrasions, sur - toutes les surfaces. Recherchez tout signe - de détérioration sur les coutures. - Immergez la vessie dans l’eau pour - rechercher tout signe de fuite ou de - perforation. 3. Matériel d’installation et de sécurité 3.1 Inspection avant l’usage Tous les accumulateurs doivent être inspectés lors de la réception afin d’identifier les dommages éventuellement survenus lors du transport. Veuillez lire toutes les instructions attentivement avant d’entreprendre une intervention quelconque. Vérifiez que tous les filetages sont bien serrés, ex. : capuchon de protection, contre-écrou de la soupape de gaz, bouche hydraulique, bague de fermeture, vis de purge, adaptateurs et raccords le cas échéant.

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AVERTISSEMENT: vérifiez que la pression de service maximum de l’accumulateur n’est pas inférieure à la pression de service maximum du système auquel il est relié (voir la section7. Marquages).

3.2 Consignes d’installation Vous pouvez obtenir des recommandations d’installation complètes auprès de notre service technique ATTENTION Si l’accumulateur était en stockage avant d’être installé sur le circuit hydraulique, les conseils suivants s’appliquent : assurez-vous que l’accumulateur contient un liquide de lubrification avant une précharge (voir 4. Mise en service) Après un stockage de courte durée: gonflez la vessie à la pression d’azote correcte avant de raccorder l’accumulateur au circuit hydraulique. Après un stockage de longue durée (huile minérale): évacuez la pression de gonflage de l’accumulateur ; purgez la pression de fluide avant de déposer le bouchon de pression. La vessie peut alors être gonflée à la pression requise. Après un stockage de longue durée (eau glycolée): évacuez la pression de gonflage et purgez l’accumulateur de tout excédent de fluide. La vessie peut maintenant être gonflée à la pression requise. 3.3 Équipement de sécurité Il est essentiel de protéger l’accumulateur contre les pressions excessives. (vannes d’isolement, dispositif de dépressurisation entre l’accumulateur et les valves d’isolation, disque de rupture pour soulager la pression d’azote ou matériel de protection contre les surchauffes) Des dispositifs de protection contre la surpression sont disponibles sur demande auprès de QHP. Les accumulateurs fonctionnent de manière optimale en position verticale, la soupape de gaz étant en position haute. L’installation doit prendre en compte toute éventualité liée aux conditions climatiques ou aux éventuels

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séismes. Les accumulateurs doivent être installés de sorte à éliminer tout mouvement en cas de rupture de la tuyauterie ou de toute tension anormale sur la tuyauterie. Les accumulateurs doivent être protégés contre les dommages provoqués par des véhicules ou un trafic (chariots élévateurs, etc.). Il est essentiel de contrôler la pression de gonflage à intervalles réguliers (voir 5. Maintenance). Les points suivants doivent par conséquent être pris en compte: - La mise en place d’un bloc de sécurité ou - d’une vanne d’isolement entre - l’accumulateur et la conduite hydraulique - afin de permettre l’isolement de la conduite - hydraulique. - Le positionnement de la soupape de gaz de - l’accumulateur par rapport à des dommages - accidentels et à l’installation d’un - équipement de gonflage. - La mise en place et le positionnement d’une - étiquette d’avertissement supplémentaire - indiquant : « Gonflage avec de l’azote - gazeux à une pression de … bar(s). » QHP est en mesure de proposer une large gamme de brides et de supports de fixation, de blocs de sécurité, de vannes d’isolement, et de disques de rupture. Contactez notre service des ventes pour plus de détails 4. Mise en service Important Les accumulateurs sont fournis sans précharge d’azote, sauf spécification contraire au moment de la commande. Les accumulateurs doivent être préchargés en azote avant leur raccordement au circuit hydraulique. Dans le cas contraire, une défaillance de la vessie pourrait survenir.

AVERTISSEMENT: n’utilisez jamais de l’oxygène ou de l’air; cela pourrait provoquer une explosion ! Utilisez uniquement de l’azote sec libre d’oxygène N2 (99.995%). AVERTISSEMENT: vérifiez l’étiquette ou le marquage de l’accumulateur afin de vous assurer que la pression de service maximum de l’accumulateur est égale ou supérieure à celle de la pression de service du système. Utilisez systématiquement une vanne de régulation de l’azote lorsque la pression de service maximum de l’accumulateur est inférieure à celle de la bouteille d’azote. La pression de gonflage dépend des conditions d’utilisation. Pour tout conseil, consultez notre Service technique. Veuillez noter qu’une pression de gonflage inférieure à 20 % de la pression de service maximum peut provoquer une défaillance de la vessie. Vérifiez que l’accumulateur contient un lubrifiant avant la précharge. On utilise généralement le fluide du circuit à cet effet ; un volume de 10 % de la capacité de l’accumulateur est habituellement suffisant. 4.1 Procédure de précharge A

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AVERTISSEMENT: Seul un personnel correctement formé et compétent doit procéder à la précharge. NE LAISSEZ JAMAIS UN ÉQUIPEMENT DE PRÉCHARGE SANS SURVEILLANCE PENDANT SON UTILISATION.

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La procédure suivante doit être respectée afin de garantir une précharge sécurisée des accumulateurs. Tout matériel de précharge utilisé doit être fourni par QHP ; consultez le catalogue pour plus de précisions. • Libérez la pression sur le côté fluide de • l’accumulateur à vessie. • Retirez le capuchon de protection (5) et, le • cas échéant, le couvercle d’étanchéité de la • soupape de gaz situés sur la soupape (3) • Reliez le régulateur d’azote (A) à la • bouteille d’azote (B). • Vérifiez que la manette (E) du groupe de • charge (C) est complètement rétractée, y • compris la goupille. • Installez le groupe de charge (C) sur la • soupape de gaz de l’accumulateur (3). • Connectez le flexible de charge (D) entre le • régulateur d’azote (A) et le groupe de • charge (C) • Vérifiez que la vanne de purge (F) est • complètement fermée. Réglez le régulateur de pression (A) de la bouteille d’azote à 25 psi (1,7 bars).

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REMARQUE: la soupape du régulateur de pression de la bouteille d’azote comporte deux manomètres (haute pression en amont et basse pression en aval). Pour éviter toute pression de charge excessive à cause d’un mauvais réglage, le réducteur de pression doit être réglé de manière à libérer toute pression qui dépasserait la pression maximum admissible (PS) de l’accumulateur. Pour éviter toute pression de charge excessive par suite d’un dysfonctionnement, le réducteur de pression doit être équipé d’un limiteur de pression en aval

• tour et demi dans le sens horaire pour • enfoncer le tiroir de la soupape. • Ouvrez le robinet de la bouteille d’azote (G) • au moyen de la clé (H). La pression du gaz • est indiquée sur le manomètre de droite du • régulateur. • Tournez la poignée du régulateur (I) dans le • sens horaire jusqu’à ce que la pression du • gaz soit indiquée sur le manomètre de • gauche. Cette pression doit être supérieure • de 10% à celle de la pression de précharge • requise. • Laissez la pression de gonflage se stabiliser; • ajustez au besoin. • Vérifiez la pression de gonflage sur le • groupe de charge (C). Lorsque celle-ci est • égale à la pression du régulateur de • pression, fermez le robinet de la bouteille • d’azote (G). • Si la pression est trop élevée, elle peut être • réduite par la vanne de purge (F) • Tournez la manette (E) du groupe de charge • dans le sens antihoraire afin de fermer la • soupape de gaz (3). • Ouvrez la vanne de purge (F) afin d’évacuer • le gaz de la soupape de charge (3). • Démontez le groupe de charge (C) et le • flexible de raccordement (D) de • l’accumulateur. • Vérifiez que la soupape de gaz de • l’accumulateur ne présente aucune fuite au • moyen d’un spray de détection des fuites • ou d’une eau savonneuse. • Remettez en place le couvercle • d’étanchéité et le capuchon de protection. L’accumulateur peut ensuite être mis en service.

ATTENTION: une précharge initiale supérieure à 25 psi (1,7 bars) provoquera un éclatement de la vessie ! • Tournez lentement la manette (E) d’un à un

5. Entretien de l’accumulateur Pour une utilisation sans défaillance à long terme, les opérations d’entretien suivantes doivent être exécutées régulièrement:

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- Vérifier la pression de gonflage d’azote - Vérifier que la soupape et les dispositifs de - protection fonctionnent correctement - Vérifier que les raccordements sont - hermétiques et sans fuite - Vérifier les supports d’installation. - Inspecter l’accumulateur visuellement 5.1 Intervalle de contrôle de la pression de la vessie Il est recommandé de respecter l’intervalle d’essai suivant : • Après l’installation • Une semaine après l’installation • Huit semaines après installation • Si aucune perte apparente de gaz ne s’est • produite, la fréquence d’essai peut être : • Une fois par an. REMARQUE: Une utilisation permanente à des températures de fonctionnement élevées exige un contrôle plus fréquent. 6. Recertification Au Royaume-Uni, la plupart des accumulateurs sont couverts par les prescriptions de la Réglementation sur la sécurité des systèmes sous pression de 2000 et par la Directive sur les équipements sous pression (PED97/23/CE)) Les points essentiels sont les suivants: • Des exigences prescrivant les limites • d’exploitation non dangereuses des • accumulateurs et la tenue de registres • démontrant que les exigences ont été • respectées. • Préparation d’un système d’indications • écrit sur les accumulateurs fonctionnant à • plus de 250 bars par litre. • Élaboration d’une procédure de • maintenance et d’exécution régulière des • contrôles de sécurité. Si vous avez besoin d’aide pour être certain de

respecter les exigences de la réglementation, n’hésitez pas à contacter notre service commercial. QHP gère des centres de recertification d’accumulateurs hydrauliques à travers le Royaume-Uni. Ils pourront vous prêter assistance sur les éléments qui précèdent. Veuillez contacter notre service commercial.. 7. Marquages Plaques signalétiques Des plaques signalétiques métalliques sont fixées sur tous les accumulateurs à vessie standard de QHP. Elles comportent les données essentielles suivantes : • Nom et adresse du fabricant/fournisseur et • modèle • Pression de service maximum • Volume de l’accumulateur • Date de fabrication • Mises en garde et information de sécurité Les données essentielles requises par le code de conception applicable sont estampillées en permanence sur l’extrémité bombée du corps de l’accumulateur. Les données / marquages typiques sont illustrés ci-dessous - Marquage CE en accord avec la Directive - 97/23 relative aux équipements sous pression - Date de fabrication (mois/année) - Numéro de série du fabricant - Dénomination/symbole du fabricant - Volume total du corps en litres - Plage de température admissible en degrés - Celsius - Pression maximum admissible PS - Pression d’essai PT - N° d’identification de l’organisme notifié (le - cas échéant)

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Informazioni Prodotto Accumulatori Caricati A Gas 5 Capsula protettiva 3 Gruppo valvola gas 4 Ghiera 6 Targhetta con sigla 2 Anello a O 1 Gruppo sacca 7 Rivestimento dell’accumulatore

9 Anello antiestrusione 10 Anello a O 11 Anello PTFE 12 Anello di serraggio 14 Valvola di sfiato 13 Chiusura ermetica 8 Gruppo valvola fluidi

1. Informazioni generali Gli accumulatori sono recipienti a pressione secondo la definizione riportata nella direttiva sugli apparecchi a pressione 97/23/CE. Si tratta di contenitori chiusi progettati e realizzati per contenere fluidi che si trovano sotto pressione. Si tratta di accumulatori idraulici con una sacca piena di azoto, che vengono usati negli impianti idraulici. Gli accumulatori idraulici sono destinati esclusivamente a ricevere e rilasciare fluidi idraulici sotto pressione. Prima della messa in funzione e durante il funzionamento degli accumulatori idraulici si devono osservare le normative in vigore nel luogo d’installazione. L’esercente dell’impianto è responsabile in modo esclusivo del corretto impiego e del rispetto di dette normative. La dichiarazione di conformità fornita insieme all’accumulatore e l’eventuale documentazione allegata devono essere

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conservate accuratamente nel luogo d’installazione, per consentire il collaudo dell’installazione e le ispezioni periodiche successive. Per qualsiasi lavoro che verrà eseguito sull’accumulatore a sacca dopo l’installazione iniziale e la messa in funzione, per es. riparazioni, sono disponibili dettagliate istruzioni di manutenzione e riparazione, che saranno fornite al cliente su richiesta AVVERTENZA: Qualsiasi intervento sugli allacciamenti idraulici e pneumatici dell’accumulatore dovrà essere eseguito unicamente da tecnici appositamente istruiti. Prima di lavorare sugli impianti idraulici, questi devono essere messi in sicurezza eliminando la pressione (compresa la precarica di gas). Gas sotto pressione Dopo aver scaricato e/o drenato completamente l‘accumulatore (ad esempio, se si deve depressurizzare il sistema idraulico prima di effettuare lavori), nell'accumulatore può raccogliersi di nuovo una certa pressione quando le linee vengono poi chiuse sul lato del fluido. Questo problema deve essere preso in considerazione in linea generale e, in particolare, prima di effettuare lavori su impianti idraulici con collegamenti ad accumulatori idraulici. Tutte le linee lato fluido collegate all’accumulatore devono quindi essere depressurizzate e lasciate aperte. Solo a questo punto il lavoro (ad esempio lo smontaggio dell’accumulatore) potrà essere effettuato. In nessun caso vanno eseguiti sull’accumulatore lavori di saldatura, brasatura o interventi di tipo meccanico.

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Pericolo di esplosione in caso saldatura o brasatura! Pericolo di scoppio e perdita della licenza di esercizio qualora vengano eseguiti interventi meccanici non autorizzati sull'accumulatore. Gli accumulatori idraulici si devono riempire unicamente con azoto secco N2 privo di ossigeno (99.995%). Non usare altri gas: pericolo di esplosione! ATTENZIONE: Il corpo dell’accumulatore può raggiungere temperature elevate. Pericolo di scottature. 2. Magazzinaggio 2.1 Accumulatori completi Tutti gli accumulatori devono essere immagazzinati in un ambiente pulito, asciutto e fresco, lontano dalla luce diretta del sole. Raccomandazioni per il magazzinaggio a breve termine: Gli accumulatori possono essere conservati nella confezione originale per diverse settimane senza deteriorarsi, purché siano immagazzinati in un ambiente pulito, asciutto e fresco, lontano dalla luce diretta del sole. Raccomandazioni per il magazzinaggio a lungo termine - Istruzioni (olio minerale) Tutti gli accumulatori sono forniti privi della precarica di azoto a meno che l’ordine non specifichi una pressione di precarica. Gli accumulatori devono essere precaricati ad azoto privo di ossigeno a circa 2-3 bar. Il foro del fluido deve essere tappato con una spina a pressione adatta dopo la precarica. Fare riferimento alla procedura di precarica descritta alla sezione 4. Primo avviamento. Raccomandazioni per il magazzinaggio a lungo termine - Istruzioni (fluidi acqua-glicole) È necessario prestare la massima cautela nel caso in cui i fluidi di sistema dell’accumulatore siano a bassa viscosità, ad esempio a base di

glicole. Seguire i seguenti passaggi: * Scaricare la precarica di azoto, riposizionare * il tappo della valvola del gas e la capsula * protettiva. * Mentre l’accumulatore è capovolto, con il * foro del fluido in alto, riempire con il fluido * di sistema fino a raggiungere il livello della * parte superiore del collegamento del foro * del fluido. È importante verificare che il * fluido di sistema sia sicuro da usare; in caso * contrario, utilizzare un fluido idoneo e * compatibile. * Dopo il riempimento, inserire una spina a * pressione adatta nel collegamento del foro * del fluido. L’accumulatore è ora pronto per il magazzinaggio a lungo termine, che non deve comunque essere superiore a un anno. 2.2 Sacche di ricambio Le specifiche tecniche complete possono essere fornite per tutti i componenti della sacca e sono disponibili su richiesta. La classificazione dei materiali elastomerici e la durata di conservazione prevista sono specificate nella normativa BS ISO 2230. Se le sacche non sono immagazzinate correttamente, sono suscettibili di danni arrecati da ozono, calore o da apparecchiature elettriche a rotazione. Le cricche diventano visibili nell’arco di 12 mesi. Condizioni ideali per il magazzinaggio - Il magazzinaggio va effettuato in un - contenitore di plastica nera sigillato, in una - scatola, lontano dalla luce diretta del sole, - dal calore o da attrezzature elettriche a - rotazione. - La temperatura di magazzinaggio deve - essere compresa fra +15°C e +25°C - Le sacche immagazzinate devono essere - gonfiate usando azoto nella loro forma - naturale (non più di 1 per forma normale).

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NOTA: le istruzioni per il magazzinaggio degli accumulatori completi e delle sacche di ricambio hanno solo carattere di raccomandazione. In caso di condizioni difficili, in cui non sia possibile seguire le raccomandazioni, si prega di contattare il nostro reparto tecnico. 2.2.1 Ispezione delle sacche di ricambio prima dell’utilizzo - Rimuovere l’imballo, evitando di usare - strumenti affilati. - Gonfiare la sacca a circa 1,5 volte la forma - normale. - Esaminare visivamente tutte le superfici - esterne alla ricerca di cricche e danni - meccanici quali tagli, strappi o abrasioni; le - giunture devono essere controllate per - escluderne il deterioramento. - Immergere in acqua e verificare la presenza - di perdite o perforazioni. 3. Attrezzature e dispositivi di sicurezza 3.1 Ispezione prima dell’utilizzo Tutti gli accumulatori devono essere ispezionati al ricevimento alla ricerca di danni che possano essersi verificati nel corso del trasporto. Leggere attentamente tutte le istruzioni prima di iniziare qualsiasi tipo di lavoro. Verificare il serraggio di tutte le parti filettate, ad es. la capsula protettiva, la ghiera di bloccaggio della valvola del gas, il foro del fluido, l'anello di serraggio, la vite di sfiato, adattatori ed accessori, ove presenti. AVVERTENZA: Verificare che la pressione operativa massima dell’accumulatore non sia inferiore alla pressione operativa massima del sistema cui sarà applicato (v. sezione 7. Marcature).

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3.2 Raccomandazioni per l’installazione Per le raccomandazioni complete per l’installazione, rivolgersi al nostro reparto tecnico.

ATTENZIONE: Se l’accumulatore era immagazzinato prima dell’installazione sul sistema idraulico, si consiglia quanto segue: assicurarsi che l’accumulatore contenga del fluido lubrificante prima di procedere alla precarica (vedere la sezione 4. Primo avviamento). Dopo il magazzinaggio a breve termine: l’accumulatore deve essere precaricato ad azoto alla pressione corretta prima dell’installazione sul sistema idraulico. Dopo il magazzinaggio a lungo termine (olio minerale): rilasciare la pressione di precarica del gas dell’accumulatore e scaricare tutta la pressione del fluido prima di rimuovere la spina a pressione. A questo punto, l’accumulatore può essere precaricato alla pressione richiesta. Dopo il magazzinaggio a lungo termine (fluidi acqua-glicole): Assicurarsi di scaricare la pressione del gas di precarica e di far fuoriuscire i fluidi di sistema in eccesso dall’accumulatore. A questo punto, l’accumulatore può essere precaricato alla pressione richiesta. 3.3 Attrezzature di sicurezza È essenziale che l’accumulatore sia protetto dalla sovrapressurizzazione (valvola di isolamento, dispositivo di riduzione pressione tra l’accumulatore idraulico e la valvola di isolamento, disco di rottura per ridurre la pressione dell’azoto o dispositivo di sicurezza contro temperature eccessive). I dispositivi di sicurezza contro la sovrapressurizzazione sono disponibili su richiesta presso QHP. Gli accumulatori svolgono al meglio la loro funzione in posizione verticale con la valvola del gas in alto. Il montaggio deve considerare la possibilità di carichi che possano essere causati da condizioni meteo avverse od eventi sismici. Gli accumulatori devono essere

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montati per eliminare qualsiasi movimento in caso di rottura delle tubazioni del sistema o per creare sollecitazioni anomale sulle stesse. Gli accumulatori devono essere protetti da ogni possibile danno causato da veicoli o dalla circolazione, come ad esempio dai muletti. È necessario verificare la pressione di precarica del gas ad intervalli regolari (v. sezione 5. Manutenzione). Pertanto si invita a considerare quanto segue: - prevedere un bloccaggio tramite valvola di - sicurezza o di isolamento tra l’accumulatore - e la linea di pressione del fluido per - permettere l’isolamento della pressione del - fluido; - studiare la posizione della valvola del gas - dell’accumulatore per evitare danni - accidentali e consentire il montaggio delle - attrezzature per la precarica; - prevedere e posizionare un’ulteriore - etichetta di avviso con “precarica con gas a - base di azoto a ….bar”. QHP è in grado di fornire una gamma completa di supporti e morsetti di montaggio, blocchi di sicurezza o valvole di isolamento, e dischi di rottura. Contatta il nostro ufficio commerciale per ulteriori dettagli. 4. Primo avviamento Importante Tutti gli accumulatori sono forniti privi di precarica di azoto, se non diversamente specificato nell’ordine. Prima di inserirli nel sistema idraulico, tutti gli accumulatori devono essere precaricati con azoto. La mancata osservanza di questo accorgimento causerà danni alla sacca. AVVERTENZA: Non usare mai ossigeno o aria poiché potrebbero provocare un’esplosione! Utilizzare solo azoto secco privo di ossigeno N2 (99.995%).

AVVERTENZA: Verificare l’etichetta o la marcatura dell’accumulatore per garantire che la sua pressione operativa massima sia uguale o superiore alla pressione operativa del sistema. Utilizzare sempre una valvola di regolazione dell’azoto quando la pressione operativa massima dell’accumulatore è superiore alla pressione del gas nella bombola di azoto. La pressione di precarica dipende dalle condizioni operative. Per una consulenza, contattare il nostro reparto tecnico. Nota: la pressione di precarica inferiore al 20% della pressione operativa massima può causare l’avaria della sacca. Prima della precarica, accertarsi che l’accumulatore contenga del lubrificante. È pratica usuale utilizzare il fluido di sistema a tale scopo, in genere il 10% della capacità dell’accumulatore è un volume sufficiente. 4.1 Procedura di precarica A

E C

I H

D G

F B

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AVVERTENZA: Le procedure di precarica devono essere effettuate soltanto da personale adeguatamente addestrato e competente. NON LASCIARE MAI L’ATTREZZATURA DI PRECARICA INCUSTODITA DURANTE L’USO.

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Attenersi alla procedura seguente per garantire una sicura precarica degli accumulatori. Tutte le attrezzature di precarica devono essere fornite da QHP; v. il catalogo informativo.

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• Rilasciare la pressione dal lato del fluido • dell’accumulatore. • Rimuovere la capsula protettiva (5) e, se • inserita, la capsula di serraggio della valvola • del gas dal gruppo (3). • Collegare il regolatore di azoto (A) alla • bombola di azoto (B). • Accertarsi che la manopola (E) del kit di • precarica (C) sia completamente ritratta, • compreso il perno. • Inserire il kit di precarica (C) nella valvola • del gas dell’accumulatore (3). • Collegare il flessibile di caricamento (D) tra • il regolatore dell’azoto (A) e il gruppo del kit • di precarica (C). • Verificare che lo sfiato (F) sia • completamente chiuso. NOTA: La valvola del regolatore di pressione dell’azoto deve avere due manometri, uno per la pressione alta (a monte) e uno per la pressione ridotta (a valle). Per evitare il sovraccarico dovuto a un’impostazione sbagliata, la pressione massima impostata sul dispositivo di riduzione della pressione non deve superare la pressione massima ammissibile PS dell’accumulatore. Per evitare il sovraccarico dovuto a malfunzionamento, il dispositivo di riduzione della pressione deve essere dotato di uno sfiato che limiti la pressione a valle. ATTENZIONE: Una precarica iniziale superiore a 25 psig farà esplodere la sacca! • Girare lentamente la manopola (E) in senso • orario facendo fare un giro o un giro e • mezzo per premere il perno principale della • valvola del gas. • Aprire la valvola della bombola di azoto (G) • con la chiave per la bombola (H); la • pressione del gas è indicata sul manometro • destro del regolatore. • Girare il regolatore (I) in senso orario fino a

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• quando la pressione del gas appare sul • misuratore sinistro. Tale pressione deve • essere del 10% superiore a quella richiesta • per la precarica. • Far stabilizzare la pressione di precarica del • gas e regolare se necessario. • Verificare la pressione di precarica del gas • sul kit di precarica (C). Quando è uguale alla • pressione riportata sul regolatore, chiudere • la valvola della bombola di azoto (G). • Se la pressione è troppo alta, questa può • essere ridotta tramite lo sfiato (F). • Girare la manopola (E) sul set di • caricamento in senso antiorario per • chiudere la valvola del gas (3). • Aprire la valvola di sfiato (F) per sfiatare il • gas dalla valvola di caricamento (3). • Rimuovere il kit di caricamento (C) ed il • flessibile di collegamento (D) • dall’accumulatore. • Verificare che la valvola del gas • dell’accumulatore non abbia perdite • utilizzando l’apposito spray rilevatore o • dell’acqua saponata. • Riposizionare il tappo di chiusura e la • capsula protettiva. L’accumulatore è ora pronto. 5. Manutenzione dell’accumulatore Per garantire un funzionamento duraturo e privo di anomalie, eseguire i seguenti interventi di manutenzione a intervalli regolari: - controllo della pressione di precarica - dell’azoto; - controllo della valvola e dei dispositivi di - sicurezza per accertarne il corretto - funzionamento; - controllo per accertare che i raccordi siano - perfettamente serrati e non abbiano perdite; - controllo degli elementi di fissaggio; - controllo visivo dell’accumulatore. 5.1 Intervalli dei controlli della precarica

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Si consiglia di rispettare i seguenti intervalli di controllo: - dopo ogni montaggio; - una settimana dopo il montaggio; - otto settimane dopo il montaggio; - se non si nota alcuna perdita di gas, i - controlli successivi si possono eseguire: - una volta all’anno. NOTA: Un impiego continuo a temperature di esercizio elevate richiede una maggiore frequenza dei controlli. 6. Ricertificazione Nel Regno Unito, la maggior parte degli accumulatori rientra nei requisiti delle Pressure Systems Safety Regulations 2000 (PSSR) e della direttiva apparecchi a pressione (PED 97/23/CE). I punti chiave ricomprendono quanto segue: • Requisiti di determinazione dei limiti • operativi sicuri dell'accumulatore e un • registro da cui risulti che gli stessi non siano • superati dalla pressione del sistema. • Preparazione di uno schema scritto per gli • accumulatori che superano i 250 bar/litri. • Preparazione di una procedura di • manutenzione, esecuzione di regolari test • di sicurezza. Ove si necessiti di assistenza per accertare il soddisfacimento dei requisiti delle normative, invitiamo a contattare il nostro reparto vendite. QHP dispone di centri di ricertificazione per gli accumulatori nel Regno Unito in grado di fornire l'assistenza richiesta. Contattare il nostro reparto vendite per maggiori informazioni.

seguenti informazioni essenziali per l’utente. • Nome ed indirizzo del produttore/fornitore • Numero del modello • Pressione operativa massima (MWP) • Volume dell’accumulatore • Data di produzione • Avvisi ed informazioni sulla sicurezza Le informazioni essenziali richieste dal codice di progettazione applicabile sono sempre riportate sulla parte terminale a cupola del corpo dell’accumulatore. Informazioni tipiche/Marcature indicate di seguito - Marcatura CE ai sensi della direttiva - apparecchi a pressione 97/23/CE - data di produzione (mese/anno) - numero di serie del produttore - nome/simbolo del produttore - volume totale del corpo della sacca in litri - intervallo delle temperature ammissibili in - gradi Celsius - pressione massima ammissibile PS - pressione di prova PT - numero identificativo dell’organismo - notificato (se pertinente)

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7. Marcature Targhette Le etichette metalliche sono affisse a tutti gli accumulatori QHP standard e riportano le

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Productinformatie Voor Balgaccumulatoren 5 Beschermkap 3 Gasklepinrichting 4 Borgmoer 6 Naambordje 2 O-ring 1 Balginrichting 7 Accumulatormantel

9 Anti-extrusie-ring 10 O-ring 11 PTFE-ring 12 Borgring 14 Ontluchtingsstop 13 Gelaagde afdichting 8 Inrichting vloeistofpoort

1. Algemene aanwijzingen Balgaccumulatoren zijn drukvaten volgens richtlijn drukapparatuur 97/23/EG. Het zijn gesloten vaten, die voor de opname van onder druk staande vloeistoffen gedimensioneerd en gebouwd zijn. Balgaccumulatoren zijn hydraulische accumulatoren die uit een met stikstof gevulde balg bestaan en in hydraulische systemen gebruikt worden. Hydraulische accumulatoren zijn uitsluitend bedoeld voor het opnemen en afstaan van drukvloeistoffen. Voor hydraulische accumulatoren moeten bij plaatsing de geldende voorschriften voor inbedrijfstelling en tijdens bedrijf in acht genomen worden. Uitsluitend de operator is voor de correcte bediening en inachtneming van deze voorschriften verantwoordelijk. De met deze balgaccumulator meegeleverde konformiteitsverklaring net zoals de bijgevoegde documentatie moet zorgvuldig in

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de buurt van de machine bewaard worden, voor het geval er een wederkerende test plaats vind. Worden behalve de opstelling en inbedrijfstelling ook andere werkzaamheden, zoals bijvoorbeeld reparaties aan balgaccumulatoren uitgevoerd, dan zijn hiervoor uitgebreide onderhouds- en reparatiehandleidingen beschikbaar. Deze kunnen indien u dit wenst toegezonden worden. WAARSCHUWING: Alle werkzaamheden aan hydraulische en pneumatische aansluitingen aan de balgaccumulator mogen slechts door daarvoor speciaal opgeleide vakmensen uitgevoerd worden. Bij onzorgvuldige montage en reparatie kunnen ernstige ongelukken veroorzaakt worden. Voor werkzaamheden aan het hydraulisch systeem moet het hydraulisch systeem drukloos gemaakt worden, met inbegrip van de gasvuldruk. Gassen onder druk Hydro-accumulatoren kunnen na het ontladen resp. volledig aflaten (bijv. door het drukloos maken alvorens werkzaamheden verricht worden aan het hydraulieksysteem) middels het achteraf afsluiten van de leidingen aan de vloeistofzijde weer een druk opbouwen. Deze wijze is in het algemeen en in het bijzonder voor werkzaamheden aan hydraulische systemen met aangesloten hydro accumulatoren in acht te nemen. Alle vloeistofzijdige, aan de Hydro-accumulatoren aangesloten leidingen zijn derhalve drukloos te maken en daarna niet meer af te sluiten. Slechts en alleen hierna mogen er pas werkzaamheden verricht worden (bijv. demontage van de accumulatoren). Aan de balgaccumulator mogen geen las,

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soldeer of mechanische werkzaamheden verricht worden. Explosiegevaar bij las- en soldeerwerkzaamheden! Barstgevaar en het intrekken van de bedrijfsvergunning in geval van mechanische werkzaamheden. Hydro accumulatoren mogen uitsluitend met stikstof worden gevuld N2 (99.995%). Geen andere gassen gebruiken. Explosiegevaar! ATTENTIE: Het accumulatorlichaam kan heet worden, Verbrandings gevaar! 2. Opslag 2.1 Complete accumulatoren Alle accumulatoren dienen te worden opgeslagen in een schone, droge en koele ruimte en uit de buurt van direct zonlicht. Aanbevelingen voor kortdurende opslag: Mits de accumulatoren zijn opgeslagen in een schone, droge en koele ruimte en uit de buurt van direct zonlicht, kunnen ze meerdere weken worden bewaard in de originele verpakking zonder verslechtering van het product. Aanbevelingen voor langdurige opslag (minerale olie) Alle accumulatoren worden geleverd zonder stikstofvulling, tenzij gespecificeerd in de order. Vóór aansluiting op het hydraulisch systeem moeten alle accumulatoren gevuld zijn met stikstof. Accumulatoren dienen te worden gevuld met zuurstofvrije stikstof tot een druk van ongeveer 2 tot 3 bar. De vloeistofpoort moet na het vullen worden afgesloten met een daarvoor geschikte drukstop. Pas de vulwerkwijze toe zoals beschreven in hoofdstuk 4.0 Inbedrijfstelling. Aanbevelingen voor langdurige opslag (vloeistoffen op water-/glycolbasis) Voorzorgsmaatregelen moeten worden

getroffen wanneer de vloeistoffen in het accumulatorsysteem een lage viscositeit hebben (bijv. vloeistoffen op glycolbasis). Hanteer de volgende werkwijze: * Ontlaad de stikstofvulling, en plaats de dop van de gasklepinrichting en de buisbeschermkap terug. * Houd de accumulator omgekeerd, met de * vloeistofpoort geheel naar boven, en vul * * het systeem met vloeistof totdat het niveau * gelijk is met de aansluiting van de poort. * * Het is belangrijk te controleren of de * systeemvloeistof veilig is voor gebruik. Is dit * niet het geval, dan moet een geschikte en * compatibele vloeistof worden gebruikt. * Breng nadat het systeem gevuld is een * geschikte drukstop aan in de aansluiting * * * van de vloeistofpoort De accumulator is klaar voor langdurige opslag. Langdurige opslag is niet langer dan 1 jaar. 2.2 Reservebalgen Voor alle bestanddelen van de balgen van QHP zijn volledige technische specificaties op verzoek verkrijgbaar. Classificatie van elastomere materialen en hun verwachte houdbaarheid zijn nauwkeurig beschreven in BS ISO 2230. Als de balgen niet correct worden opgeslagen, kunnen deze verslechteren onder invloed van ozon, hitte of roterende elektrische apparatuur. Barsten worden binnen 12 maanden zichtbaar. Ideale omstandigheden voor opslag - Opslag in een zwarte en afgedichte plastic zak, in een doos, uit direct zonlicht en uit de buurt van roterende elektrische apparaten. - Opslagtemperatuur: +15°c to +25°c - Opgepompt met stikstofgas tot zijn natuurlijke vorm en zo opgeslagen. (Niet groter dan 1x de normale vorm)

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OPMERKING: De opslaginstructies voor zowel volledige accumulatoren als reservebalgen betreffen slechts aanbevelingen. In geval van mogelijke extreme omstandigheden waarbij de aanbevelingen niet kunnen worden opgevolgd, neem dan contact op met onze technische afdeling voor advies. 2.2.1 Reservebalgen Inspectie vóór gebruik - Verwijder alle verpakking; gebruik geen - scherpe instrumenten. - Blaas de balg op tot circa 1,5 x de normale - vorm. - Controleer alle uitwendige oppervlakken op - barstjes, mechanische schade, zoals - inkepingen, scheurtjes of afgesleten delen, - en controleer naden op verslechtering. - Dompel onder in water en controleer op - lekkage en perforaties. 3. Installatie en veiligheidsapparatuur 3.1 Inspectie vóór gebruik Alle accumulatoren moet bij ontvangst worden geïnspecteerd op beschadiging die tijdens het vervoer kan zijn opgelopen. Lees alle instructies zorgvuldig door voordat u met werkzaamheden aanvangt, ongeacht hun aard. Controleer of alle onderdelen met schroefdraad stevig vastzitten, bijvoorbeeld beschermkap, borgmoer van gasklep, vloeistofpoort, borgring, ontluchtingsschroef, adapters en alle fittingen, voor zover van toepassing. ATTENTIE: Controleer of de maximale werkdruk van de accumulator niet minder is dan de maximale werkdruk van het systeem waarop hij wordt aangesloten (zie sectie (7) Markeringen).

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3.2 Aanbevelingen voor installatie De volledige, uitgebreide aanbevelingen voor installatie kunt u opvragen bij onze technische afdeling.

ATTENTIE: Indien de accumulator was opgeslagen vóór aansluiting op het hydraulisch systeem, volg dan de volgende aanbeveling op: Zorg ervoor dat de accumulator is voorzien van smeervloeistof voordat deze wordt gevuld (zie 4. Inbedrijfstelling) Na kortdurende opslag: de accumulator moet worden gevuld tot de juiste stikstofdruk, vóór aansluiting op het hydraulisch systeem. Na langdurige opslag (minerale olie): De gasvuldruk van de accumulator en alle vloeistofdruk moeten worden ontladen vóór verwijdering van de drukstop. Vervolgens kan de accumulator worden gevuld tot de vereiste druk. Na langdurige opslag (vloeistoffen op water-/glycolbasis): Zorg ervoor dat de gasvuldruk wordt ontladen en laat overtollige systeemvloeistof uit de accumulator afvloeien. Vervolgens kan de accumulator worden gevuld tot de vereiste druk. 3.3 Veiligheidsapparatuur Het is van wezenlijk belang dat de accumulator is beveiligd tegen overdruk. (Een afsluitvoorziening, een aflaat mogelijkheid tussen hydraulische accumulator en afsluitvoorziening, barstschijfinrichting om de stikstofdruk te verminderen, of een veiligheidsvoorziening tegen temperatuursoverschrijding) Overdrukbeveiligingsvoorzieningen zijn op aanvraag verkrijgbaar bij QHP Accumulatoren zijn het meest efficiënt in de verticale stand, met de gasklep geheel bovenaan. Bij montage moet rekening worden gehouden met mogelijke belastingen als gevolg van slechte weersomstandigheden of seismische gebeurtenissen. Accumulatoren moeten zodanig worden gemonteerd dat bewegingen in het geval van een gebarsten

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leiding of abnormale spanningen op het leidingwerk van het systeem worden voorkomen. Accumulatoren moeten worden beveiligd tegen beschadiging door voertuigen of verkeer, bijvoorbeeld vorkheftrucks. Het is noodzakelijk om de gasvuldruk regelmatig te controleren (zie (d) Onderhoud). Er moet rekening worden gehouden met het volgende: - De aanwezigheid van een veiligheidskleppenblok of isolatieklep tussen de accumulator en de - vloeistofdrukleiding zodat de vloeistofdruk - kan worden geïsoleerd. - Locatie van de gasklep van de accumulator - in verband met beschadiging door ongeval - en het aanbrengen van de vulapparatuur. - Voorziening en locatie van een extra - waarschuwingslabel met de tekst "vullen - met stikstofgas op ....bar". QHP kan een uitgebreid assortiment van montageklemmen en beugels, veiligheidsblokken of isolatiekleppen, en barstschijven Neem contact op met onze verkoopafdeling voor meer informatie. 4. Inbedrijfstelling Belangrijk Alle accumulatoren worden geleverd zonder stikstofvulling, tenzij gespecificeerd in de order. Vóór aansluiting op het hydraulisch systeem moeten alle accumulatoren gevuld zijn met stikstof. Indien dit niet gebeurt, kan de balg defect raken. WAARSCHUWING: Gebruik nooit zuurstof of lucht – dit kan een explosie veroorzaken! Gebruik alleen zuurstofvrij stikstofgas N2 (99.995%). WAARSCHUWING: Controleer het label of de markering op de accumulator om te verifiëren of de maximale werkdruk van de accumulator gelijk is aan of groter is dan de werkdruk van het systeem.

Gebruik altijd een stikstofregelklep wanneer de maximale werkdruk van de accumulator hoger is dan de gasdruk in de stikstofcilinder. De vuldruk is afhankelijk van de bedrijfsomstandigheden. Neem voor advies contact op met onze technische afdeling. Een lagere vuldruk dan 20% van de maximale werkdruk kan ervoor zorgen dat de balg defect raakt. Zorg dat de accumulator vóór het vullen smerende vloeistof bevat. Het is gebruikelijk om voor dit doel systeemvloeistof te gebruiken, gewoonlijk is 10% van de accumulatorcapaciteit voldoende. 4.1 Voorvulprocedure: A

E C

I H

D G

F B

3

WAARSCHUWING: Vulwerkzaamheden mogen alleen worden uitgevoerd door speciaal daarvoor opgeleide vakmensen. LAAT VULAPPARATUUR NOOIT ONBEHEERD ACHTER TIJDENS GEBRUIK. Voor veilig vullen van accumulatoren moet de onderstaande procedure worden gevolgd. Alle vulapparatuur moet zijn geleverd door QHP – zie de catalogus voor details • Ontlaad de druk uit de vloeistofzijde van de • balgaccumulator. • Verwijder de beschermkap (5) en de • afsluitdop (3) van de gasklepinrichting, • indien aangebracht. • Bevestig de stikstofregelaar (A) aan de • stikstoffles (B) • Zorg dat het handwiel (E) op de vulset (C) • geheel is teruggetrokken, met inbegrip van

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• de pin. • Bevestig de vulset (C) aan de gasklep van • de accumulator (3). • Sluit de slang (D) aan tussen de stikstof • regelaar (A) en de vulset (C). • Controleer of de ontluchter (F) geheel is • gesloten. Stel de gasregelaar van de stikstoffles (A) in op 25 psi. OPMERKING: De klep van de stikstofdrukregelaar dient te zijn voorzien van twee meters: één voor de hoge druk (opwaarts), en één voor de verminderde druk (neerwaarts). Om overdruk als gevolg van incorrecte instellingen te voorkomen dient de maximumdruk van de drukverlager te zijn ingesteld op een niveau dat de maximum toegestane druk PS van de accumulator niet overschrijdt. Om overdruk als gevolg van een defect te voorkomen, dient de drukverlager te worden voorzien van een ontluchtingsinstrument dat de neerwaartse druk beperkt. ATTENTIE: Een eerste voordruk van meer dan 25 psig zal de balg doen barsten! • Draai de hendel (E) langzaam rechtsom, • één tot anderhalve draai, om de kernstift • van de gasklep te ontluchten. • Open de cilinderafsluiter (G) met de • flessleutel (H). De gasdruk wordt • aangegeven op de rechter meter van de • regelaar. • Draai de hendel van de regelaar (I) • rechtsom totdat de gasdruk op de linker • meter wordt aangegeven. Deze druk moet • 10% hoger zijn dan de vereiste vuldruk. • Laat de gasvuldruk stabiliseren, stel bij • indien nodig. • Controleer de gasvuldruk op de vulset (C). • Sluit de klep (G) van de stikstoffles wanneer

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• deze druk gelijk is aan de druk op de • drukregelaar. • Als de druk te hoog is, kan deze worden • verminderd met het ontluchtingsventiel (F) • Draai de hendel (E) op de vulset linksom • om de gasklep (3) af te dichten. • Open het ontluchtingsventiel (F) om gas via • de vulklep (3) te ontluchten. • Verwijder de vulset (C) en de • verbindingsslang (D) van de accumulator. • Controleer de gasklep van de accumulator • op lekkage met een lekspray of zeepsop. • Breng de afsluitdop en beschermkap weer • aan. De accumulator is nu klaar om in bedrijf te worden gesteld. 5. Onderhoud van de accumulator Om een lang storingsvrij funktioneren te garanderen, moeten volgende onderhoudswerkzaamheden regelmatig uitgevoerd worden: - Het controleren van de voorvuldruk van de - stikstof, - Aansluitingen op vastheid en lekkages - controleren, - Armaturen en veiligheidsapparaten op - toestand controleren, - Bevestigingelementen controleren. - De accumulator visueel inspecteren 5.1 Controle-intervallen voor vullingen Het wordt aangeraden de volgende controle intervallen in acht te nemen: - Na elke inbouw, - Een week na inbouw, - acht weken na inbouw. - Indien er geen merkbaar gasverlies - optreedt, kunnen de controle intervallen in - de toekomst - eenmaal per jaar gedaan worden.

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OPMERKING: Continubedrijf bij hoge bedrijfstemperaturen benodigen kortere controle intervallen

accumulator.

6. Hercertificering In het VK vallen de meeste accumulatoren onder de eisen van de zogenaamde "Pressure Systems Safety Regulations 2000 (PSSR)" en de "Pressure Equipment Directive (PED)". De hoofdpunten zijn: • Eisen om de veilige bedrijfslimieten van de • accumulator vast te stellen en • documentatie om aan te tonen dat deze • niet door de systeemdruk worden • overschreden. • Opstellen van een schriftelijk schema voor • accumulatoren boven 250 bar/liter. • Opstellen van een onderhoudsprocedure, uitvoeren van veiligheids- en regelmatige inspecties. Neem contact op met onze verkoopafdeling als u hulp nodig heeft om te zorgen dat u aan de relevante richtlijnen voldoet. In het VK heeft QHP centra voor hercertificering van accumulatoren die met het bovenstaande kunnen helpen. Neem contact op met onze verkoopafdeling voor meer informatie.

- CE-markering overeenkomstig de Richtlijn - Drukapparatuur 97/23/EG - Productiedatum, (Maand/Jaar) - Serienummer fabrikant - Naam/symbool fabrikant - totaal mantelvolume in liters - toegestaan temperatuurbereik in graden - Celsius - maximum toegestane druk PS - testdruk PT - identificatienummer aangemelde instantie (indien van toepassing)

Standaard informatie / Hieronder weergegeven markering

7. Markeringen Naamplaten Alle standaard balgaccumulatoren van QHP zijn voorzien van metalen labels die voorzien zijn van de volgende essentiële informatie. • Naam en adres van fabrikant/leverancier • Modelnummer • Maximale werkdruk (MWP) • Accumulatorvolume • Fabricagedatum • Waarschuwing en veiligheidsinformatie Essentiële informatie die is vereist volgens de relevante ontwerpcode is permanent gestanst op het bolle uiteinde van de mantel van de

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Информация о продукции Для пневмогидроаккумуляторов 5 Предохранительный колпчок 3 Пневмоклапан в сборе 4 Контргайка 6 Фирменная табличка с основными данными 2 Кольцевое уплотнение 1 Пневмогидроаккумулятор в сборе 7 Корпус аккумулятора

9 Кольцо противовыдавливания 10 Кольцевое уплотнение 11 Тефлоновое уплотнение 12 Запорное кольцо 14 Прокачная заглушка 13 Клеевое уплотнение 8 Гидроклапан в сборе

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1. Общие указан Пневмогидроаккумуляторы являются сосудами, работающими под давлением, как определено Предписанием 97/23/EG для устройств, работающих под давлением. Они представляют собой замкнутые сосуды, рассчитанные и сконструированные для аккумулирования гидравлического давления. Пневмогидроаккумуляторами являются аккумуляторы с наполненным азотом баллоном для использования в гидравлических установках. Пневмогидроаккумуляторы предназначены исключительно для приема и последующего выпуска жидкости под давлением. Перед установкой гидроаккумулятора и во время его эксплуатации необходимо соблюдать предписания, для данного места установки. Заводской оператор несет полную ответственность за обеспечение использования по назначению и соблюдение действующих правил. Поставляемые вместе с аккумулятором сертификат соответствия и

прочая документация должны тщательно храниться на месте установки для последующих периодических проверок. Если кроме установки и ввода в эксплуатацию будут проводиться и другие работы, например, ремонт аккумуляторов, то для этих целей имеются подробные инструкции по техническому обслуживанию и ремонту. Они могут быть высланы по запросу. ПРЕДУПРЕЖДЕНИЕ Все работы на гидравлических и пневматических подсоединениях аккумулятора могут выполнять только обученные для этого специалисты. Неправильная установка или эксплуатация могут стать причиной серьезных аварий. Перед началом любых работ на гидравлическом оборудовании необходимо сбросить давление из гидравлической системы, включая предварительный заряд газа. Гaзы noд дaвлeниeм После сброса давления и/или полного опорожнения аккумулятора (например, после сброса давления в гидравлической системе перед началом работ), в аккумуляторе может снова возрасти давление, когда напорная линия рабочей жидкости будет позже перекрыта. Об этой проблеме необходимо всегда помнить, а особенно перед началом проведения работ на гидравлической системе, содержащей подсоединенные гидроаккумуляторы. Следовательно, все трубы, подсоединенные к аккумулитору, должны быть без давления и линии должны оставаться открытыми (открытая запорная арматура). Только тогда можно правильно проводить работы (например, демонтаж аккумулятора). Никогда нельзя производить на аккумуляторе сварочные, паяльные или механические работы.

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ОПАСНОСТЬ взрыва при сварочных и паяльных работах! Опасность разрыва и последующее лишение разрешения на эксплуатацию при неправомерном выполнении механических работ на аккумуляторе. Гидроаккумуляторы должны наполняться только сухим, не содержащим кислорода азотом N2 (99.995%). Не использовать другие газы: Опасность взрыва! ВНИМАНИЕ: Корпус гидроаккумулятора может нагреваться. Опасность ожога. 2. Хранение 2.1 Аккумуляторы в сборе Все аккумуляторы должны храниться в чистом, сухом, прохладном помещении, защищенными от прямых солнечных лучей. Рекомендации по кратковременному хранению: При условии, что аккумуляторы хранятся в чистом, сухом, прохладном помещении защищенными от прямых солнечных лучей, их можно держать в заводской упаковке в течение нескольких недель без ухудшения их состояния. Рекомендации по долговременному хранению (Минеральное масло) Все аккумуляторы поставляются без предварительной зарядки азотом, если в заказе не указано давление предварительной зарядки. Гидроаккумуляторы следует предварительно зарядить примерно до 2 – 3 бар азотом, не содержащим кислорода. После предварительной зарядки необходимо закрыть гидроклапан соответствующей герметичной заглушкой. Процедуру предварительной зарядки см. в пункте 4.0 Ввод в эксплуатацию. Рекомендации по долговременному хранению (Водный раствор гликоля) При использовании в системе аккумулятора жидкостей с низкой вязкостью, например, на основе гликоля, следует предпринять меры предосторожности. Необходимо сделать

следующее: * Сбросить давление предварительного • заряда азота, заменить колпачок • пневмоклапана и установить защитный • колпачок. * Перевернув аккумулятор гидроклапаном • вверх, заполнить его жидкостью, • используемой в системе, до верха • гидроклапана. Важно убедиться, что • жидкость, используемая в системе, • безопасна для использования – если это • не так, следует использовать подходящую • совместимую жидкость. * После заполнения установите • соответствующую пробку давления в • гидроклапан. Теперь аккумулятор готов к долговременному хранению. Долговременное хранение не должно превышать один год. 2.2 Запасные баллоны Можно получить полные технические спецификации на материалы всех баллонов, они предоставляются по требованию. Классификация эластичных материалов и сроки их хранения приведены в BS ISO 2230. При неправильном хранении баллонов они подвержены воздействию озона, тепла, УФ-излучения, или электрического оборудования с вращающимися узлами. Спустя 12 месяцев станет заметным растрескивание. Идеальные условия хранения - Хранить в черном пластиковом - герметичном мешке, коробке, - защищенными от прямых солнечных - лучей, тепла или электрического - оборудования с вращающимися узлами. - Температура хранения от +15°c до +25°c - Хранить заполненными газом азотом, с - сохранением естественной формы. (Не - более 1х нормального размера)

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УКАЗАНИЕ: Инструкции по хранению аккумуляторов в сборе и запасных баллонов являются только рекомендациями. В

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случае суровых условий, когда рекомендации выполнить невозможно, просим обратиться за советом в наш технический отдел. 2.2.1 Проверка запасных баллонов перед использованием - Удалите упаковку, не используя острые - инструменты - Надуйте баллон до размера, примерно в - 1.5 раза превышающего его обычную - форму - Выполните визуальный осмотр всех - наружных поверхностей на - растрескивание, механические - повреждения, такие как порезы, разрывы, - потертости, проверьте состояние швов на - износ. - Погрузите баллон в воду и проверьте на - наличие протечек или проколов. 3. Установка и защитное оборудование 3.1 Осмотр перед использованием При получении все аккумуляторы необходимо осматривать на наличие любых повреждений, которые могли произойти во время транспортировки. До начала любых работ внимательно прочитайте все инструкции. Проверьте все резьбовые детали на плотность посадки, например, защитный колпачок, контргайку пневмоклапана, гидроклапан, стопорное кольцо, винт стравливания давления, переходники и фитинги, если они используются. ПРЕДУПРЕЖДЕНИЕ: Убедитесь, что максимальное рабочее давление аккумулятора не меньше максимального бочего давления системы, к которой он присоединяется (см. раздел 7. Маркировка). 3.2 Рекомендации по установке В нашем техническом отделе можно запросить полные рекомендации по установке.

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ВНИМАНИЕ: Если до присоединения к гидравлической системе аккумулятор находился на хранении, рекомендуется следующее: перед

предварительной зарядкой убедитесь, что в аккумуляторе имеется смазочная жидкость (см. 4. Ввод в эксплуатацию) После кратковременного хранения: перед присоединением к гидравлической системе аккумулятор необходимо предварительно зарядить азотом до соответствующего давления. После долговременного хранения (Минеральное масло): Сбросить давление предварительного заряда газа аккумулятора, перед удалением пробки давления необходимо сбросить давление жидкости. Затем можно предварительно зарядить аккумулятор до требуемого давления. После долговременного давления (Водный раствор гликоля): Убедитесь, что давление предварительного заряда газа сброшено, лишняя жидкость из аккумулятора удалена. Затем можно предварительно зарядить гидроаккумулятор до требуемого давления. 3.3 Защитное оборудование Важно защитить аккумулятор от избыточного давления. (В число защитных элементов входят запорное устройство, устройство сброса давления между гидроаккумулятором и запорным клапаном, конструкция разрывного диска для сброса давления азота, или предохранительное устройство против превышения температуры) По заказу компания QHP поставляет оборудование защиты от избыточного давления. Аккумуляторы наиболее эффективно работают в вертикальном положении с пневмоклапаном, расположенным сверху. При монтаже следует принимать во внимание любую возможность нагрузок, которые могут быть вызваны неблагоприятными погодными или сейсмическими явлениями. Аккумуляторы необходимо устанавливать так, чтобы исключить любые смещения в случае разрыва трубопровода или при

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возникновении аварийных напряжений в трубопроводе системы. Аккумуляторы необходимо защищать от повреждений транспортными средствами, например, вилочными погрузчиками. Необходимо регулярно проверять давление предварительной зарядки газом (см. раздел 5. Техническое обслуживание). Необходимо предусмотреть следующие моменты: - Наличие блока предохранительного - клапана или запорного клапана между - аккумулятором и линией находящейся под - давлением жидкости для обеспечения - возможности отсечения давления - жидкости. - Расположение пневмоклапана - аккумулятора в отношении возможности - случайных повреждений и присоединения - оборудования для предварительной - зарядки. - Наличие и расположение дополнительной - предупредительной этикетки: - «предварительная зарядка азотом при … - бар». Компания QHP может предоставить полный ряд монтажных зажимов и кронштейнов, блоков предохранительных клапанов или запорных клапанов и разрывных дисков. Свяжитесь с нашим отделом продаж для деталей 4 Ввод в эксплуатацию Важная информация Все аккумуляторы поставляются без предварительной зарядки азотом, если это не указано в заказе. Перед подключением к гидравлической системе все аккумуляторы должны быть предварительно заряжены азотом. Невыполнение этого приводит к выходу из строя баллона. ПРЕДУПРЕЖДЕНИЕ: Использовать кислород или воздух запрещается – это может привести к взрыву! Использовать только азот без содержания кислорода N2 (99.995%)

ПРЕДУПРЕЖДЕНИЕ: Проверьте маркировку или этикетку аккумулятора, чтобы убедиться, что максимальное рабочее давление аккумулятора равно или превышает рабочее давление системы. Всегда используйте регулировочный клапан азота, когда максимальное рабочее давление аккумулятора меньше давления газа в баллоне с азотом. Давление предварительной зарядки зависит от рабочих условий. За рекомендациями обращайтесь в наш технический отдел. Помните, что если давление предварительной зарядки меньше, чем 20% от максимального рабочего давления, это может привести к выходу баллона из строя. Убедитесь, что аккумулятор перед предварительной зарядкой содержит смазывающую жидкость. Как правило, для этой цели используется рабочая жидкость системы; обычно объем, равный 10% емкости аккумулятора, является достаточным 4.1 Процедура предварительной зарядки: A

E C

I H

D G

F B

3

ПРЕДУПРЕЖДЕНИЕ: Предварительную зарядку должен проводить только специально обученный и квалифицированный персонал. ОБОРУДОВАНИЕ ПРЕДВАРИТЕЛЬНОЙ ЗАРЯДКИ ВО ВРЕМЯ ИСПОЛЬЗОВАНИЯ ОСТАВЛЯТЬ БЕЗ НАДЗОРА ЗАПРЕЩАЕТСЯ. Для обеспечения безопасной предварительной зарядки аккумуляторов необходимо выполнять следующую последовательность действий. Все

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оборудование для предварительной зарядки должно поставляться компанией QHP – см. каталог. • Сбросить давление в жидкостном контуре • пневмогидроаккумулятора. • Снимите защитный колпачок (5) и • уплотняющий колпачок пневмоклапана • (3), если он установлен на устройстве • Присоедините азотный регулятор (A) к • баллону с азотом (B). • Полностью откройте вентиль (E) на узле • зарядки (C), включая сердечник газового • клапана. • Подключите узел зарядки (C) к • пневмоклапану аккумулятора (3). • Подсоедините шланг для зарядки (D) • между азотным регулятором (A) и узлом • зарядки (C). • Убедитесь, что спускной клапан (F) • полностью закрыт. Установите регулятор азота баллона (A) на давление 25 фунтов на кв. дюйм. УКАЗАНИЕ: Клапан регулятора давления азота имеет два манометра, один для высокого давления (выше по потоку) и один для пониженного давления (ниже по потоку). Чтобы избежать чрезмерного заряда из-за неправильной установки, на устройстве понижения давления необходимо установить максимальное давление, не превышающее максимально допустимое давление PS аккумулятора. Чтобы избежать чрезмерного заряда из-за сбоя, устройство понижения давления должно быть снабжено предохранительным устройством, ограничивающим давление ниже по потоку.

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ВНИМАНИЕ: Предварительный заряд свыше 25 фунтов на кв. дюйм вызывает разрыв баллона! • Для нажатия на сердечник газового • клапана, медленно поверните маховик (E) • по часовой стрелке на один-полтора • оборота. • Откройте клапан (G) баллона с азотом, с

• помощью ключа (H). Давление газа будет • показано на правом манометре регулятора. • Поворачивайте рукоятку регулятора (I) по • часовой стрелке до тех пор, пока не будет • показано давление газа на левом • манометре. Это давление должно быть на • 10% выше требуемого давления • предварительной зарядки. • Подождите стабилизации давления газа • предварительной зарядки, при • необходимости скорректируйте его. • Проверьте давление предварительной • зарядки газом на узле зарядки (C). Когда • оно будет равно давлению на регуляторе • давления, закройте клапан (G) азотного • баллона. • Если давление слишком высоко, его можно • снизить травлением через жиклер (F). • Поверните рукоятку (E) на узле зарядки • против часовой стрелки для закрывания • газового клапана (3). • Откройте спускной клапан (F) для выпуска • газа через клапан зарядки (3). • Отсоедините узел зарядки (C) и • соединительный шланг (D) от аккумулятора. • Проверьте пневмоклапан аккумулятора на • наличие протечек, используя мыльную • воду или спрей для обнаружения протечек. • Снова установите герметизирующий • колпачок и защитный колпачок. Теперь аккумулятор готов к вводу в эксплуатацию. 5. Техническое обслуживание аккумулятора Для обеспечения длительной и безотказной работы, необходимо регулярно проводить следующую процедуру технического обслуживания: - Проверка давления предварительной - зарядки азотом. - Проверка арматуры и предохранительных - устройств на исправность, - Проверка того, что соединения плотно - затянуты и отсутствуют утечки, - Проверка крепежных элементов

42

263

- Визуальный осмотр аккумулятора 5.1 Частота проверки предварительной зарядки Рекомендуется соблюдать следующие интервалы проверок: - После каждой установки - Через неделю после установки - Через восемь недель после установки - Если не происходит заметной утечки газа, - то последующие проверки могут - проводиться: - Один раз в год. УКАЗАНИЕ: Длительная работа при высоких рабочих температурах требует сокращения интервалов между проверками. 6. Освидетельствование В Великобритании большинство аккумуляторов отвечают требованиям Правил безопасности систем, работающих под давлением 2000 (Pressure System Safety Regulations, PSSR) и Директивы по оборудованию, работающему под давлением (Pressure Equipment Directive, PED) (PED97/23/EC) Ключевые пункты включают: • Требования по определению безопасных • эксплуатационных пределов давления • аккумулятора и записи, показывающие, • что давление в системе не превышает эти • значения. • Подготовка проекта в письменном виде • для аккумуляторов свыше 250 бар/литров. • Установление процедуры технического • обслуживания, выполнение проверки • соблюдения требований техники • безопасности и периодических проверок. • Если Вам требуется помощь для • обеспечения выполнения всех • законодательных требований, просим • обращаться в наш отдел продаж. Если Вы хотите убедиться, что Ваши условия отвечают требованиям положений, за более подробной информацией обращайтесь

в наш Отдел продаж. Компания QHP располагает центрами переподготовки по аккумуляторам и повторной сертификации, расположенными по всей Великобритании, куда можно обратиться для получения помощи по вопросам, перечисленным выше. За более подробной информацией обращайтесь в наш Отдел продаж. 7. Маркировки Фирменные таблички с основными данными Металлические таблички прикреплены ко всем стандартным пневмогидроаккумуляторам, выпускаемым компанией QHP, и содержат следующую важную информацию для пользователя. • Название и адрес изготовителя/номер • модели поставщика • Максимальное рабочее давление • (Maximum working pressure [MWP]) • Объем аккумулятора • Дата изготовления • Предупредительная информация и • сведения по безопасности Важная информация, требуемая применимыми конструкторскими нормами и правилами, штампуется на куполообразном конце оболочки аккумулятора. Ниже приводится стандартная информация / маркировка - Маркировка CE в соответствии с - Директивой по оборудованию, - работающему под давлением - 97/23/EC - Дата изготовления, (месяц/год) - Серийный номер изготовителя - Название/логотип изготовителя - Общий объем емкости в литрах - Диапазон допустимых температур в - градусах по Цельсию - Максимальное допустимое давление PS - Давление при испытании PT - Идентификационный номер - Уполномоченного органа (если применимо)

RUS 43

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QHP are able to provide a comprehensive range of mounting clamps and brackets, safety blocks, isolation valves and burst discs. See our full catalogue or contact our Sales Department for details. Visit our website:

www.qhp.co.uk

QHP Ltd is part of the Hydac International Group Taylor House, Minerva Avenue West Chester Employment Park Chester, United Kingdom, CH1 4QL T: +44 (0) 1244 393500 F: +44 (0) 1244 393501 E: [email protected] www.qhp.co.uk

265

Operating instructions

GB

Pressure gauges Examples:

Model 432.56, overpressure safety up to 100 bar

Model 732.14, overpressure safety up to 400 bar

Model 213.40

1. Safety WARNING! Before installation, commissioning and operation, ensure that the appropriate pressure gauge has been selected in terms of measuring range, design and suitable wetted material (corrosion) for the specific measuring conditions. In order to guarantee the measuring accuracy and long-term stability specified, the corresponding load limits must be observed. Only qualified persons authorised by the plant manager are permitted to install, maintain and service the pressure gauges. For hazardous media such as oxygen, acetylene, flammable or toxic gases or liquids, and refrigeration plants, compressors, etc., in addition to all standard regulations, the appropriate existing codes or regulations must also be followed. After an external fire, pressure media can leak out, particularly at soft solder joints. All gauges must be checked and, if necessary, replaced before recommissioning the plant.

„

„

„

Notes in accordance with Pressure Equipment Directive 97/23/EC „ The pressure gauges are "pressure accessories" in accordance with Article 1, Paragraph 2.1.4 „ The volume of the pressure bearing housings of WIKA pressure gauges is < 0.1 L „ The pressure gauges carry CE marking for Fluid Group 1G in accordance with Annex 2, Table 1 when their permissible working pressure exceeds 200 bar Pressure gauges that do not carry the CE mark are manufactured in accordance with Article 3, Paragraph 3 "Sound engineering practice".

2. Mechanical connection In accordance with the general technical regulations for pressure gauges (e.g. EN 837-2). When screwing the gauges in the force required for this must not be applied through the case or terminal box, rather only through the spanner flats provided for this purpose (using a suitable tool). Mounting with spanner







Applied standards EN 837-1 Bourdon tube pressure gauges, dimensions, metrology, requirements and testing EN 837-2 Selection and installation recommendations for pressure gauges EN 837-3 Diaphragm and capsule pressure gauges, dimensions, metrology, requirements and testing

Non-observance of the respective regulations can result in serious injury and/or damage to equipment.

Specifications: see data sheet on www.wika.de Subject to technical modifications.

© WIKA Alexander Wiegand SE & Co. KG 2009

Correct sealing of pressure gauge connections with parallel threads  must be made using suitable sealing rings, sealing washers or WIKA profile seals. The sealing of tapered threads (e.g. NPT threads) is made by providing the thread  with additional sealing material such as, for example, PTFE tape (EN 837-2). Spanner flats





WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg/Germany Tel. +49 9372 132-0 Fax +49 9372 132-406 [email protected] www.wika.de

2408976.04 11/2013

Sealing face 

Sealing by the thread 

The torque depends on the seal used. Connecting the gauge using a clamp socket or a union nut is recommended, so that it is easier to orientate the gauge correctly. When a blow-out device is fitted to a pressure gauge, it must be protected

against being blocked by debris and dirt. With safety pressure gauges (see dial symbol k) it must be ensured that the free space behind the blow-out back is at least 15 mm. After mounting, set the compensating valve (if available) from CLOSE to OPEN. With models 4 and 7, do not open the flange mounting screws. Requirements for the installation point If the line to the gauge is not sufficiently rigid for vibration-free mounting, a pipe-support bracket should be used to secure it (possibly via a flexible capillary). If vibration cannot be prevented through suitable installation, liquid-filled gauges should be used. The instruments should be protected against coarse dirt and wide fluctuations in ambient temperature. Note for model 732.14 for front bezel mounting: The front bezel serves as centring and as the aperture in the mounting panel. Securing and thus the weight-bearing must be made via the pressure connection piping. 3. Permissible ambient and operating temperatures When mounting the pressure gauge it must be ensured that, taking into consideration the influence of convection and heat radiation, no deviation above or below the permissible ambient and medium temperatures can occur. The influence of temperature on the display accuracy must be observed. 4. Storage The pressure gauge should be kept in its original packing until installation. The gauge should be protected from external damage during storage. Storage temperature range: -40 ... +70 °C. Protect the gauges from humidity and dust. 5. Maintenance and repairs The instruments are maintenance-free. Checks should be carried out on a regular basis to ensure the measuring accuracy of the pressure gauge. The checks or recalibrations must be carried out by qualified skilled personnel with the appropriate equipment. When dismounting, close the compensating valve (if available). WARNING! Residual media in dismounted pressure gauges can result in a risk to personnel, the environment and equipment. Take sufficient precautionary measures.

266

Technical Information

Selection, Installation, Handling and Operation of Elastic Element Pressure Gauges WIKA Data Sheet IN 00.05

■ Gauge vented The service connection is closed and the

pressure element is open to atmosphere. The zero point can be set.

The service connection is open, the pressure element is pressurised.

■ On



■

The user must ensure that the appropriate pressure gauge, with respect to scale range and performance, is selected. The optimal selection of the scale range occurs when the operating pressure lies in the middle third of the scale range.

Pressure gauge cocks feature three positions: ■

General



■

■ Purging The service connection is open; the pressure

medium is vented to atmosphere. The pressure element is not in use.

Pressure gauge valves, either with or without a test connection (DIN 16270 or 16271 resp.) are equipped with a vent plug between valve body and pressure connection. Loosening the vent plug enables controlled venting through the thread.

The pressure gauge should be installed in such a way as to avoid exposure to heat and vibration and to enable the dial indication to be easily read. The pressure connections must be sealed. It is common practise to install an isolating device between the pressure tapping point and the pressure gauge, to enable the gauge to be replaced and the zero point to be checked while the Plant is running.

Isolating devices The isolating device may be either a pressure gauge cock or a pressure gauge valve, depending on operating conditions and requirements.

WIKA Data Sheet IN 00.05 ∙ 02/2009

For certain applications (e.g. steam vessels) the isolating valves must have a test connecton, so that the pressure gauge can can be tested without being disconnected. Pressure gauge valves to DIN 16272 feature discretely isolatable test connections.

Pressure gauge mounting provisions If the pipe to the gauge is not rigid enough for a vibration-free installation, the gauge should be mounted by means of a mounting device for surface or pipe mounting, and, if necessary, with a capillary extension.

Damping of the measuring system If vibrations cannot be eliminated by appropriate installation, then liquid-filled gauges should be used.

Page 1 of 4

267

Pressure test connection



= density of ambient air in (kg/m³) (standard value 1.205 kg/m³ at 20 °C)

ρL





= density of pressure medium in (kg/m³)

∆h

= Level difference in metres (m)

g

= Acceleration due to gravity in (m/s²) (standard value = 9.81 m/s²)

The corresponding indication will be lower by the value of ∆p if the gauge is mounted above, but higher by the value of ∆p if the gauge is mounted below the pressure tapping point. Pressure gauges will normally be mounted with the dial in the vertical plane. For different positions, the orientation symbol on the dial should be adhered to.

Installation and commissioning Correct sealing of pressure gauge connections with parallel threads  is achieved by means of a suitable sealing ring, sealing washer or WIKA profile seals. The sealing of tapered threads (e.g. NPT threads) is made by the thread itself , with additional sealing material such as, for example, PTFE tape (EN 837-2).  Parallel and  tapered thread connection

 

The pressure test connection, with a sufficiently large bore (≥ 6 mm diameter), should be arranged, as far as possible, over a shut-off device, in a position where the accuracy of reading will not be affected by the flow of the media being measured. The piping between the pressure test connection and the pressure gauge should have an inner diameter large enough to avoid blockages or delays in pressure transmission. It should also not have any sharp bends. It is recommended that it is laid with a continuous incline of approx. 1:15.

ρM



Should the measuring medium be subject to rapid fluctuations in pressure, or pressure surges have to be taken into account, these must not be allowed to act directly on the pressure element. The pressure surges must be restricted in their effect, for example, by fitting integral restrictor screws (to reduce the cross-section in the pressure channel) or by using adjustable snubber devices. In cases where it is necessary to select a range lower than the maximum pressure which could briefly occur in the system, in order to obtain a high reading resolution, the pressure element must be protected against damage. An overload protection device (external protection) should be fitted; with a pressure surge these close immediately, and only gradually with a slow pressure rise. The set closing pressure thus depends on the temporal pressure profile. A further possibility is to use a pressure gauge with a high overpressure safety (internal protection).

= (ρM - ρL) • g • ∆h • 10-5 (bar) = Offset of measuring range where



Overload protection for pressure elements

∆p



For pressure media which are aggressive, hot, highlyviscous, crystallising or contain particles, and which must not enter the pressure element, diaphragm seals provide separation. For transmission of the pressure to the pressure element, a neutral pressure transmission fluid is used, which is chosen to match the measuring range, the temperature and the compatibility with the pressure medium. The connection between the pressure gauge and the diaphragm seal must not, under any circumstances, be loosened.

For gases or liquids containing solids separation should be provided which can be separated and emptied while the plant is running. If the pressure gauge has to be mounted higher or lower than the tapping point, if the pressure medium in the lines does not have the same density, this shifts the measuring range. The offset is determined from the difference in density (ρM - ρL) and the height difference ∆h according to the equation:



Diaphragm seals / Protection

The piping should be arranged and fitted so that it can withstand the stresses caused by expansion, vibration and the influence of heat. When the media is gaseous, a water drain point should be provided at the lowest point. For liquid pressure media, an air bleed should be provided at the highest point.



The operating temperature of the pressure gauge, resulting from the effects of pressure medium, ambient temperature and possibly heat radiation must not exceed the temperature span the pressure gauge is intended for. Suitably shaped tailpipes or syphons with water filling may be used to separate the pressure gauge and its isolating device from hot pressure media. The influence of the temperature on the display accuracy should be considered.

Piping



Effects of temperature

Page 2 of 4

spanner flats sealing face 

sealing by the thread 

In order to simplify the correct orientation of the gauge, connecting the gauge by means of a union nut or a LH-RH adjusting nut is recommended. When screw-fitting or unscrewing the pressure gauge, the torque must not be applied to the housing, but only to the spanner flats on the stem.

WIKA Data Sheet IN 00.05 ∙ 02/2009

268

 

No pressure higher than indicated by the working pressure symbol ▼ (final value) must be applied to the gauge during hydrostatic pressure test of the system (EN 837-1 and EN 837-3). Otherwise the gauge must be isolated or removed during this operation. In the case of diaphragm gauges, care should be taken not to accidentally loosen the bolts that retain upper and lower diaphragm housing. No attempts should be made to remove a pressurized gauge. The pressure system must be totally vented if the gauge cannot be otherwise isolated. Any residual pressure medium contained in the pressure element may be hazardous or toxic. This should be taken into account when handling and storing pressure gauges which have been removed. Pressure gauges whose pressure elements are filled with water or a water mixture should be protected against freezing.

Operation Isolating equipment should only be opened slowly, in order to avoid pressure surges. Steady working pressure is indicated on the dial by the identifying mark ▼ (EN 837-1 and EN 837-3). For fluctuating working pressure, lower values are applicable. To check the zero point during operation, the isolating device should be closed and the pressure element relieved. The pointer must fall within the thickened portion of the zero mark h. If the pointer remains outside of the crossbar, this generally results from a lasting deformation of the pressure element, which would need to be submitted for a closer examination, in order to avoid measuring errors or damage. On-site testing of the pressure gauge is feasible by means of isolating devices enabling connection of a test gauge together with a suitable pressure source. The permissible error limits are defined in EN 837-1 and EN 837-3.

■

■

■

■

■

For hazardous pressure media such as ■ oxygen ■ acetylene ■ flammable gases or liquids ■ toxic gases or liquids ■ steam ■ ammonia and other refrigerants ■

If the pressure gauge is positioned lower than the pressure test connection, the tailpipe should be thoroughly cleaned prior to fitting the gauge. For internal pressure compensation, some pressure gauge models are provided with a resealable pressure vent with the inscription CLOSE and OPEN. This pressure vent is supplied closed (lever in CLOSE position). Prior to inspection and/or after installation and prior to initial operation, the gauges must be vented (lever in OPEN position).

as well as for refrigeration systems, compressors, etc. require attention beyond that of the standard regulations. In these instances, the appropriate specific safety codes or regulations must be considered.

Storage For the storage of the pressure gauge before installation, the following points should be observed in order to prevent damage: The pressure gauge should remain in its original packing and stored so that it is protected from damage from external influences. Should the gauge be taken out (e.g. for testing), afterwards reuse the original packaging material. Storage temperature range from -40 °C to +70 °C. Variations in these storage temperatures are possible for different instruments. The permissible temperature range is given in the appropriate data sheet. Gauges should be protected against dust and humidity.

Reference documents Cited DlN standards and other DIN EN standards DIN EN 837-1 Pressure gauges; part 1: Bourdon tube pressure gauges; Dimensions, metrology, requirements and testing DIN EN 837-2 Pressure gauges; part 2: Selection and installation recommendation for pressure gauges DIN EN 837-3 Pressure gauges; part 3: Diaphragm and capsule pressure gauges; Dimensions, metrology, requirements and testing DIN 16270 PN 250 and PN 400 valves without test connection for pressure gauges DIN 16271 PN 250 and PN 400 valves with test connection for pressure gauges DIN 16272 PN 250 and PN 400 valves with blocking test connection for pressure gauges

WIKA Data Sheet IN 00.05 ∙ 02/2009

Page 3 of 4

269

Accessories for pressure gauges

Overpressure protector

Adjustable snubber

Pressure gauge valve

Pressure gauge cock

U-form syphon

Trumpet-form syphon

Adaptor for surface mounting bracket

Pressure gauge valve with extra valve for test connector

LH-RH adjusting nut

Surface mounting bracket

Arrangements for pressure measurement Proven measuring arrangements for various types of media. Contents of tail pipe Typically Contents of tail pipe Typically

Liquid Condensate

Liquid media

Liquid with vapour

Boiling liquid

Vapour only Liquefied gas

Gaseous media

Gas only

Wet gas

Dry air

Moist air Flue gas

Pressure instrument higher than tapping point

Liquid gas condensate Steam

Pressure instrument lower than tapping point

The specifications given in this document represent the state of engineering at the time of publishing. We reserve the right to make modifications to the specifications and materials.

WIKA Data Sheet IN 00.05 ∙ 02/2009 02/2009 GB

Page 4 of 4







WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg/Germany Tel. (+49) 9372/132-0 Fax (+49) 9372/132-406 E-mail [email protected] www.wika.de

270

Mechanical temperature measurement

Bimetal thermometer Model 55, stainless steel version WIKA data sheet TM 55.01 for further approvals see page 6

Applications ■

■ General process instrumentation in the chemical and

■

petrochemical industries, oil and gas industries, energy and water/wastewater industries ■ Temperature measurement in harsh and aggressive environments

Special features ■

■ Scale ranges from -70 ... +600 °C ■

■ For extreme ambient temperatures ■

■ Maintenance-friendly bayonet case ■

■ All stainless steel construction ■

■ Individual stem length from 63 ... 1,000 mm

Description  

The model 55 bimetal thermometer has been developed and is manufactured in accordance with the EN 13190 standard. The high-quality thermometer has been designed especially for the requirements of the process industry. Especially in the chemical and petrochemical, oil and gas, and power engineering industries, the temperature measuring instrument completely manufactured from stainless steel is used successfully.

Fig. left: Bimetal thermometer, model R5502 Fig. right: Bimetal thermometer, adjustable stem and dial, model S5550

The model 55 satisfies the high requirements for resistance against aggressive media. As an option, the case, the stem and the process connection can be made from 316Ti (1.4571) to fulfil the highest requirements. WIKA data sheet TM 55.01 ∙ 03/2015

To allow optimum fitting to the process, individual insertion lengths and different process connections can be selected. When it comes to harsh climatic conditions at the place of use, the model 55 is the right choice, as it can be used at temperatures ranging from -40 °C to +70 °C. Page 1 of 6

271

Standard version Measuring element Bimetal coil

Window Instrument glass NS 63: window from polycarbonate

Nominal size in mm 63, 100, 160

Pointer Aluminium, black, micro adjustable pointer

Connection designs S Standard (male threaded connection) 1 Plain stem (without thread) 2 Male nut 3 Union nut 4 Compression fitting (sliding on stem) 5 Union nut and loose threaded connection Model overview Model

A5525 A5500 A5501 R5526 R5502 R5503 S5550 S5551

NS

63 100 160 63 100 160 100 160

Zero adjustment on case back side, external only for adjustable stem and dial (option) Insertion length L1 63 ... 1,000 mm minimum/maximum length is dependent on the measuring range and diameter

Version

Back mount (axial)

Permissible temperatures -50 ... +70 °C (without case filling liquid) -40 ... +70 °C (with case filling liquid) for storage, transport and ambient at case

Lower mount (radial) Back mount, adjustable stem and dial

Permissible operating pressure at the stem max. 25 bar, static

Accuracy class Class 1 per EN 13190

Ingress protection IP 65 per EN 60529

Working range Normal (1 year): Measuring range (EN 13190) Short time (24 h max.): Scale range (EN 13190)

Options ■

■ Scale range °F, °C/°F (dual scale)

■ Liquid damping up to max. 250 °C (at the sensor) ■

Case, bayonet ring Stainless steel 1.4301 (304)

■

■ Laminated safety glass, clear non-splintering plastic ■

■ Stem diameter 6, 10, 12 mm

Stem, process connection Stainless steel 1.4571 (316Ti)

■

■ Ingress protection IP 66 ■

■ Thermometer with switch contacts (data sheet TV 25.01) ■ Special measuring ranges or dial printing to customer ■

Dial Aluminium white, black lettering

specifications (on request)

■

■ Version per ATEX Ex II 2 GD c TX

Scale ranges, measuring ranges 1), error limits (EN 13190) Scale graduation per WIKA standard Scale range in °C

-70 ... +30 -50 ... +50 -30 ... +50 -20 ... +60 0 ... 60 0 ... 80 0 ... 100 0 ... 120 0 ... 160 0 ... 200 0 ... 250 0 ... 300 0 ... 400 0 ... 500 0 ... 600

Measuring range 1) in °C

-60 ... +20 -40 ... +40 -20 ... +40 -10 ... +50 10 ... 50 10 ... 70 10 ... 90 10 ... 110 20 ... 140 20 ... 180 30 ... 220 30 ... 270 50 ... 350 50 ... 450 100 ... 500

Scale spacing in °C

1 1 1 1 1 1 1 2 2 2 5 5 5 5 10

Error limit ±°C

1.0 1.0 1.0 1.0 1.0 1.0 1.0 2.0 2.0 2.0 2.5 5.0 5.0 5.0 10.0

1) The measuring range is indicated on the dial by two triangular marks. Only within this range is the stated error limit valid per EN 13190.

Page 2 of 6

WIKA data sheet TM 55.01 ∙ 03/2015

272

Connection designs

NS

63, 100, 160

G

i

G½B G¾B ½ NPT ¾ NPT

SW

14 16 19 20

27 32 22 30

d4

3073050.05

Standard design (male thread connection) Connection, male: G ½ B, G ¾ B, ½ NPT, ¾ NPT Insertion length l1 = 63, 100, 160, 200, 250 mm Nominal size Process connection Dimensions in mm Ød

26 32 -

8 8 8 8

Legend: G Male thread i Thread length Ø d4 Diameter of the sealing collar

SW Ød l2

Spanner width Stem diameter active length

3073050.05

Design 1, plain stem (without thread) Insertion length l1 = 140, 200, 240, 290 mm Nominal size Dimensions in mm NS

d1

Ød

63 100, 160

14 18

8 8

a for axial

15 15

a for adjustable stem and dial

25 25

Legend: a Distance to the case/ articulated joint Ø d1 Plain diameter

Ød l2

Legend: G Male thread i Thread length incl. collar SW Spanner width

Ø d Stem diameter l2 Active length

Stem diameter active length

3073050.05

Design 2, male nut Insertion length l1 = 80, 140, 180, 230 mm

Nominal size Process connection Dimensions in mm NS

63, 100, 160

G

G½B

i

20

SW

Ød

27

8

3073050.05

Design 3, union nut Insertion length l1 = 89, 126, 186, 226, 276 mm

Nominal size Process connection Dimensions in mm NS

63, 100, 160

G1

G½ G¾ M24 x 1.5

i

8.5 10.5 13.5

SW

Ød

27 32 32

8 8 8

Legend: G1 Female thread i Thread length SW Spanner width

Ø d Stem diameter l2 Active length

3073050.05

Design 4, compression fitting (sliding on stem) Standard insertion length l1 = 63, 100, 160, 200, 250 mm Length L = l1 + 40 mm

Nominal size Process connection Dimensions in mm NS

63, 100, 160

G

G½B G¾B M18 x 1.5 ½ NPT ¾ NPT

i

14 16 12 19 20

WIKA data sheet TM 55.01 ∙ 03/2015

SW 27 32 24 22 30

d4

26 32 23 -

Ød

8 8 8 8 8

Sealing ring

Legend: G Male thread i Thread length Ø d4 Diameter of the sealing collar

SW Spanner width Ø d Stem diameter l2 Active length

Page 3 of 6

273

3073050.05

Design 5, union nut and loose threaded connection G ½ B, G ¾ B, M18 x 1.5 and ½ NPT, ¾ NPT Minimum immersion depth lmin approx. 60 mm Insertion length l1 = variable Length L = l1 + 40 mm Stainless steel 1.4571

Nominal size Process connection Dimensions in mm NS

63, 100, 160

G

G½B G¾B M18 x 1.5 ½ NPT ¾ NPT

i

14 16 12 19 20

SW

27 32 24 22 30

d4

26 32 23 -

Ød 8 8 8 8 8

Legend: G Male thread i Thread length Ø d4 Diameter of the sealing collar

SW Spanner width Ø d Stem diameter l2 Active length

Dimensions in mm

3073068.01

3073076.01

Lower mount (LM)

Back mount (BM)

NS

Dimensions in mm b

b1 1)

d 2)

d4

Ø D1

Ø D2

F 1)

G

SW

63 100 160

35 50 50

60 83 83

8 8 8

26 26 26

64 101 161

62 99 159

57 83 113

G½B G½B G½B

27 27 27

Weight in kg

Model A55xx Model R55xx

0.25 0.8 1.1

0.25 0.8 1.1

1) With scale ranges ≥ 0 ... 300 °C the dimensions increase by 40 mm 2) Option: stem Ø 6, 10, 12 mm

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274

3073084.01

Adjustable stem and dial version

NS 100 160

Dimensions in mm

b

25 25

b1

68 68

d 1) 8 8

Ø D1 101 161

Ø D2 99 159

F 68 68

Weight in kg Model S55xx 0.5 0.7

1) Option: stem Ø 6, 10, 12 mm

Thermowell In principle, the operation of a mechanical thermometer without a thermowell with low process-side loading (low pressure, low viscosity and low flow velocities) is possible. However, in order to enable exchanging the thermometer during operation (e.g. instrument replacement or calibration) and to ensure a better protection of the instrument and also the plant and the environment, it is advisable to use a thermowell from the extensive WIKA thermowell portfolio. For further information on the calculation of the thermowell, see Technical information IN 00.15.

WIKA data sheet TM 55.01 ∙ 03/2015

Page 5 of 6

275

CE conformity ATEX directive (option) 94/9/EC, II 2 GD c TX

Approvals (options) ■

■ NEPSI, ignition protection type “ia” - intrinsic safety, China ■

■ EAC, import certificate, ignition protection type “c” -

■

■

constructional safety , customs union Russia/Belarus/ Kazakhstan ■ GOST, metrology/measurement technology, Russia ■ CRN, safety (e.g. electr. safety, overpressure, ...), Canada

Certificates (options) ■

■ 2.2 test report ■

■ 3.1 inspection certificate ■

■ DKD/DAkkS calibration certificate

Approvals and certificates, see website

Ordering information Model / Nominal size / Scale range / Connection size / Connection location / Options

Page 6 of 6

WIKA data sheet TM 55.01 ∙ 03/2015

WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg/Germany Tel. +49 9372 132-0 Fax +49 9372 132-406 [email protected] www.wika.de

276

03/2015 EN

© 2008 WIKA Alexander Wiegand SE & Co. KG, all rights reserved. The specifications given in this document represent the state of engineering at the time of publishing. We reserve the right to make modifications to the specifications and materials.

Operating instructions Betriebsanleitung Mode d'emploi Manual de instrucciones

Bimetal thermometer, models 53, 54, 55 (ATEX)

GB

Bimetall-Thermometer, Typen 53, 54, 55 (ATEX)

D

Thermomètre bimétallique, types 53, 54, 55 (ATEX) F Termómetro bimetálico, modelos 53, 54, 55 (ATEX) E

Model R5502





CE Ex II 2 GD c TX

Model S5413

277

3-18



Page

Seite

F Mode d'emploi types 53, 54, 55 (ATEX)

Page

19-32 33-48



D Betriebsanleitung Typen 53, 54, 55 (ATEX)



GB Operating instructions models 53, 54, 55 (ATEX)



E Manual de instrucciones modelos 53, 54, 55 (ATEX) Página 49-62

© 2010 WIKA Alexander Wiegand SE & Co. KG All rights reserved. / Alle Rechte vorbehalten. WIKA® is a registered trademark in various countries. WIKA® ist eine geschützte Marke in verschiedenen Ländern.

Vor Beginn aller Arbeiten Betriebsanleitung lesen! Zum späteren Gebrauch aufbewahren! Lire le mode d‘emploi avant de commencer toute opération ! A conserver pour une utilisation ultérieure ! ¡Leer el manual de instrucciones antes de comenzar cualquier trabajo! ¡Guardar el manual para una eventual consulta!

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Prior to starting any work, read the operating instructions! Keep for later use!

Contents

Contents

GB

1. General information

4

2. Safety

6

3. Specifications

10

4. Design and function

10

5. Transport, packaging and storage

11

6. Commissioning, operation

12

7. Maintenance and cleaning

14

8. Dismounting, return and disposal

15

Appendix: EC Declaration of Conformity

17

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Declarations of conformity can be found online at www.wika.com.

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3

1. General information 1. General information ■

■ The bimetal thermometers described in the operating instructions

have been designed and manufactured using state-of-the-art technology. All components are subject to stringent quality and environmental criteria during production. Our management systems are certified to ISO 9001 and ISO 14001.

■

■ These operating instructions contain important information on

handling the instrument. Working safely requires that all safety instructions and work instructions are observed.

■

■ Observe the local accident prevention regulations and general

safety regulations, in effect for the instrument's range of use.

■

■ The operating instructions are part of the instrument and must

be kept in the immediate vicinity of the instrument and readily accessible to skilled personnel at any time.

■

■ Skilled personnel must have carefully read and understood the

operating instructions, prior to beginning any work.

■

■ The manufacturers liability is void in the case of any damage

caused by using the product contrary to its intended use, non-compliance with these operating instructions, assignment of insufficiently qualified skilled personnel or unauthorised modifications to the instrument.

■

■ The general terms and conditions contained in the sales

documentation shall apply.

■ Further information:

- Internet address: - Relevant data sheet:

4

www.wika.de / www.wika.com TM 53.01, TM 54.01, TM 55.01

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■

■ Subject to technical modifications. ■

GB

1. General information Explanation of symbols WARNING! ... indicates a potentially dangerous situation that can result in serious injury or death, if not avoided.

GB

CAUTION! ... indicates a potentially dangerous situation that can result in light injuries or damage to equipment or the environment, if not avoided. Information ... points out useful tips, recommendations and information for efficient and trouble-free operation. WARNING! ... indicates a potentially dangerous situation in the hazardous area that can result in serious injury or death, if not avoided.

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WARNING! ... indicates a potentially dangerous situation that can result in burns caused by hot surfaces or liquids, if not avoided.

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5

2. Safety 2. Safety WARNING! Before installation, commissioning and operation, ensure that the appropriate bimetal thermometer has been selected in terms of measuring range, design and specific measuring conditions. The compatibility of the wetted parts of the process connection (thermowell, thermowell stem) with the medium must be tested. Non-observance can result in serious injury and/or damage to equipment.

GB

Further important safety instructions can be found in the individual chapters of these operating instructions. 2.1 Intended use These bimetal thermometers are used for measuring temperature in hazardous areas of industrial applications. The instrument has been designed and built solely for the intended use described here, and may only be used accordingly.

The manufacturer shall not be liable for claims of any type based on operation contrary to the intended use.

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The technical specifications contained in these operating instructions must be observed. Improper handling or operation of the instrument outside of its technical specifications requires the instrument to be taken out of service immediately and inspected by an authorised WIKA service engineer.

2. Safety 2.2 Personnel qualification

■

■

WARNING! Risk of injury should qualification be insufficient! Improper handling can result in considerable injury and damage to equipment. ■ The activities described in these operating instructions may only be carried out by skilled personnel who have the qualifications described below. ■ Keep unqualified personnel away from hazardous areas. Skilled personnel Skilled personnel are understood to be personnel who, based on their technical training, knowledge of measurement and control technology and on their experience and knowledge of country-specific regulations, current standards and directives, are capable of carrying out the work described and of independently recognising potential hazards. 2.3 Additional safety instructions for instruments per ATEX

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WARNING! Non-observance of these instructions and their contents may result in the loss of explosion protection. WARNING! It is imperative that the application conditions and safety requirements of the EC-type examination certificate are followed. Temperature measuring instruments must be earthed via the process connection! Bimetal thermometers contain no internal heat source, and, when correctly installed and operated, cause no increase in temperature!

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7

GB

2. Safety

The following surface temperatures must not be exceeded:

Potentially explosive atmosphere

Permissible surface temperature

Gas, air, vapour, mist

≤ 80 % of the ignition temperature in °C

Dust, air

≤ 2/3 of the minimum ignition temperature in °C 1)  

1) If dust should settle on the instrument (up to a max. 5 mm layer thickness), a safety margin of 75 K must be maintained between the minimum ignition temperature of the dust layer and the surface temperature! For thicker dust layers a greater safety margin should be incorporated!

2.4 Special hazards WARNING! Observe the information given in the applicable type examination certificate and the relevant countryspecific regulations for installation and use in potentially explosive atmospheres (e.g. IEC 60079-14, NEC, CEC). Non-observance can result in serious injury and/or damage to the equipment. For additional important safety instructions for insturments with ATEX approval see chapter 2.3 “Additional safety instructions for instruments per ATEX”. WARNING! Residual media in dismounted instruments can result in a risk to persons, the environment and equipment. Take sufficient precautionary measures.

8

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GB

A heat return flow from the process, which exceeds the ignition temperature of the surrounding hazardous area, is not permitted and must be prevented through appropriate thermal insulation!

2. Safety WARNING! For filled instruments, make sure that the medium temperature is lower than 250 °C. Reason: The sheath also contains a filling liquid; at a temperature > 250 °C, this liquid may become cloudy or change colour or, in some cases, may ignite.

GB

2.5 Labelling, safety marks Product label Model

Year of manufacture

Explanation of symbols

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Before mounting and commissioning the instrument, ensure you read the operating instructions! CE, Communauté Européenne Instruments bearing this mark comply with the relevant European directives. ATEX European Explosion Protection Directive (Atmosphère = AT, explosible = EX) Instruments bearing this mark comply with the requirements of the European Directive 94/9/EC (ATEX) on explosion protection. WIKA operating instructions models 53, 54, 55 (ATEX)

285

9

3. Specifications / 4. Design and function 3. Specifications Model 53

Model 54

Measuring element Nominal size Instrument version ■ Model A5x ■ Model R5x ■ Model S5x Permissible ambient temperature Working pressure ■ Continuous load (1 year) ■ Short term (max. 24 h) Case, ring Stem, process connection Ingress protection

Bimetal coil 3", 5"

63, 80, 100, 160 63, 100, 160

■

■

■

■

Specifications

■

Model 55

Back mount (axial) Lower mount (radial) Back mount, housing can rotate and swivel -20 ... +60 °C max. -50 ... +60 °C Measuring range (EN 13190) Scale range (EN 13190) Stainless steel 1.4301 (304) Stainless steel 1.4571 (316Ti) IP 65 per EN 60529 / IEC 529 IP 66, liquid-filled

For further specifications see WIKA data sheet TM 53.01, TM 54.01 or TM 55.01 and order documentation.

4. Design and function 4.1 Description The bimetal thermometers of this series are intended for installation in pipelines, vessels, plant and machinery. Sheath and case are made of stainless steel. To allow fitting to the process, different installation lengths and process connections are available. Through the high protection class of the thermometer (IP 65) and its liquid damping, operation under vibration conditions is possible.

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4. Design, function / Transport, packaging ... 4.2 Scope of delivery Cross-check scope of delivery with delivery note.

GB

5. Transport, packaging and storage 5.1 Transport Check instrument for any damage that may have been caused by transport. Obvious damage must be reported immediately. 5.2 Packaging Do not remove packaging until just before mounting. Keep the packaging as it will provide optimum protection during transport (e.g. change in installation site, sending for repair). 5.3 Storage Permissible conditions at the place of storage: Storage temperature: -20 ... +60 °C

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■

■

■

Avoid exposure to the following factors: ■ Direct sunlight or proximity to hot objects ■ Mechanical vibration, mechanical shock (putting it down hard) ■ Soot, vapour, dust and corrosive gases Store the instrument in its original packaging in a location that fulfils the conditions listed above. If the original packaging is not available, pack and store the thermometer as described below: 1. Wrap the thermometer in an antistatic plastic film. 2. Place the thermometer, along with shock-absorbent material, in the packaging. 3. If stored for a prolonged period of time (more than 30 days), place a bag, containing a desiccant, inside the packaging.

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11

5. Transport ... / 6. Commissioning, operation WARNING! Before storing the instrument (following operation), remove any residual media. This is of particular importance if the medium is hazardous to health, e.g. caustic, toxic, carcinogenic, radioactive, etc.

GB

The use of liquid damping is always recommended for temperatures near the dew point (±1 °C around 0 °C).

6. Commissioning, operation The bimetal thermometer must be earthed via the process connection! When screwing the instruments in, the force required to do this must not be applied through the casing, but only through the spanner flats provided for this purpose and using a suitable tool.

When mounting a bimetal dial indicating thermometer that can be rotated and swivelled, the specific instructions must be followed. In order to set the indicator to the desired position, the following steps must be taken: 1. The lock nut or union nut must be loosened at the process connection. 2. The hexagon bolts and slotted screws at the swivel joint must be loosened. 12

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Installation with open-ended spanner

6. Commissioning, operation loosening Make sure to loosen the screws GB on the opposite side as well!

3. Position the indicator as required, tighten the hexagon bolts and slotted screws, and finally tighten the lock nut or union nut firmly. Permissible vibration load at the installation site The instruments should always be installed in locations free from vibration. If this is not possible, the following limit values must not be exceeded: Frequency range < 150 Hz Acceleration < 0.5 g (5 m/s2) When using thermowells, they must be filled with a thermal contact medium in order to reduce the heat transfer resistance between the outer wall of the sensor and the inner wall of the thermowell. The working temperature of the thermal compound is -40 ... +200 °C.

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WARNING! Do not fill hot thermowells. There is a risk of the oil spraying out!

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13

6. Commissioning ... / 7. Maintenance and ...

GB

Thermowell Stem

CAUTION! When using thermowells, please ensure that the stem does not touch the bottom of the thermowell since, due to the different expansion coefficients of the materials, the stem may become buckled at the bottom of the thermowell. (Formula for the calculation of the insertion length l1 see the respective thermowell's data sheet)

Required safety clearance

7. Maintenance and cleaning 7.1 Maintenance These bimetal thermometers are maintenance-free! The indicator should be checked once or twice every year. For this the instrument must be disconnected from the process and checked using a temperature calibrator.

7.2 Cleaning CAUTION! ■

■

■ Clean the thermometer with a moist cloth. ■ Wash or clean the thermometer before returning it, in

order to protect personnel and the environment from exposure to residual media.

14

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Repairs must only be carried out by the manufacturer.

7. Maintenance, cleaning / 8. Dismounting ... ■

■ Residual media in the dismounted instrument can result

in a risk to personnel, the environment and equipment. Take sufficient precautionary measures.

For information on returning the instrument see chapter 8.2 “Returns”.

8. Dismounting, return and disposal WARNING! Residual media in the dismounted instrument can result in a risk to persons, the environment and equipment. Take sufficient precautionary measures. 8.1 Dismounting WARNING! Risk of burns! Let the instrument cool down sufficiently before dismounting it! During dismounting there is a risk of dangerously hot pressure media escaping.

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8.2 Returns WARNING! Absolutely observe when shipping the instrument: All instruments delivered to WIKA must be free from any kind of hazardous substances (acids, bases, solutions, etc.). When returning the instrument, use the original packaging or a suitable transport package.

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15

GB

8. Dismounting, return and disposal To avoid damage: 1. Wrap the instrument in an antistatic plastic film. 2. Place the instrument, along with shock-absorbent material, in the packaging. Place shock-absorbent material evenly on all sides of GB the transport packaging. 3. If possible, place a bag, containing a desiccant, inside the packaging. 4. Label the shipment as transport of a highly sensitive measuring instrument. Information on returns can be found under the heading “Service” on our local website. 8.3 Disposal Incorrect disposal can put the environment at risk.

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Dispose of instrument components and packaging materials in an environmentally compatible way and in accordance with the countryspecific waste disposal regulations.

Appendix: EC Declaration of Conformity

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Inhalt

Inhalt 1. Allgemeines

20

2. Sicherheit

22

3. Technische Daten

26

4. Aufbau und Funktion

26

5. Transport, Verpackung und Lagerung

27

6. Inbetriebnahme, Betrieb

28

7. Wartung und Reinigung

30

8. Demontage, Rücksendung und Entsorgung

31

Anlage: EG-Konformitätserklärung

17

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Konformitätserklärungen finden Sie online unter www.wika.de.

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19

D

1. Allgemeines 1. Allgemeines ■

■ Die in der Betriebsanleitung beschriebenen Bimetall-Thermometer

werden nach dem aktuellen Stand der Technik konstruiert und gefertigt. Alle Komponenten unterliegen während der Fertigung strengen Qualitäts- und Umweltkriterien. Unsere Managementsysteme sind nach ISO 9001 und ISO 14001 zertifiziert.

D ■

■ Diese Betriebsanleitung gibt wichtige Hinweise zum Umgang mit

dem Gerät. Voraussetzung für sicheres Arbeiten ist die Einhaltung aller angegebenen Sicherheitshinweise und Handlungsanweisungen.

■

■ Die für den Einsatzbereich des Gerätes geltenden örtlichen Unfall-

verhütungsvorschriften und allgemeinen Sicherheitsbestimmungen einhalten.

■

■ Die Betriebsanleitung ist Produktbestandteil und muss in unmittel-

barer Nähe des Gerätes für das Fachpersonal jederzeit zugänglich aufbewahrt werden.

■

■ Das Fachpersonal muss die Betriebsanleitung vor Beginn aller

Arbeiten sorgfältig durchgelesen und verstanden haben.

■

■ Die Haftung des Herstellers erlischt bei Schäden durch bestim-

mungswidrige Verwendung, Nichtbeachten dieser Betriebsanleitung, Einsatz ungenügend qualifizierten Fachpersonals sowie eigenmächtiger Veränderung am Gerät.

■

■ Es gelten die allgemeinen Geschäftsbedingungen in den Verkaufs-

unterlagen.

■

■ Weitere Informationen:

- Internet-Adresse: - zugehöriges Datenblatt:

20

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■

■ Technische Änderungen vorbehalten.

1. Allgemeines Symbolerklärung WARNUNG! … weist auf eine möglicherweise gefährliche Situation hin, die zum Tod oder zu schweren Verletzungen führen kann, wenn sie nicht gemieden wird. D VORSICHT! … weist auf eine möglicherweise gefährliche Situation hin, die zu geringfügigen oder leichten Verletzungen bzw. Sach- und Umweltschäden führen kann, wenn sie nicht gemieden wird. Information … hebt nützliche Tipps und Empfehlungen sowie Informationen für einen effizienten und störungsfreien Betrieb hervor.

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WARNUNG! … weist auf eine möglicherweise gefährliche Situation im explosionsgefährdeten Bereich hin, die zum Tod oder zu schweren Verletzungen führen kann, wenn sie nicht gemieden wird. WARNUNG! … weist auf eine möglicherweise gefährliche Situation hin, die durch heiße Oberflächen oder Flüssigkeiten zu Verbrennungen führen kann, wenn sie nicht gemieden wird.

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2. Sicherheit 2. Sicherheit WARNUNG! Vor Montage, Inbetriebnahme und Betrieb sicherstellen, dass das richtige Bimetall-Thermometer hinsichtlich Messbereich, Ausführung und spezifischen Messbedingungen ausgewählt wurde. Die Verträglichkeit der messstoffberührten Bauteile des Prozessanschlusses (Schutzrohr, Tauchrohr etc.) muss mit dem Messstoff geprüft werden. Bei Nichtbeachten können schwere Körperverletzungen und/oder Sachschäden auftreten.

D

Weitere wichtige Sicherheitshinweise befinden sich in den einzelnen Kapiteln dieser Betriebsanleitung. 2.1 Bestimmungsgemäße Verwendung Diese Bimetall-Thermometer dienen zum Messen von Temperatur bei industriellen Anwendungen in explosionsgefährdeten Bereichen. Das Gerät ist ausschließlich für den hier beschriebenen bestimmungsgemäßen Verwendungszweck konzipiert und konstruiert und darf nur dementsprechend verwendet werden.

Ansprüche jeglicher Art aufgrund von nicht bestimmungsgemäßer Verwendung sind ausgeschlossen.

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Die technischen Spezifikationen in dieser Betriebsanleitung sind einzuhalten. Eine unsachgemäße Handhabung oder ein Betreiben des Gerätes außerhalb der technischen Spezifikationen macht die sofortige Stilllegung und Überprüfung durch einen autorisierten WIKA-Servicemitarbeiter erforderlich.

2. Sicherheit 2.2 Personalqualifikation

■

■

WARNUNG! Verletzungsgefahr bei unzureichender Qualifikation! Unsachgemäßer Umgang kann zu erheblichen Personenund Sachschäden führen. D ■ Die in dieser Betriebsanleitung beschriebenen Tätigkeiten nur durch Fachpersonal nachfolgend beschriebener Qualifikation durchführen lassen. ■ Unqualifiziertes Personal von den Gefahrenbereichen fernhalten. Fachpersonal Das Fachpersonal ist aufgrund seiner fachlichen Ausbildung, seiner Kenntnisse der Mess- und Regelungstechnik und seiner Erfahrungen sowie Kenntnis der landesspezifischen Vorschriften, geltenden Normen und Richtlinien in der Lage, die beschriebenen Arbeiten auszuführen und mögliche Gefahren selbstständig zu erkennen. 2.3 Zusätzliche Sicherheitshinweise für Geräte nach ATEX

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WARNUNG! Die Nichtbeachtung dieser Inhalte und Anweisungen kann zum Verlust des Explosionsschutzes führen. WARNUNG! Einsatzbedingungen und sicherheitstechnische Daten der EG-Baumusterprüfbescheinigung unbedingt beachten. Temperaturmessgeräte über den Prozessanschluss erden! Bimetall-Thermometer beinhalten keine eigene Wärmequelle und verursachen bei bestimmungsgemäßen Einbau und Betrieb keine Temperaturerhöhung!

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2. Sicherheit Ein Wärmerückfluss aus dem Prozess, welcher die Zündtemperatur der umgebenden explosionsfähigen Atmosphäre überschreitet ist nicht zulässig und muss durch geeignete Wärmeisolierung verhindert werden!

D Folgende Oberflächentemperaturen nicht überschreiten: Explosionsfähige Atmosphäre Gas, Luft, Dampf, Nebel

Staub, Luft

 

≤ 80 % der Zündtemperatur ≤ 2/3 der MindestzündZulässige Oberflächen- in °C temperatur in °C 1) temperatur 1) Bei Staubablagerungen auf dem Gerät (bis max. 5 mm Schichtdicke) ist ein Sicherheitsabstand von 75 K zwischen der Mindestzündtemperatur der Staubschicht und der Oberflächentemperatur einzuhalten! Bei dickeren Staubschichten sind größere Sicherheitsabstände zu berücksichtigen!

2.4 Besondere Gefahren

Weitere wichtige Sicherheitshinweise für Geräte mit ATEXZulassung siehe Kapitel 2.3 „Zusätzliche Sicherheitshinweise für Geräte nach ATEX“. WARNUNG! Messstoffreste im ausgebauten Gerät können zur Gefährdung von Personen, Umwelt und Einrichtung führen. Ausreichende Vorsichtsmaßnahmen ergreifen.

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WARNUNG! Die Angaben der geltenden Baumusterprüfbescheinigung sowie die jeweiligen landesspezifischen Vorschriften zur Installation und Einsatz in explosionsgefährdeten Bereichen (z. B. IEC 60079-14, NEC, CEC) einhalten. Bei Nichtbeachten können schwere Körperverletzungen und/ oder Sachschäden auftreten.

2. Sicherheit

D

 

 

WARNUNG! Bei gefüllten Geräten ist darauf zu achten, dass die Mediumstemperatur unter 250 °C liegt. Grund: Im Tauchschaft befindet sich auch die Füllflüssigkeit, diese kann sich bei einer Temperatur > 250 °C vertrüben bzw. verfärben und gegebenenfalls zum Brand führen. 2.5 Beschilderung, Sicherheitskennzeichnungen Typenschild Typ

Herstellungsjahr

Symbolerklärung

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Vor Montage und Inbetriebnahme des Gerätes unbedingt die Betriebsanleitung lesen! CE, Communauté Européenne Geräte mit dieser Kennzeichnung stimmen überein mit den zutreffenden europäischen Richtlinien. ATEX Europäische Explosionsschutz-Richtlinie (Atmosphère = AT, explosible = EX) Geräte mit dieser Kennzeichnung stimmen überein mit den Anforderungen der europäischen Richtlinie 94/9/EG (ATEX) zum Explosionsschutz. WIKA Betriebsanleitung Typen 53, 54, 55 (ATEX)

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3. Technische Daten / 4. Aufbau, Funktion 3. Technische Daten Messelement Nenngröße Geräteausführung ■ Typ A5x ■ Typ R5x ■ Typ S5x

Bimetallwendel 3", 5" 63, 80, 100, 160

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Typ 53

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Zulässige Umgebungstemperatur Verwendungsbereich ■ Dauerbelastung (1 Jahr) ■ kurzzeitig (max. 24 h) Gehäuse, Ring Tauchschaft, Prozessanschluss Schutzart

Typ 54

Typ 55 63, 100, 160

Anschlusslage rückseitig (axial) Anschlusslage unten (radial) Anschlusslage rückseitig, Gehäuse dreh- und schwenkbar -20 ... +60 °C max. -50 ... +60 °C Messbereich (EN 13190) Anzeigebereich (EN 13190) CrNi-Stahl 1.4301 (304) CrNi-Stahl 1.4571 (316Ti) IP 65 nach EN 60529 / IEC 529 IP 66, flüssigkeitsgefüllt

Weitere technische Daten siehe WIKA-Datenblatt TM 53.01, TM 54.01 oder TM 55.01 und Bestellunterlagen.  

4. Aufbau und Funktion 4.1 Beschreibung Das Bimetall-Thermometer dieser Typenreihen sind vorgesehen zum Einbau in Rohrleitungen, Behälter, Anlagen und Maschinen. Tauchschaft und Gehäuse sind aus CrNi-Stahl gefertigt. Zur optimalen Anpassung an den Prozess sind verschiedene Einbaulängen und Prozessanschlüsse erhältlich. Durch die hohe Schutzart der Thermometer (IP 65) und Flüssigkeitsdämpfung ist der Einsatz bei Vibrationen möglich. 26

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Technische Daten

4. Aufbau, Funktion / 5. Transport, ... 4.2 Lieferumfang Lieferumfang mit dem Lieferschein abgleichen.

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5. Transport, Verpackung und Lagerung 5.1 Transport Gerät auf eventuell vorhandene Transportschäden untersuchen. Offensichtliche Schäden unverzüglich mitteilen. 5.2 Verpackung Verpackung erst unmittelbar vor der Montage entfernen. Die Verpackung aufbewahren, denn diese bietet bei einem Transport einen optimalen Schutz (z. B. wechselnder Einbauort, Reparatursendung). 5.3 Lagerung Zulässige Bedingungen am Lagerort: Lagertemperatur: -20 ... +60 °C

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Folgende Einflüsse vermeiden: ■ Direktes Sonnenlicht oder Nähe zu heißen Gegenständen ■ Mechanische Vibration, mechanischer Schock (hartes Aufstellen) ■ Ruß, Dampf, Staub und korrosive Gase Das Gerät in der Originalverpackung an einem Ort, der die oben gelisteten Bedingungen erfüllt, lagern. Wenn die Originalverpackung nicht vorhanden ist, dann das Thermometer wie folgt verpacken und lagern: 1. Das Gerät in eine antistatische Plastikfolie einhüllen. 2. Das Gerät mit dem Dämmmaterial in der Verpackung platzieren. 3. Bei längerer Einlagerung (mehr als 30 Tage) einen Beutel mit Trocknungsmittel der Verpackung beilegen.

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5. Transport ... / 6. Inbetriebnahme, Betrieb WARNUNG! Vor der Einlagerung des Gerätes (nach Betrieb) alle anhaftenden Messstoffreste entfernen. Dies ist besonders wichtig, wenn der Messstoff gesundheitsgefährdend ist, wie z. B. ätzend, giftig, krebserregend, radioaktiv, usw.

D

Empfohlen wird bei Temperaturen um den Taupunkt (±1 °C um 0 °C) immer die Verwendung einer Flüssigkeitsdämpfung.

6. Inbetriebnahme, Betrieb Das Bimetall-Thermometer über den Prozessanschluss erden! Beim Einschrauben der Geräte darf die dazu erforderliche Kraft nicht über das Gehäuse aufgebracht werden, sondern mit geeignetem Werkzeug nur über die dafür vorgesehenen Schlüsselflächen.

Bei der Montage eines dreh- und schwenkbaren Bimetall-Zeigerthermometers sind besondere Vorschriften zu beachten. Um die Anzeige in die gewünschte Position zu bringen, müssen folgende Schritte eingehalten werden: 1. Die Konter- oder Überwurfmutter muss am Prozessanschluss gelöst sein. 2. Sechskant- und Schlitzschrauben müssen am Schwenkgelenk gelöst sein. 28

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Montage mit Gabelschlüssel

6. Inbetriebnahme, Betrieb lösen Unbedingt auch die auf der gegenüberliegenden Seite liegenden Schrauben lösen!

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3. Anzeige positionieren, Sechskant- und Schlitzschrauben anziehen und schließlich die Konter- oder Überwurfmutter fest anziehen. Zulässige Schwingungsbelastung am Einbauort Die Geräte sollten grundsätzlich nur an Stellen ohne Schwingungsbelastung eingebaut werden. Falls dies nicht möglich ist, dürfen folgende Grenzwerte nicht überschritten werden: Frequenzbereich < 150 Hz Beschleunigung < 0,5 g (5 m/s2)

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Bei Verwendung von Schutzrohren ist möglichst durch Einfüllen eines Wärmekontaktmittels der Wärmeübertragungswiderstand zwischen Fühleraußenwand und Schutzrohrinnenwand zu reduzieren. Die Arbeitstemperatur der Wärmeleitpaste beträgt -40 ... +200 °C. WARNUNG! Nicht in heiße Schutzrohre einfüllen. Gefahr durch herausspritzendes Öl!

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6. Inbetriebnahme, Betrieb / 7. Wartung ...

D Schutzrohr Tauchschaft

VORSICHT! Bei der Verwendung von Schutzrohren beachten, dass der Tauchschaft nicht den Boden des Schutzrohres berührt, da durch die unterschiedlichen Ausdehnungskoeffizienten der Materialen sich der Tauchschaft am Boden des Schutzrohres verbiegen könnte. (Formeln zur Berechnung der Einbaulänge l1 siehe entsprechendes Schutzrohr-Datenblatt)

Benötigter Sicherheitsabstand

7. Wartung und Reinigung 7.1 Wartung Diese Bimetall-Thermometer sind wartungsfrei! Eine Überprüfung der Anzeige sollte etwa 1- bis 2-mal pro Jahr erfolgen. Dazu ist das Gerät vom Prozess zu trennen und mit einem Temperaturkalibrator zu kontrollieren.

7.2 Reinigung VORSICHT! ■

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■ Das Thermometer mit einem feuchten Tuch reinigen. ■ Ausgebautes Thermometer vor der Rücksendung

spülen bzw. säubern, um Personen und Umwelt vor Gefährdung durch anhaftende Messstoffreste zu schützen.

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Reparaturen sind ausschließlich vom Hersteller durchzuführen.

7. Wartung und Reinigung / 8. Demontage, ... ■

■ Messstoffreste im ausgebauten Gerät können zur

Gefährdung von Personen, Umwelt und Einrichtung führen. Ausreichende Vorsichtsmaßnahmen ergreifen.

Hinweise zur Rücksendung des Gerätes siehe Kapitel 8.2 „Rücksendung“.

8. Demontage, Rücksendung und Entsorgung WARNUNG! Messstoffreste im ausgebauten Gerät können zur Gefährdung von Personen, Umwelt und Einrichtung führen. Ausreichende Vorsichtsmaßnahmen ergreifen. 8.1 Demontage WARNUNG! Verbrennungsgefahr! Vor dem Ausbau das Gerät ausreichend abkühlen lassen! Beim Ausbau besteht Gefahr durch austretende, gefährlich heiße Messstoffe.

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8.2 Rücksendung WARNUNG! Beim Versand des Gerätes unbedingt beachten: Alle an WIKA gelieferten Geräte müssen frei von Gefahrstoffen (Säuren, Laugen, Lösungen, etc.) sein. Zur Rücksendung des Gerätes die Originalverpackung oder eine geeignete Transportverpackung verwenden.

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8. Demontage, Rücksendung und Entsorgung Um Schäden zu vermeiden: 1. Das Gerät in eine antistatische Plastikfolie einhüllen. 2. Das Gerät mit dem Dämmmaterial in der Verpackung platzieren. Zu allen Seiten der Transportverpackung gleichmäßig dämmen. 3. Wenn möglich einen Beutel mit Trocknungsmittel der Verpackung beifügen. D 4. Sendung als Transport eines hochempfindlichen Messgerätes kennzeichnen. Hinweise zur Rücksendung befinden sich in der Rubrik „Service“ auf unserer lokalen Internetseite. 8.3 Entsorgung Durch falsche Entsorgung können Gefahren für die Umwelt entstehen.

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Gerätekomponenten und Verpackungsmaterialien entsprechend den landesspezifischen Abfallbehandlungs- und Entsorgungsvorschriften umweltgerecht entsorgen.

Sommaire

Sommaire 1. Généralités

34

2. Sécurité

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3. Caractéristiques techniques

40

4. Conception et fonction

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5. Transport, emballage et stockage

41

6. Mise en service, exploitation

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7. Entretien et nettoyage

44

8. Démontage, retour et mise au rebut

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Annexe : Déclaration de conformité CE

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Déclarations de conformité se trouve sur www.wika.fr.

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1. Généralités 1. Généralités ■

■ Le thermomètre bimétallique décrit dans le mode d'emploi est

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■ Ce mode d'emploi donne des indications importantes concernant

l'utilisation de l'instrument. Il est possible de travailler en toute sécurité avec ce produit en respectant toutes les consignes de sécurité et d'utilisation.

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■ Respecter les prescriptions locales de prévention contre les

accidents et les prescriptions générales de sécurité en vigueur pour le domaine d'application de l'instrument.

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■ Le mode d'emploi fait partie de l'instrument et doit être conservé à

proximité immédiate de l'instrument et accessible à tout moment pour le personnel qualifié.

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■ Le personnel qualifié doit, avant de commencer toute opération,

avoir lu soigneusement et compris le mode d'emploi.

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■ La responsabilité du fabricant n'est pas engagée en cas de

dommages provoqués par une utilisation non conforme à l'usage prévu, de non respect de ce mode d'emploi, d'utilisation de personnel peu qualifié de même qu'en cas de modifications de l'instrument effectuées par l'utilisateur.

■

■ Les conditions générales de vente mentionnées dans les

■

■ Sous réserve de modifications techniques. ■ Pour obtenir dautres informations :

- Consulter notre site internet : www.wika.fr - Fiche technique correspondante : TM 53.01, TM 54.01, TM 55.01

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documents de vente s'appliquent.

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conçu et fabriqué selon les dernières technologies en vigueur. Tous les composants sont soumis à des critères de qualité et d'environnement stricts durant la fabrication. Nos systèmes de gestion sont certifiés selon ISO 9001 et ISO 14001.

1. Généralités Explication des symboles AVERTISSEMENT ! … indique une situation présentant des risques susceptibles de provoquer la mort ou des blessures graves si elle n'est pas évitée. ATTENTION ! … indique une situation potentiellement dangereuse et susceptible de provoquer de légères blessures ou des dommages matériels et pour l'environnement si elle n'est pas évitée. Information … met en exergue les conseils et recommandations utiles de même que les informations permettant d'assurer un fonctionnement efficace et normal. AVERTISSEMENT ! … indique une situation en zone explosive présentant des risques susceptibles de provoquer la mort ou des blessures graves si elle n'est pas évitée.

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AVERTISSEMENT ! … indique une situation présentant des risques susceptibles de provoquer des brûlures dues à des surfaces ou liquides chauds si elle n'est pas évitée.

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2. Sécurité 2. Sécurité AVERTISSEMENT ! Avant le montage, la mise en service et le fonctionnement, s'assurer que le thermomètre bimétallique a été choisi de façon adéquate, en ce qui concerne la plage de mesure, la version et les conditions de mesure spécifiques. Vérifier si les composants du raccord process en contact avec le fluide (doigt de gant, tube plongeur) sont compatibles avec le fluide de mesure. Un non-respect de cette consigne peut entraîner des blessures corporelles graves et/ou des dégâts matériels.

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Vous trouverez d'autres consignes de sécurité dans les sections individuelles du présent mode d'emploi. 2.1 Utilisation conforme à l'usage prévu Ces thermomètres bimétalliques sont utilisés pour la mesure de la température dans les zones dangereuses des applications industrielles.

Les spécifications techniques mentionnées dans ce mode d'emploi doivent être respectées. En cas d'utilisation inadéquate ou de fonctionnement de l'instrument en dehors des spécifications techniques, un arrêt et contrôle doivent être immédiatement effectués par un collaborateur autorisé du service de WIKA. Aucune réclamation ne peut être recevable en cas d'utilisation non conforme à l'usage prévu.

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L'instrument est conçu et construit exclusivement pour une utilisation conforme à l'usage prévu décrit ici et ne doit être utilisé qu'en conséquence.

2. Sécurité 2.2 Qualification du personnel

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AVERTISSEMENT ! Danger de blessure en cas de qualification insuffisante ! Une utilisation non conforme peut entraîner d'importants dommages corporels et matériels. ■ Les opérations décrites dans ce mode d'emploi ne doivent être effectuées que par un personnel ayant la qualification décrite ci-après. ■ Tenir le personnel non qualifié à l'écart des zones dangereuses. Personnel qualifié Le personnel qualifié est, en raison de sa formation spécialisée, de ses connaissances dans le domaine de la technique de mesure et de régulation et de ses expériences de même que de sa connaissance des prescriptions nationales des normes et directives en vigueur, en mesure d'effectuer les travaux décrits et de reconnaître automatiquement les dangers potentiels. 2.3 Consignes de sécurité complémentaires pour les instruments selon ATEX

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AVERTISSEMENT ! Le non respect de ces instructions et de leurs contenus peut entraîner une perte de la protection contre les explosions. AVERTISSEMENT ! Les consignes de sécurité de l'attestation d'examen de type et les conditions d'application doivent impérativement être respectées. Les thermomètres doivent être mis à la terre par le raccord process ! WIKA mode d'emploi types 53, 54, 55 (ATEX)

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2. Sécurité Puisque les thermomètres bimétalliques ne disposent pas d'une source de chaleur interne, les instruments montés ne peuvent pas causer une augmentation de température ! Un retour de la chaleur du processus dépassant la température d'inflammation de l'environnement présentant des risques d'explosion n'est pas permis et doit être évité par l'intermédiaire d'une isolation F thermique appropriée ! Les températures de surface suivantes ne doivent pas être dépassées :

Atmosphère présentant un risque d'explosion

Température ≤ 80 % de la température de surface d'inflammation en °C admissible

Poussière, air

≤ 2/3 de la température minimum d'inflammation en °C 1)  

Gaz, air, vapeur, brouillard

1) Lorsqu'il y a risque de formation d'une couche de poussière au-dessus de l'instrument (jusqu'à une épaisseur de max. 5 mm), une différence de température de 75 K entre la température d'inflammation de la couche de poussière et la température de surface doit être observée ! Pour les couches de poussière plus épaisses, respecter une différence plus élevée !

 

AVERTISSEMENT ! Respecter les indications de l'attestation d'examen de type valable de même que les prescriptions nationales respectives concernant l'installation et l'utilisation en zone explosive (par exemple CEI 60079-14, NEC, CEC). Un non-respect de cette consigne peut entraîner des blessures corporelles graves et/ou des dégâts matériels. Autres consignes de sécurité importantes pour les instruments avec homologation ATEX, voir chapitre 2.3 "Consignes de sécurité complémentaires pour les instruments selon ATEX". 38

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2.4 Dangers particuliers

2. Sécurité AVERTISSEMENT ! Les restes de fluides se trouvant dans des instruments démontés peuvent mettre en danger les personnes, l'environnement ainsi que l'installation. Prendre des mesures de sécurité suffisantes. AVERTISSEMENT ! Pour les instruments remplis de liquide, veiller à ce que la température du fluide de mesure ne dépasse pas 250 °C. Raison: Le liquide se trouvant dans le tube plongeur peut se troubler ou changer de couleur ou même s‘enflammer si la température dépasse 250 °C. 2.5 Etiquetage, marquages de sécurité Plaque signalétique Type

Année de fabrication

Explication des symboles

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Avant de monter et mettre l'instrument en service, lire impérativement le mode d'emploi ! CE, Communauté Européenne Les instruments avec ce marquage sont conformes aux directives européennes pertinentes. ATEX Directive européenne sur les instruments destinés à être utilisés en atmosphère explosible (Atmosphère = AT, explosible = EX) Les instruments avec ce marquage sont conformes aux exigences de la directive européenne 94/9/CE (ATEX) sur la protection contre les explosions. WIKA mode d'emploi types 53, 54, 55 (ATEX)

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3. Caractéristiques techniques / 4. Conception ... 3. Caractéristiques techniques Caractéristiques techniques Type 53

■ ■ ■

■ Type S5x

Température ambiante admissible Pression de service ■ Fonctionnement continu (1 an) ■ temporaire (max. 24 h) Boîtier, anneau Tube plongeur, raccord process Indice de protection ■

Type 55

Hélice bimétallique 3", 5" 63, 80, 100, 160

Elément de mesure Diamètre Version de l'instrument ■ Type A5x ■ Type R5x

■

63, 100, 160

Situation de branchement en arrière (axial) Situation de branchement en bas (radial) Situation de branchement en arrière (axial), boîtier pivotant et orientable -20 ... +60 °C max. -50 ... +60 °C Étendue de mesure (EN 13190) Echelle de mesure (EN 13190) Acier inox 1.4301 (304) Acier inox 1.4571 (316Ti) IP 65 selon EN 60529 / IEC 529 IP 66, rempli de liquide

Pour les autres caractéristiques techniques, voir fiche technique WIKA TM 53.01, TM 54.01 ou TM 55.01 et les documents de commande.

4. Conception et fonction 4.1 Description Les thermomètres bimétalliques de cette série sont conçus pour l'installation dans des conduites, réservoirs, systèmes ou machines. Le tube plongeur et le boîtier sont en acier inox. Pour l'adaptation optimale au processus, des tubes de différentes longueurs de montage et raccords process sont disponibles. Grâce à l'indice de protection élevée des thermomètres (IP 65) et à l'amortissement par liquide, ils peuvent être utilisés dans des zones de vibrations. 40

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Type 54

4. Conception et fonction / 5. Transport, ... 4.2 Détail de la livraison Comparer le détail de la livraison avec le bordereau de livraison.

5. Transport, emballage et stockage F

5.1 Transport Vérifier s'il existe des dégâts sur l'instrument liés au transport. Communiquer immédiatement les dégâts constatés. 5.2 Emballage N'enlever l'emballage qu'avant le montage. Conserver l'emballage, celui-ci offre, lors d'un transport, une protection optimale (par ex. changement de lieu d'utilisation, renvoi pour réparation). 5.3 Stockage Conditions admissibles sur le lieu de stockage : Température de stockage : -20 ... +60 °C

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Eviter les influences suivantes : ■ Lumière solaire directe ou proximité d'objets chauds ■ Vibrations mécaniques, chocs mécaniques (mouvements brusques en le posant) ■ Suie, vapeur, poussière et gaz corrosifs Conserver l'instrument dans l'emballage original dans un endroit qui satisfait aux conditions susmentionnées. Si l'emballage original n'est pas disponible, emballer et stocker le thermomètre comme suit : 1. Emballer le thermomètre dans une feuille de plastique antistatique. 2. Placer le thermomètre avec le matériau isolant dans l'emballage. 3. En cas d'entreposage long (plus de 30 jours), mettre également un sachet absorbeur d'humidité dans l'emballage.

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5. Transport, emballage, stockage / 6. Mise ... AVERTISSEMENT ! Enlever tous les restes de fluides adhérents avant l'entreposage de l'appareil (après le fonctionnement). Ceci est particulièrement important lorsque le fluide représente un danger pour la santé, comme p. ex. des substances corrosives, toxiques, carcinogènes, radioactives etc. Lorsque le thermomètre est utilisé dans une plage de températures près du point de rosée (±1 °C, près de 0 °C), l'utilisation d'un amortissement par liquide est recommandée.

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6. Mise en service, exploitation  

Le thermomètre bimétallique doit être mis à la terre par le raccord process ! Lors du vissage des instruments, le couple de serrage ne doit pas être appliqué sur le boîtier mais seulement sur les surfaces prévues et ce avec un outil approprié.

Lors du montage d'un thermomètre bimétallique à cadran pivotant et orientable, des prescriptions particulières doivent être observées. Pour placer l'affichage dans la position requise, il convient de respecter les points suivants : 1. Le contre-écrou ou l'écrou-raccord doit être desserré sur le raccord process. 2. Les boulons et vis doivent être desserrées sur l'articulation pivotante. 42

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Montage avec clé à fourche

6. Mise en service, exploitation desserrer

 

Desserrer impérativement également les vis situées sur le côté opposé !

3. Positionner l'affichage, serrer les boulons et les vis. Pour finir, serrer le contre-écrou ou l'écrou-raccord à fond. Contrainte de vibration admissible sur le point de montage L'instrument ne doit être installé que dans des endroits exempts de vibrations. Lorsque cela n'est pas possible, veiller à ce que les valeurs limites suivantes ne soient pas dépassées : Plage de fréquence < 150 Hz Accélération < 0,5 g (5 m/s2)

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En cas d'utilisation de doigts de gants, il convient de réduire au maximum la résistance de transmission de la chaleur entre la paroi extérieure du capteur et la paroi intérieure du doigt de gant en ajoutant un agent de contact thermique. La température de service de la pâte thermique est de -40 ... +200 °C. AVERTISSEMENT ! Ne pas verser dans des doigts de gant chauds ! Risque de projection d'huile !

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6. Mise en service, exploitation

F Doigt de gant Tube plongeur Ecart de sécurité requis

ATTENTION ! Lors de l'utilisation des doigts de gants, veiller à ce que le tube plongeur ne touche pas le fond du doigt de gant, en raison des différents coefficients d'extension des matériaux, il y a risque de déformation du tube plongeur sur le fond du doigt de gant. (Formules pour le calcul de la longueur utile l1 voir la fiche technique du doigt de gant correspondant)

7. Entretien et nettoyage 7.1 Entretien Ces thermomètres bimétalliques ne nécessitent pas d‘entretien ! Un contrôle de l'affichage et des fonctions de commande est recommandé 1 à 2 fois/an. Pour le contrôle de l'affichage et des fonctions de commande, il faut isoler l'appareil du process et le contrôler avec un calibrateur de température.

7.2 Nettoyage ATTENTION ! ■

■

■ Nettoyer le thermomètre avec un chiffon humide. ■ Laver ou nettoyer le thermomètre démonté avant de

le retourner afin de protéger les collaborateurs et l'environnement contre le danger lié aux restes de fluides adhérents.

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Les réparations ne doivent être effectuées que par le fabricant.

7. Entretien et nettoyage / 8. Démontage, ... ■

■ Les restes de fluides se trouvant dans des appareils

démontés peuvent mettre en danger les personnes, l'environnement ainsi que l'installation. Prendre des mesures de sécurité suffisantes.

Indications concernant le retour de l'appareil, voir chapitre 8.2 "Retour".

8. Démontage, retour et mise au rebut AVERTISSEMENT ! Les restes de fluides se trouvant dans des instruments démontés peuvent mettre en danger les personnes, l'environnement ainsi que l'installation. Prendre des mesures de sécurité suffisantes. 8.1 Demontage

AVERTISSEMENT ! Danger de brûlure ! Avant le démontage du thermomètre, laisser refroidir suffisamment l'appareil ! Danger de brûlure lié à la sortie de fluides dangereux chauds.

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8.2 Retour

AVERTISSEMENT ! En cas d'envoi de l'appareil, il faut respecter impérativement ceci : Tous les appareils livrés à WIKA doivent être exempts de toutes substances dangereuses (acides, solutions alcalines, solutions, etc.).

Pour retourner l'instrument, utiliser l'emballage original ou un emballage adapté pour le transport. WIKA mode d'emploi types 53, 54, 55 (ATEX)

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8. Démontage, retour et mise au rebut Pour éviter des dommages : 1. Emballer l'instrument dans une feuille de plastique antistatique. 2. Placer l'instrument avec le matériau isolant dans l'emballage. Isoler de manière uniforme tous les côtés de l'emballage de transport. 3. Mettre si possible un sachet absorbeur d'humidité dans l'emballage. 4. Indiquer lors de l'envoi qu'il s'agit d'un instrument de mesure très sensible à transporter. F Des informations relatives à la procédure de retour de produit(s) défectueux sont disponibles sur notre site internet au chapitre “Services”. 8.3 Mise au rebut Une mise au rebut inadéquate peut entraîner des dangers pour l'environnement.

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Eliminer les composants des appareils et les matériaux d'emballage conformément aux prescriptions nationales pour le traitement et l'élimination des déchets et aux lois de protection de l'environnement en vigueur.

Annexe : Déclaration de conformité CE

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Contenido

Contenido 1. Información general

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2. Seguridad

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3. Datos técnicos

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4. Diseño y función

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5. Transporte, embalaje y almacenamiento

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6. Puesta en servicio, funcionamiento

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7. Mantenimiento y limpieza

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8. Desmontaje, devolución y eliminación

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Anexo: Declaración de conformidad CE

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Declaraciones de conformidad puede encontrar en www.wika.es.

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1. Información general 1. Información general ■

■ Los termómetros bimetálicos descritos en el manual de

instrucciones están construidos y fabricados según los conocimientos actuales. Todos los componentes están sujetos a criterios rígidos de calidad y medio ambiente durante la producción. Nuestros sistemas de gestión están certificados según ISO 9001 e ISO 14001.

■

■ Este manual de instrucciones proporciona indicaciones

importantes acerca del manejo del instrumento. Para un trabajo seguro, es imprescindible cumplir con todas las instrucciones de seguridad y manejo indicadas.

■

■ Cumplir normativas sobre la prevención de accidentes y las

normas de seguridad en vigor en el lugar de utilización del instrumento.

■

■ El manual de instrucciones es una parte integrante del instrumento

y debe guardarse en la proximidad del mismo para que el personal especializado pueda consultarlo en cualquier momento.

■

■ El personal especializado debe haber leído y entendido el manual

de instrucciones antes de comenzar cualquier trabajo.

■

■ El fabricante queda exento de cualquier responsabilidad en caso

de daños causados por un uso no conforme a la finalidad prevista, la inobservancia del presente manual de instrucciones, un manejo por personal insuficientemente cualificado así como una modificación no autorizada del instrumento. documentación de venta.

■

■ Modificaciones técnicas reservadas. ■ Para obtener más informaciones consultar:

- Página web: www.wika.es - Hoja técnica correspondiente: TM 53.01, TM 54.01, TM 55.01

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■

■ Se aplican las condiciones generales de venta incluidas en la

■

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1. Información general Explicación de símbolos ¡ADVERTENCIA! ... indica una situación probablemente peligrosa que pueda causar la muerte o lesiones graves si no se evita. ¡CUIDADO! ... indica una situación probablemente peligrosa que pueda causar lesiones leves o medianas o daños materiales y medioambientales si no se evita.

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Información ... destaca consejos y recomendaciones útiles así como informaciones para una utilización eficaz y libre de fallos. ¡ADVERTENCIA! ... indica una situación probablemente peligrosa en una atmósfera potencialmente explosiva que causa la muerte o lesiones graves si no se evita.

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¡ADVERTENCIA! ... indica una situación probablemente peligrosa que pueda causar quemaduras debido a superficies o líquidos calientes, si no se evita.

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2. Seguridad 2. Seguridad ¡ADVERTENCIA! Antes de proceder con el montaje, la puesta en servicio y el funcionamiento asegurarse de que se haya seleccionado el termómetro bimetálico adecuado en relación con rango de medida, versión y condiciones de medición específicas. Hay que controlar si los componentes en contacto con el fluido de la conexión a proceso (vaina, bulbo, etc.) son compatibles con el fluido. El no respetar las instrucciones puede generar lesiones graves y/o daños materiales.

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Los distintos capítulos de este manual de instrucciones contienen otras importantes indicaciones de seguridad. 2.1 Uso conforme a lo previsto Esos termómetros bimetálicos sirven para medir la temperatura en aplicaciones industriales en atmósferas potencialmente explosivas. El instrumento ha sido diseñado y construido únicamente para la finalidad aquí descrita y debe utilizarse en conformidad a la misma.

No se admite ninguna reclamación debido a un manejo no adecuado.

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Cumplir las especificaciones técnicas de este manual de instrucciones. Un manejo no apropiado o una utilización del instrumento no conforme a las especificaciones técnicas requiere la inmediata puesta fuera de servicio y la comprobación por parte de un técnico autorizado por WIKA.

2. Seguridad 2.2 Cualificación del personal

■

¡ADVERTENCIA! ¡Riesgo de lesiones debido a una insuficiente cualificación! Un manejo no adecuado puede causar considerables daños personales y materiales. ■ Las actividades descritas en este manual de instrucciones deben realizarse únicamente por personal especializado con la consiguiente cualificación. ■ Mantener alejado a personal no cualificado de las zonas peligrosas. ■

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Personal especializado Debido a su formación profesional, a sus conocimientos de la técnica de regulación y medición así como a su experiencia y su conocimiento de las normativas, normas y directivas vigentes en el país de utilización el personal especializado es capaz de ejecutar los trabajos descritos y reconocer posibles peligros por sí solo. 2.3 Instrucciones de seguridad adicionales para instrumentos según ATEX

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¡ADVERTENCIA! La inobservancia del contenido y de las instrucciones puede originar la pérdida de la protección contra explosiones. ¡ADVERTENCIA! Es imprescindible observar las condiciones de uso y los datos de seguridad del certificado CE de tipo. ¡Poner a tierra los instrumentos de medición a través de la conexión al proceso! Los termómetros bimetálicos no tienen fuente de calor propia y no causan un aumento de temperatura si están instalados y utilizados según la finalidad prevista!

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2. Seguridad No está permitido un reflujo térmico proveniente del proceso que supere la temperatura de encendido de la atmósfera potencialmente explosiva y debe ser impedido mediante un aislamiento térmico adecuado! No sobrepasar las temperaturas superficiales siguientes:

Atmósfera potencialmente explosiva

Temperatura ≤ 80 % de la temperatura superficial de encendido en °C permitida  

≤ 2/3 de la temperatura de encendido mínima en °C 1)

1) Si hay depósitos de polvo en el instrumento (espesor de 5 mm como máximo) hay que mantener una distancia de seguridad de 75 K entre la temperatura mínima de encendido de la capa de polvo y la temperatura superficial! Si las capas de polvo son más espesas, hay que mantener distancias de seguridad mayores!

2.4 Riesgos específicos ¡ADVERTENCIA! Cumplir las indicaciones del certificado de tipo así como las normativas vigentes en el país de utilización acerca de la instalación y el uso en atmósferas potencialmente explosivas (p. ej. IEC 60079-14, NEC, CEC). Riesgo de lesiones graves y/o daños materiales en caso de inobservancia. Consultar el capítulo 2.3 "Instrucciones de seguridad adicionales para instrumentos según ATEX" para más instrucciones de seguridad importantes para instrumentos con certificación ATEX. ¡ADVERTENCIA! Restos de medios en instrumentos desmontados pueden causar riesgos para personas, medio ambiente e instalación. Tomar adecuadas medidas de precaución. 54

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Polvo, aire

 

Gas, aire, vapor, niebla

2. Seguridad ¡ADVERTENCIA! Hay que asegurarse que los instrumentos llenados no deben ser expuestos a una temperatura del medio superior a 250 °C. Causa: En el bulbo se encuentra el líquido de relleno que puede enturbiarse o cambiar de color y con una temperatura > de 250 °C puede provocar eventualmente un incendio.

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2.5 Rótulos, marcados de seguridad Placa indicadora de modelo Modelo

Año de fabricación

Explicación de símbolos

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¡Es absolutamente necesario leer el manual de instrucciones antes del montaje y la puesta en servicio del instrumento! CE, Communauté Européenne Los instrumentos con este marcaje cumplen las directivas europeas aplicables. ATEX Directiva europea para garantizar la seguridad frente a las explosiones (Atmosphère = AT, explosible = EX) Los instrumentos con este marcaje están conformes a las exigencias de la directiva europea 94/9/CE (ATEX) relativa a la prevención de explosiones.

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3. Datos técnicos / 4. Diseño y función 3. Datos técnicos Modelo 53 Modelo 54

Modelo 55

Elemento de medición Diámetro nominal Construcción del aparato ■ Modelo A5x ■ Modelo R5x ■ Modelo S5x Temperatura ambiente admisible Rango de servicio ■ Carga a largo plazo (1 año) ■ a corto plazo (máx. 24 h) Caja, anillo Bulbo, conexión a proceso Tipo de protección

Espiral bimetálico 3", 5" 63, 80, 100, 160

63, 100, 160

■

Conexión dorsal (axial) Conexión inferior (radial) Conexión dorsal, caja giratoria y orientable en la caja +60 °C máx. (otras a petición) Rango de medida (EN 13190) Rango de indicación (EN 13190) Acero inoxidable 1.4301 (304) Acero inoxidable 1.4571 (316Ti) IP 65 según EN 60529 / IEC 529 IP 66, lleno de líquido

Para más datos técnicos véase las hojas técnicas TM 53.01, TM 54.01 o TM 55.01 y la documentación de pedido.  

4. Diseño y función 4.1 Descripción El termómetro bimetálico de esta serie es adecuado para el uso en tubería, depósitos, instalaciones y máquinas. El bulbo y la caja son de acero inoxidable. Para optimizar la adaptación al proceso disponemos de varias longitudes y conexiones a proceso. La protección IP 65 y el líquido de relleno permiten el uso también en aplicaciones con vibraciones.

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■

■

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■

Datos técnicos

4. Diseño y función / 5. Transporte, embalaje ... 4.2 Volumen de suministro Comprobar mediante el albarán si se ha entregado la totalidad de las piezas.

5. Transporte, embalaje y almacenamiento 5.1 Transporte Comprobar si el instrumento presenta eventuales daños causados en E el transporte. Notificar de inmediato cualquier daño evidente. 5.2 Embalaje No quitar el embalaje hasta justo antes del montaje. Guardar el embalaje ya que es la protección ideal para el transporte (por ejemplo un cambio del lugar de instalación o un envío del instrumento para posibles reparaciones). 5.3 Almacenamiento Condiciones admisibles en el lugar de almacenamiento: Temperatura de almacenamiento: -20 ... +60 °C

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■

■

■

Evitar lo siguiente: ■ Luz solar directa o proximidad a objetos calientes ■ Vibración mecánica, impacto mecánico (apoyarlo de golpe) ■ Hollín, vapor, polvo y gases corrosivos Almacenar el instrumento en su embalaje original en un lugar que cumple las condiciones arriba mencionadas. Si no se dispone del embalaje original, empaquetar y almacenar el termómetro como sigue: 1. Envolver el termómetro en un film de plástico antiestático. 2. Colocar el termómetro junto con el material aislante en el embalaje. 3. Para un almacenamiento prolongado (más de 30 días) colocar una bolsa con un desecante en el embalaje.

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5. Transporte, embalaje ... / 6. Puesta en ... ¡ADVERTENCIA! Antes de almacenar el instrumento (después del funcionamiento), eliminar todos los restos de medios adherentes. Esto es especialmente importante cuando el medio es nocivo para la salud, como p. ej. cáustico, tóxico, cancerígeno, radioactivo, etc. Con temperaturas alrededor del punto de condensación (±1 °C alrededor de 0 °C) se recomienda siempre el relleno de líquido.

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6. Puesta en servicio, funcionamiento ¡Poner a tierra el termómetro bimetálico través de la conexión al proceso! Para atornillar el aparato, se debe utilizar la fuerza mediante el uso de herramientas adecuadas sobre las superficies planas de ajuste -previstas para este fin-.

Para la instalación de un termómetro bimetálico, de caja giratoria y orientable, hay que seguir instrucciones específicas. Para posicionar el indicador de forma deseada es imprescindible observar los siguientes pasos: 1. Soltar la contratuerca o la tuerca de unión en el racor de proceso. 2. Soltar tornillos hexagonales y de ranura en la articulación virable. 58

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Montaje mediante llave de boca

6. Puesta en servicio, funcionamiento soltar ¡Asegurarse de soltar también los tornillos del lado opuesto!

3. Posicionar el indicador, apretar los tornillos hexagonales y de ranura y finalmente apretar firmemente la contratuerca o la tuerca de unión. Oscilación admisible en el lugar de instalación Instalar los instrumentos sólo en lugares sin carga vibrante. Si esto no es posible, no se debe sobrepasar en ningun caso los siguientes valores límites: Rango de frecuencias < 150 Hz Aceleración < 0,5 g (5 m/s2)

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Si se utilizan vainas, reducir la resistencia de transferencia de calor entre la pared exterior del sensor y la pared interior de la vaina llenando la vaina con un agente de contacto. La temperatura de trabajo de la pasta térmica está entre -40 ... +200 °C. ¡ADVERTENCIA! No llenar en vainas calientes. ¡Peligro debido a aceite que sale!

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6. Puesta en servicio, ... / 7. Mantenimiento ...

Vaina Bulbo

Distancia de seguridad necesaria

7. Mantenimiento y limpieza 7.1 Mantenimiento ¡Los termómetros bimetálicos no necesitan mantenimiento! Controlar el instrumento y la función de conmutación una o dos veces al año. Para eso, separar el instrumento del proceso y controlarlo con un dispositivo de calibración de temperatura.

7.2 Limpieza ¡CUIDADO! ■

■ Limpiar el termómetro con un trapo húmedo. ■ Lavar o limpiar el termómetro desmontado antes de

devolverlo para proteger a los empleados y el medio ambiente de los peligros causados por restos de medios.

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Todas las reparaciones las debe efectuar únicamente el fabricante.

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¡CUIDADO! Si se utilizan vainas, hay que asegurarse de que el bulbo no tenga contacto con el fondo de la vaina porque los diferentes coeficientes de dilatación de los materiales pueden causar la deformación del bulbo en el fondo de la vaina. (Para las fórmulas para calcular las longitudes de montaje l1, véase la ficha técnica de la vaina correspondiente)

7. Mantenimiento, limpieza / 8. Desmontaje, ... ■

■ Restos de medios en instrumentos desmontados

pueden causar riesgos para personas, medio ambiente e instalación. Tomar adecuadas medidas de precaución.

Véase el capítulo 8.2 "Devolución" para obtener más información acerca de la devolución del instrumento.

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8. Desmontaje, devolución y eliminación ¡ADVERTENCIA! Restos de medios en instrumentos desmontados pueden causar riesgos para personas, medio ambiente e instalación. Tomar adecuadas medidas de precaución. 8.1 Desmontaje ¡ADVERTENCIA! ¡Riesgo de quemaduras! ¡Dejar enfriar el instrumento lo suficiente antes de desmontarlo! Peligro debido a medios muy calientes que se escapan durante el desmontaje.

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8.2 Devolución ¡ADVERTENCIA! Es imprescindible observar lo siguiente para el envío del instrumento: Todos los instrumentos enviados a WIKA deben estar libres de sustancias peligrosas (ácidos, lejías, soluciones, etc.).

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8. Desmontaje, devolución y eliminación Utilizar el embalaje original o un embalaje adecuado para la devolución del instrumento. Para evitar daños: 1. Envolver el instrumento en un film de plástico antiestático. 2. Colocar el instrumento junto con el material aislante en el embalaje. Aislar uniformemente todos los lados del embalaje de transporte. 3. Si es posible, adjuntar una bolsa con secante. 4. Aplicar un marcaje que indique que se trata de un envío de un instrumento de medición altamente sensible. E Comentarios sobre el procedimiento de las devoluciones encuentra en el apartado „Servicio“ en nuestra página web local. 8.3 Eliminación de residuos Una eliminación incorrecta puede provocar peligros para el medio ambiente.

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Eliminar los componentes de los instrumentos y los materiales de embalaje conforme a los reglamentos relativos al tratamiento de residuos y eliminación vigentes en el país de utilización.

WIKA global Europe Austria WIKA Messgerätevertrieb Ursula Wiegand GmbH & Co. KG Perfektastr. 83 1230 Vienna Tel. +43 1 8691631 Fax: +43 1 8691634 [email protected] www.wika.at Belarus WIKA Belrus Ul. Zaharova 50B, Office 3H 220088 Minsk Tel. +375 17 2945711 Fax: +375 17 2945711 [email protected] www.wika.by

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Benelux WIKA Benelux Industrial estate De Berk Newtonweg 12 6101 WX Echt Tel. +31 475 535500 Fax: +31 475 535446 [email protected] www.wika.nl Bulgaria WIKA Bulgaria EOOD Akad.Ivan Geshov Blvd. 2E Business Center Serdika, office 3/104 1330 Sofia Tel. +359 2 82138-10 Fax: +359 2 82138-13 [email protected] www.wika.bg

Croatia WIKA Croatia d.o.o. Hrastovicka 19 10250 Zagreb-Lucko Tel. +385 1 6531-034 Fax: +385 1 6531-357 [email protected] www.wika.hr Finland WIKA Finland Oy Melkonkatu 24 00210 Helsinki Tel. +358 9 682492-0 Fax: +358 9 682492-70 [email protected] www.wika.fi France WIKA Instruments s.a.r.l. Parc d‘Affaires des Bellevues 8 rue Rosa Luxembourg 95610 Eragny-sur-Oise Tel. +33 1 343084-84 Fax: +33 1 343084-94 [email protected] www.wika.fr

Poland WIKA Polska spółka z ograniczoną odpowiedzialnością sp. k. Ul. Legska 29/35 87-800 Wloclawek Tel. +48 54 230110-0 Fax: +48 54 230110-1 [email protected] www.wikapolska.pl Romania WIKA Instruments Romania S.R.L. 050897 Bucuresti Calea Rahovei Nr. 266-268 Corp 61, Etaj 1 Tel. +40 21 4048327 Fax: +40 21 4563137 [email protected] www.wika.ro

Russia ZAO WIKA MERA Wjatskaya Str. 27, Building 17 Office 205/206 127015 Moscow Tel. +7 495-648018-0 Germany Fax: +7 495-648018-1 WIKA Alexander Wiegand SE [email protected] & Co. KG www.wika.ru Alexander-Wiegand-Str. 30 63911 Klingenberg Serbia Tel. +49 9372 132-0 WIKA Merna Tehnika d.o.o. Fax: +49 9372 132-406 Sime Solaje 15 [email protected] 11060 Beograd www.wika.de Tel. +381 11 2763722 Fax: +381 11 753674 Italy [email protected] WIKA Italia S.r.l. & C. S.a.s. www.wika.rs Via G. Marconi 8 Spain 20020 Arese (Milano) Instrumentos WIKA S.A.U. Tel. +39 02 93861-1 C/Josep Carner, 11-17 Fax: +39 02 93861-74 08205 Sabadell Barcelona [email protected] Tel. +34 933 9386-30 www.wika.it Fax: +34 933 9386-66 [email protected] www.wika.es

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WIKA global Switzerland MANOMETER AG Industriestrasse 11 6285 Hitzkirch Tel. +41 41 91972-72 Fax: +41 41 91972-73 [email protected] www.manometer.ch Turkey WIKA Instruments Istanbul Basinc ve Sicaklik Ölcme Cihazlari Ith. Ihr. ve Tic. Ltd. Sti. Bayraktar Bulvari No. 17 34775 Yukari Dudullu Istanbul Tel. +90 216 41590-66 Fax: +90 216 41590-97 [email protected] www.wika.com.tr

Ukraine TOV WIKA Prylad M. Raskovoy Str. 11, A PO 200 02660 Kyiv Tel. +38 044 4968380 Fax: +38 044 4968380 [email protected] www.wika.ua United Kingdom WIKA Instruments Ltd Merstham, Redhill RH13LG Tel. +44 1737 644-008 Fax: +44 1737 644-403 [email protected] www.wika.co.uk

North America Canada WIKA Instruments Ltd. Head Office 3103 Parsons Road Edmonton, Alberta, T6N 1C8 Tel. +1 780 4637035 Fax: +1 780 4620017 [email protected] www.wika.ca Mexico Instrumentos WIKA Mexico S.A. de C.V. Viena 20 Ofna 301 Col. Juarez, Del. Cuauthemoc 06600 Mexico D.F. Tel. +52 55 50205300 Fax: +52 55 50205300 [email protected] www.wika.com.mx





WIKA Alexander Wiegand SE & Co. KG Alexander-Wiegand-Strasse 30 63911 Klingenberg • Germany Tel. +49 9372 132-0 Fax +49 9372 132-406 [email protected] www.wika.de 64

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Further WIKA subsidiaries worldwide can be found online at www.wika.com. Weitere WIKA Niederlassungen weltweit finden Sie online unter www.wika.de. La liste des autres filiales WIKA dans le monde se trouve sur www.wika.fr Otras sucursales WIKA en todo el mundo puede encontrar en www.wika.es.