Sulzer Pumps_eomr100188253.pdf

WUXI JINHUAYUN PAKISTAN ICI SODA Manual ASH POWER PROJECT Operation and Maintenance PUMP TYPE:MC80-260B/10 114831 Sulzer Order Number:0100081790

Line REFERENCE Item:000010 10100188253 SULZER NO. END OF MANUFACTURE REPORT PUMP SERIAL NO.532277,532278,532279

Document Index 文件清单

MC80-260B/1001882530010

Pump General Arrangement Drawing Pump Data Sheet and Curve Pump Cross Section Drawing &Parts List Pump P & I diagram Pump Instrument List Pump junction box wiring diagram Pump Utility Consumption list Mechanical Seal &System Drawing Coupling Drawing Motor Drawing Pump IOM Quality Manufacture Records

泵总布置图 泵数据单,曲线 泵剖面图&零件清单 P&ID 图 泵仪表清单 泵接线图 工程耗用清单 机械密封&密封系统 联轴器图纸 电机图纸 泵操作手册 质量制造记录

D

C

B

A

CONTRACT DATA

A 4 SUCT

Cartridge removed space 2000mm

855

DISCH

530

530

180

买方 PURCHASER:

无锡金华运电 力设备有 限公司

用户 USER:

Pakistan

项目 JOB/PROJECT:

ICI Soda Ash Power Plant

用户 订单号 CUST. PO#: 应用 SERVICE: 安装 地点 INSTALLED AT: 泵制 造商 PUMP OEM:

-

SULZER ORDER NO.:

IDENTIFICATION NUMBERS

A向 A T I OT O

PUMP

DRIVER

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

N

375 355

375

3

100

200

泵 型及大小 SIZE&TYPE :

~475

~700

a

~700

1185

a

转 速 SPEED:

2980

转 向 ROTATION:

CW

机 械密封 MECH SEAL:

集装式

(AS VIEWED FROM DRIVER 从驱动端看 ) API代码 API CODE: -

制 造型式 MFR TYPE: 630

250

11

155

a

4020

强调 ：泵 进出口主 管道布 置请注 意避开机 封冲洗 管路 ，避免干 涉！

a

10- 28 适用 于地脚螺栓M2 4x500 GB799 及对应垫圈螺母

冲 洗方 案 API PIPING PLAN: 23+M

电机参数/DRIVER SPECIFICATIONS

≥1000mm

a

3

泵 /PUMP SPECIFICATIONS

850

50

200

CUSTOMER TAG NO'S

SULZER SERIAL NO.

(2585 )

R

4

汽机房 0米 层 SULZER PUMPS SUZHOU LTD. 100188253-0010

地 脚 螺栓 灌 浆 预 留孔 尺 寸

100 x100

10-M20-70 底 座 调 平螺 栓

电 机 MOTOR:

1LA8353-2PC90-Z

机 座号 FRAME:

355

功 率 HP:

355kW 3ph

相 PHASE:

推 荐 的 维 护 空 间 （ 各 处）

转速 SPEED:

2980r/min

电压 VOLTAGE: 415V

成 套 FURNISHED BY: SULZER

频率 CYCLE:

50Hz

近似重量 /APPROXIMATE WEIGHTS 600 KG

底座 BASE:

2000 KG

驱动 机 DRIVER:

1900 KG

附件 AUXILIARY: 1420

DO NOT SCALE. DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

图中尺寸请勿缩放。未特殊说明，尺寸单位均为毫米。 UNLESS OTHERWISE SPECIFIED TOLERANCES 未注尺寸公差

仅用 于确 定 管口 及安 装布 置 /CERTIFIED

FOR NOZZLE & FOUNDATION ONLY

ANCHOR H OLES LOCATION DIMENSION S 地 脚 螺 栓 孔 位 置 尺 寸  3

初步 资料 ， 仅供 参考 /P RE LIMINARY ONLY

1. 注意! 设备启动前请仔细调整对中,所有法兰上的孔中心对称,管路应力不得超过设 备允许应力,详见安装维护说明书. 880

880

880

880

2. 地面最小维护空间为离最近障碍物至少1500mm.

最大管口载荷/MAXIMUM NOZZLE LOADINGS FORCE IN (N)

SIMILAR DRG.

X-轴向

Y

Suction Discharge y

z

z Mz

Fy My Fx Mx

-

MACHINING REGULATIONS SEE DRAWING STANDARDS.

D

C

FORCE

O

COPYRIGHT © (2015/05/20) SULZER PUMPS (SUZHOU) INC. 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 (SUZHOU) INC.

Forces(N) Fx Fy Fz Load Constant 0 0 -33045 Tension -6780 -8020 -23265 Constant + Nozzle Load Exception + Earthquake Shear -6780 8020 -23265 B

Fz

MOMENTS

Z 1

OUTLINE&AUX CONNEC TION DIM EN SIONS 外 形 及 辅 助 管 口 位 置 尺 寸  12

100

50

250

NOZZLES LOCATIO N D IMENSIONS 主 管 口 位 置尺 寸  3

Fx Fy

MOMENTS IN (Nm) SUCT

DISCH

4980 4100

2140 1780

2015.06.18

2015.06.18

现场布管 注意事项

Aiping Sun

Victor Zhang

Lihua Fu

MODIFICATION

MODIFIED

CHECKED

APPROVED

a 增加用户 接管规格和 材料； REV.

SEP. PARTS LIST:

NO

FORMAT

Fz

6220

2660

MC

Fr

8960

3860

80-260B/10

Mx My

4600

1900

2630

940

Mz

3520

1440

Mr

6260

2560

Pakistan ICI 100188253-0010

-

SUBSTITUTE FOR:

- ORIGINAL SCALE: DRAWN:

外形图

CHECKED:

2015/05/20 Victor Zhang

基础位 置 APPROVED:

GENERAL ARRANGEMENT DRAWING XXX

1 1:1

2015/05/20 Aiping Sun

MC-Motor

PART NO.

2015.06.18

SULZER PUMPS (SUZHOU) LTD. THIRD ANGLE PROJECTION DESIGN GROUP

A1

REPLACED BY:

ANSI D-SIZE 22x34

1500

4600 KG

最终 确认 /CERTIFIED FINAL

备注/NOTES:

2

100 KG

总重 TOTAL:

05/2012

2

泵头 PUMP:

2015/05/20 Lihua Fu

ZH PGA1001882530010-01 1 / 2 A

ICAD

710

≥1000mm

D

C

B

A

CONTRACT DATA

4

买方 PURCHASER:

无锡金华运电 力设备有 限公司

用户 USER:

Pakistan

项目 JOB/PROJECT:

ICI Soda Ash Power Plant

用户 订单号 CUST. PO#: 应用 SERVICE: 安装 地点 INSTALLED AT: 泵制 造商 PUMP OEM:

-

SULZER ORDER NO.:

4

汽机房 0米 层 SULZER PUMPS SUZHOU LTD. 100188253-0010

IDENTIFICATION NUMBERS

PO

PUMP

DRIVER

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

PI

PD

CI

3

CI

CO

CUSTOMER TAG NO'S

SULZER SERIAL NO.

3

泵 /PUMP SPECIFICATIONS

CO

泵 型及大小 SIZE&TYPE :

AD2

AD2

转 速 SPEED:

2980

转 向 ROTATION:

CW

机 械密封 MECH SEAL:

集装式

(AS VIEWED FROM DRIVER 从驱动端看 ) API代码 API CODE: -

制 造型式 MFR TYPE: 冲 洗方 案 API PIPING PLAN: 23+M

电机参数/DRIVER SPECIFICATIONS 电 机 MOTOR:

1LA8353-2PC90-Z

机 座号 FRAME:

355

功 率 HP:

355kW 3ph

相 PHASE:

CO

转速 SPEED:

2980r/min

电压 VOLTAGE: 415V

成 套 FURNISHED BY: SULZER

频率 CYCLE:

50Hz

近似重量 /APPROXIMATE WEIGHTS 调整螺栓

地脚螺栓

2

600 KG

底座 BASE:

2000 KG

驱动 机 DRIVER:

1900 KG

附件 AUXILIARY:

薄金属垫

垫

泵头 PUMP:

2

100 KG 4600 KG

50

总重 TOTAL:

垫 混凝土 基础

CI PD

1

CO

冷却水 出口 /COOLING HEADER - OUTLET

1"

CI

冷却水 入口 /COOLING HEADER - INLET

1" -

AD2

Copyright ©, (Date of Drawing), Sulzer Pumps. All rights reserved. No part of this drawing may be reproduced, distributed, or transmitted in

PD

泵排液 /PUMP DRAIN

PO

泵出口 /PUMP DISCHARGE NOZZLE

3"

PI

泵入口 /PUMP SUCTION NOZZLE

6"

项目

ITEM

any form or by any means, electronic or mechanical, including photocopying and recording, without the express PRIOR written

底座排 液 /BASE DRAIN

说明 /DESCRIPTION

Φ32x2.5 a Φ32x2.5 a NPT1"

1/2" Φ18x2

a

Φ88.9×7.5 a Φ168.4×7.1 a

尺寸 用户接 口管规格

SIZE Customer Connection Piping Size

接口清单 /CONNECTION LEGEND

consent of Sulzer Pumps.

D

C

B

a 增加用户接 管规格和材料 ； 现场布管注 意事项 a ANSI B16.5 Class150 RF 20 REV. MODIFICATION a NO FORMAT A1 ANSI B16.5 Class150 RF 20 SEP. PARTS LIST: REPLACED BY: a MC ANSI B16.5 Class300 RF 20 a ANSI B16.5 Class900 RF 20 80-260B/10 a Pakistan ICI ANSI B16.5 Class300 RF 20 配对法兰型式及材料 COUNTER FLANGE

100188253-0010

2015.06.18

2015.06.18

Aiping Sun

Victor Zhang

Lihua Fu

MODIFIED

CHECKED

APPROVED

XXX

1

SULZER PUMPS (SUZHOU) LTD. THIRD ANGLE PROJECTION DESIGN GROUP

SUBSTITUTE FOR:

- ORIGINAL SCALE: DRAWN:

1:1 2015/05/20 Aiping Sun

CHECKED:

2015/05/20 Victor Zhang

APPROVED:

GENERAL ARRANGEMENT DRAWING PART NO.

2015.06.18

2015/05/20 Lihua Fu

ZH PGA1001882530010-01 2 / 2 A

Pump Performance Datasheet Customer Inquiry Number/ID Item number Service Quantity

: Shanghai Yunneng Energy technology co., LTD : : 001 : BFP :3

Operating Conditions Flow, rated : 101.0 (23.00) m3/h Differential head / pressure, rated (requested) : 910.0 (1,040.9) m Suction pressure, rated / max : 2.47 / 2.47 bar.g NPSH available, rated : 8.0 m Frequency : 50 Hz Performance Speed, rated : 2,980 rpm Impeller diameter, rated : 257 mm Impeller diameter, maximum : 260 mm Impeller diameter, minimum : 230 mm Efficiency : 75.2 (34.7) % NPSH (3% head drop) / margin required : 3.3 (2.2) / 0.0 m Ns (imp. eye flow) / Nss (imp. eye flow) : 953 / 10,210 US Units MCSF : 22.56 m3/h Head, maximum, rated diameter : 1,044.7 m Head rise to shutoff : 14.82 (0.37) % Flow, best eff. point (BEP) : 109.8 m3/h Flow ratio (rated / BEP) : 91.99 (20.95) % Diameter ratio (rated / max) : 98.85 % Head ratio (rated dia / max dia) : 96.90 % Cq/Ch/Ce/Cn [Karassik BFW] : 1.00 / 1.00 / 1.03 / 1.00 Selection status : Acceptable

Sulzer Reference ID Type / Size Stages Based on curve number Date of Last Update

: PAK.0262-CHN.15.0015-F0 : MC 80-260 (B) : 10 : 4337.03.111-01 : 09 Jan 2015 4:10 AM

Liquid Liquid type : Water Additional liquid description : Solids diameter, max : 0.00 mm Solids concentration, by volume : 0.00 % Temperature, rated / max : 130.0 / 130.0 deg C Fluid density, rated / max : 0.935 / 0.935 kg/dm3 Viscosity, rated : 0.23 cSt Vapor pressure, rated : 2.70 bar.a Material Material selected : Chrome Steel Pressure Data Maximum casing/bowl working pressure : 98.25 bar.g Maximum allowable working pressure : 155.0 bar.g Maximum allowable suction pressure : 40.00 bar.g Hydrostatic test pressure : N/A Driver & Power Data Driver sizing specification : Rated power Margin over specification : 0.00 % Service factor : 1.00 Power, hydraulic : 234 (60.97) kW Power, rated : 311 (176) kW Minimum recommended motor rating

: 355 kW / 476 hp

Multiple Conditions Datasheet Customer Inquiry Number/ID Item number Service

: Shanghai Yunneng Energy technology co., LTD : : 001 : BFP

Condition #

Type / Size Stages Impeller diameter, rated Flow, rated Head, rated (requested) Suction pressure, rated / max NPSH available, rated Speed, rated Selection status Cq/Ch/Ce/Cn [Karassik BFW] Efficiency NPSH (3% head drop) Power, rated

Max operation deg C kg/dm3 cSt

mm m3/h m bar.g m rpm

% m kW

:3

Sulzer Reference ID : PAK.0262-CHN.15.0015-F0 Date of Last Update : 09 Jan 2015 4:10 AM

1

Description Temperature, max Fluid density, rated / max Viscosity, rated Primary condition

Quantity

130.0 0.935 / 0.935 0.23

2

3

4

5

Rated operation 130.0 0.935 / 0.935 0.23 MC 80-260 (B) 10 257

101.0 910.0 2.47 / 2.47 8.0 2,980 Acceptable 1.00 / 1.00 / 1.03 / 1.00 75.2 3.3 311

86.00 890.0 2.47 / 2.47 8.0 2,887 Acceptable 1.00 / 1.00 / 1.03 / 1.00 73.8 2.8 264

Type / Size

: MC 80-260 (B)

Stages Speed, rated

: 10 : 2,980

6

7

8

Multiple Conditions Curve

Customer

: Shanghai Yunneng Energy technology co., LTD : : 001 : BFP :3 : PAK.0262-CHN.15.0015-F0 : 09 Jan 2015 4:10 AM : 101.0 m3/h : 910.0 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 : 0.935 / 0.935 kg/dm3

Type / Size

: MC 80-260 (B)

Stages Speed, rated Based on curve number Efficiency Power, rated NPSH (3% head drop) Viscosity Cq/Ch/Ce/Cn [Karassik BFW]

: 10 : 2,980 rpm : 4337.03.111-01 : 75.2 % : 311 kW : 3.3 m : 0.23 cSt : 1.00 / 1.00 / 1.03 / 1.00

Submergence

:-

位号 106.001 902.02 920.02 914.005 903.006 903.007 914.011 182.012 107.001 902.02 920.02 562.004 914.005 903.006 903.007 914.011 182.009 108.01 108.02 441.02 905.01 920.01 550.01 412.01 412.02 412.05 412.06 412.12 412.08 412.07 426.1 426.11 426.12 171.02 177.01 177.001 502.05 502.02 541.01 904.027 231.02 230.02 210.01 940.01 940.02 940.03

描述 SUCTION CASE Double end stud（bm=1.25d);M20X110 Hex. full nuts;M20 Hex. socket head cap scr.;M10X30 THREADED PLUG, HEX. HEAD;RH;ASME B16.11 THREADED PLUG, HEX. HEAD;RH;ASME B16.11 Hex. socket head cap scr.;M16X100; FOOT 110X100X75 DISCHARGE CASE;MACHINED;MC;80-260 Double end stud（bm=1.25d);M20X110 Hex. full nuts;M20 Parallel pins;5 m6x16; Hex. socket head cap scr.;M10X30 THREADED PLUG, HEX. HEAD;RH;ASME B16.11 THREADED PLUG, HEX. HEAD;RH;ASME B16.11 Hex. socket head cap scr.;M16X100; FOOT 110X100X75 STAGE CASE;MACHINED;MC/MD;80-260 STAGE CASE;MACHINED;MC/MD;80-260 SEAL HOUSING;MACHINED;MC;80-260 TIE BOLT;MACHINED HEXAGON NUT;M36;RH WASHER;FLAT O-RING;329.570 MM;5.330 MM;382 O-RING;209.140 MM;3.530 MM;267 O-RING;151.990 MM;3.530 MM;258 O-RING;151.990 MM;3.530 MM;258 O-RING;171.040 MM;3.530 MM;261 O-RING;69.440 MM;3.530 MM;232 O-RING;190.090 MM;3.530 MM;264 BEARING ISOLATOR;INPRO;VBXX-D-700-0780-1 BEARING ISOLATOR;INPRO;VBXX-D-700-0550-0 BEARING ISOLATOR;INPRO;VBXX-D-700-0400-0 DIFFUSER;MACHINED;MC/MD;80-260;B DIFFUSER LAST STAGE;MACHINED;MC/MD;80-26 DIFFUSER LAST STAGE;CAST/RAW;N/A STATIONARY RING;MACHINED STATIONARY RING;MACHINED INTERSTAGE BUSHING;MACHINED SCREW GB/T80 SUCTION IMPELLER;MACHINED;MC;80-260;B IMPELLER;MACHINED;MC/MD;80-260;B SHAFT D 85X1905 SQUARE AND RECTANGULAR THIN KEYS SQUARE AND RECTANGULAR THIN KEYS KEY;A (RND-RND);DIN6885

规格 M20X110 M20 M10X30 1.0_11.5NPT 0.5_14NPT M16X100;

M20X110 M20 5 M6X16; M10X30 1.0_11.5NPT 0.5_14NPT M16X100; B B M36;1.500 MM;1160.000 MM;RH 37.000 MM;66.000 MM;6.000 MM

78.000 MM;101.000 MM;18.000 MM 55.000 MM;81.000 MM;18.000 MM 40.000 MM;66.000 MM;18.000 MM

150.400 MM;175.000 MM;16.000 MM 140.400 MM;165.000 MM;21.000 MM 85.360 MM;95.000 MM;20.000 MM M5X8 A4-70 CLOCKWISE 10×6×32 GB/T1567 316 200HB MIN 10×6×32 GB/T1567 316 200HB MIN 16.000 MM;10.000 MM;80.000 MM

数量 1 8 8 4 1 2 4 2 1 8 8 1 2 1 2 4 2 1 8 2 8 16 16 10 2 1 1 1 1 1 2 1 1 9 1 1 1 9 9 57 1 9 1 10 1 1

单位 PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE

材料 Gr CA6NM CL A 290 HB Max Gr B7 Zn Finish-1 Gr 2H Zn Finish-1 8.8 Zn coated Gr B8M CL 1 Gr B8M CL 1 8.8 Zn coated 1.0038/S235JR Gr CA6NM CL A 290 HB Max Gr B7 Zn Finish-1 Gr 2H Zn Finish-1 A4 (316/316L) 8.8 Zn coated Gr B8M CL 1 Gr B8M CL 1 8.8 Zn coated 1.0038/S235JR Gr CA6NM CL A 290 HB Max Gr CA6NM CL A 290 HB Max Gr CA6NM CL A 290 HB Max Gr B16 Gr 7M WNT (soft nitrided) 1.0503+C Hrdnd or ASTM A 108 Gr 1045, 60 KSI Min Yld EPDM T230 (Ethylene- Propylene) EPDM T230 (Ethylene- Propylene) NBR 70 (Buna N, Nitrile) NBR 70 (Buna N, Nitrile) EPDM T230 (Ethylene- Propylene) EPDM T230 (Ethylene- Propylene) EPDM T230 (Ethylene- Propylene) Bronze Bronze Bronze ASTM A743 Gr CA6NM or A487 Gr CA6NM, Cl, A (23-28RC) ASTM A743 Gr CA6NM or A487 Gr CA6NM, Cl, A (23-28RC) ASTM A743 Gr CA6NM or A487 Gr CA6NM, Cl, A (23-28RC) UNS S42000; Soft Nitride; 320 - 350HB; UNS S42000; Soft Nitride; 320 - 350HB; UNS S42000; Soft Nitride; 320 - 350HB; A4 (316/316L) ASTM A743 Gr CA6NM or A487 Gr CA6NM, Cl, A (23-28RC) ASTM A743 Gr CA6NM or A487 Gr CA6NM, Cl, A (23-28RC) A276 T420/U4021 QT700 Shaft Material 316 200 HB Minimum 316 200 HB Minimum 1018 Cold Finished 125 HB Min or DIN 1.0503+C

940.04 940.05 520.01 920.17 931.02 551.05 920.15 932.01 330.01 360.01 360.02 914.02 914.03 932.007 673.01 638.01 525.01 525.02 831.01 832.01 320.03 320.01 903.016 903.017 900.01 433.001 433.002

SQUARE AND RECTANGULAR THIN KEYS SQUARE AND RECTANGULAR THIN KEYS SLEEVE;MACHINED BEARING NUT LOCK WASHER 60 WASHER SHAFT NUT;M55;RH RETAINING RING;DIN471 BEARING HOUSING;MACHINED BEARING COVER;MACHINED;8 BEARING COVER;MACHINED;7 Hex. socket head cap scr.;M12X75; Hex. socket head cap scr.;M12X90; RETAINING RING;DIN472 AIR RELEASE FILTER OILER FOR PUMPS SPACER SLEEVE D 60/78X93,5 SPACER SLEEVE D 60/78X72 FAN FAN COVER TAPER ROLLER BEARING CYLINDRICAL ROLLER BEARING THREADED PLUG, HEX. HEAD;RH;ASME B16.11 THREADED PLUG, HEX. HEAD;RH;ASME B16.11 Slotted cheese head screws;M4X8 MECHNICAL SEAL DE MECHNICAL SEAL NDE

10×6×32 GB/T1567 316 200HB MIN 6×4×20 GB/T1567 45 125HB MIN 62.000 MM;85.000 MM;35.000 MM M60X2 GB812 4级螺母 GB/T858 60 60 30.000 MM;1.500 MM

M12X75; M12X90; 130.000 MM;4.000 MM NPT1/2 H120-NPT1/4-3.5, L1=200

112 T=32.7 112 B=99 G=16 31312 J2/DF03 NU312ECJ CARBON STEEL SKF 0.5_14NPT 0.25_18NPT M4X8

2 1 1 1 1 1 1 1 2 1 1 4 4 1 2 2 1 1 1 1 1 1 4 4 4 1 1

PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE PCE

316 200 HB Minimum 1018 Cold Finished 125 HB Min or DIN 1.0503+C A276 T420/U4021 QT700 Shaft Material Steel - Min UTS 350 MPa or 50 Ksi Q235B 1.0503+C Hrdnd or ASTM A 108 Gr 1045, 60 KSI Min Yld Steel Steel Spring Gr 60-40-18 Gr 60-40-18 Gr 60-40-18 8.8 Zn coated 8.8 Zn coated Steel Spring Galvanized Steel Galvanized Steel A276 T420/U4021 QT700 Shaft Material A276 T420/U4021 QT700 Shaft Material Aluminum Q235B Carbon Steel Carbon Steel Gr B8M CL 1 Gr B8M CL 1 8.8 Zn coated Material per BOM Material per BOM

电动给水泵仪表清单 MOTOR DRIVEN PUMPSETS INSTRUMENT LIST 编制： 编制： DRAWN:

Jian Liu

日期： 日期： DATE:

2015/4/21

版本: 版本 VERSION:

b

校核： 校核： CHECKED:

Aiping Sun

日期： 日期： DATE:

2015/4/21

修订: 修订 MODIFICATION:

Jian Liu

批准： 批准： APPROVED： ：

Kevin Wang

日期： 日期： DATE:

2015/4/21

日期： 日期： DATE:

2015.8.10

修改部分仪表位号

设计及运行 Design&Operating

NO.

位号 KKS编码 编码 TAG KKS CODE

安装位置 Location

功用 Service Description

装置 Device

项目号 SAP NO.

100188253-0010

项目名称 PROJECT

ICI Soda Ash Power Plant

设备位号 TAG NO.

PU0801/0802/0803

标定及控制 Calibration&Control 信号类型 Signal Type

过程介质 Process Media

过程条件 Process Conditions

范围 Range

仪表描述 Instrumentation Specification

设定点1 设定点 Set Point 1

设定点1 设定点 Set Point 1

性质 Type

设定点 setpoint

功能 Fct

性质 Type

设定点 setpoint

功能 Fct

控制 Controled By

制造商 Manufacturer

型号 Model

防护等级 IP

备注 Remarks

电动主泵 1

PI

2103/05/07

仪表盘

入口压力

压力表

N/A

锅炉水

TBA

0-1.0Mpa

N/A

N/A

N/A

N/A

N/A

N/A

N/A

安徽天康

Y-150B

IP64

2

PG

2104/06/08

仪表盘

出口压力

压力表

N/A

锅炉水

TBA

0-16Mpa

N/A

N/A

N/A

N/A

N/A

N/A

N/A

安徽天康

Y-150B

IP64

3

PG

103

仪表盘

平衡管压力

压力表

N/A

锅炉水

TBA

0-1.6Mpa

N/A

N/A

N/A

N/A

N/A

N/A

N/A

安徽天康

Y-150B

IP64

3

TE

101A/B

轴承箱体

驱动端轴承箱油池温度

热电阻

Pt100，三线制

润滑油

TBA

0-150℃

H

100℃

报警

HH

110℃

跳机

DCS

安徽天康

ST-01

IP65

4

TE

102A/B

轴承箱体

驱动端轴承箱油池温度

热电阻

Pt100，三线制

润滑油

TBA

0-150℃

H

100℃

报警

HH

110℃

跳机

DCS

安徽天康

ST-01

IP65

4

TE

103A/B

泵入口管道

泵入口温度

热电阻

Pt100，三线制

锅炉水

TBA

0-200℃

H

客户提供

报警

HH

客户提供

跳机

DCS

安徽天康

ST-01

IP65

Plan23冲洗水管路系统 冲洗水管路系统 5 6

TE

131A/B

驱动端冲洗水回水管路

温度检测

热电阻

Pt100，三线制

冲洗水

TBA

0-100℃

H

80℃

报警

HH

100℃

跳机

DCS

安徽天康

ST-01

IP65

TE

132A/B

非驱动端冲洗水回水管路

温度检测

热电阻

Pt100，三线制

冲洗水

TBA

0-100℃

H

80℃

报警

HH

100℃

跳机

DCS

安徽天康

ST-01

IP65

Note：电机仪表请参考电机图纸

图纸号：/Drawing No. PIL1001882530010-01

页/Sheet 1/1

D

C

B

A

4

4

ICI Soda Ash Power Plant MC80-260B/10 0010 3

3

MOTOR+MC NOTES: ALL INSTRUEMENT TAGS(KKS CODE) PLEASE REFER TO P&ID.

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FORMAT A2 DESIGN GROUP .

SUBSTITUTE FOR

SPSZH

1ST ANGLE PROJECTION

.

ORIGINAL SCALE DRAWN:

ICI SODA ASH POWER PLANT

CHECKED:

SPSZH APPROVED:

100188253 Sulzer Other

PART NO.

690 D

C

B

.

21-APR-2015 1 JIAN LIU 21-APR-2015 MARTIN MA 21-APR-2015 KEVIN WANG

ZH PWD1001882530010-01 1 / 3 A

D

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B SKID EDGE JUNCTION BOX

TE101

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JB-101 1

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2

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6

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11 12

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1 TE132 1 x (3x1.5) mm SQ.

2

3

13 14

3

15

SH

16

B/SPARE

3

2

3 30

2

2

NOTES:

MOTOR DRIVEN PUMP: TEMPERATURE MEASURING

.

.

.

.

. REV. MODIFICATION SEP. PARTS LIST

.

REPLACED BY

MC

1

80-260B/10

.

.

.

MODIFIED

CHECKED

APPROVED

FORMAT A2 DESIGN GROUP .

SUBSTITUTE FOR

SPSZH

1ST ANGLE PROJECTION

.

ORIGINAL SCALE DRAWN:

ICI SODA ASH POWER PLANT

CHECKED:

SPSZH APPROVED:

100188253 PART NO.

690 D

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21-APR-2015 1 JIAN LIU 21-APR-2015 MARTIN MA 21-APR-2015 KEVIN WANG

ZH PWD1001882530010-01 2 / 3 A

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. REV. MODIFICATION SEP. PARTS LIST

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REPLACED BY

MC

1

80-260B/10

.

.

.

MODIFIED

CHECKED

APPROVED

FORMAT A2 DESIGN GROUP .

SUBSTITUTE FOR

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1ST ANGLE PROJECTION

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ORIGINAL SCALE DRAWN:

ICI SODA ASH POWER PLANT

CHECKED:

SPSZH APPROVED:

100188253 PART NO.

690 D

C

B

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21-APR-2015 1 JIAN LIU 21-APR-2015 MARTIN MA 21-APR-2015 KEVIN WANG

ZH PWD1001882530010-01 3 / 3 A

PUMP UTILITY LIST 项目/Item

要求/Requirement

说明/Comment

轴承润滑油（驱动端） Bearing Oil （DE） 轴承润滑油（非驱动端） Bearing Oil （NDE）

油品：SAE 15W-40 油量: 0.2L 油品：SAE 15W-40 油量: 0.25L

详见安装手册推荐的润滑油及油量 详见安装手册推荐的润滑油及油量

PLAN 23 UTILITY LIST 项目/Item

要求/Requirement

冷却水 Cooling Water

流量 Flow: 温度 Temperature : 压力 Pressure :

说明/Comment 3 m³/h < 33℃ 2-3 bar

If the pressure is >6 bar, Please feedback, the orifice is required.

买方/Purchaser: 用户/User: 项目/Job/Project:

无锡金华运电力设备有限公司 CI Soda Ash Power Plant

客户订单号/Customer P.O.: 客户位号/Customer Tag No.:

订单号/Sulzer Order No.:

给水泵 巴基斯坦 苏州苏尔寿泵业有限公司 100188253-0010

序列号/Sulzer Serial No.:

532277/532278/532279

泵名称/Service: 安装地点/Installed at: 泵厂商/Pump OEM:

Rev

INITIAL RELEASE Change

Amanda Gu By 公用工程消耗清单 UTILITY CONSUMPTION LIST

Approved

PUC101882530010-01

2015.05.05 Date REV 00

SULZER PUMPS SUZHOU LTD.  433 JIANLIN ROAD  SUZHOU,P.R.CHINA  VOICE: 0512-8187-3670 FAX: 0512-8187-3888

Sulzer Pumps Suzhou Ltd. Engineering Document Review 工程文件评审 This review does not relieve the supplier or originator from the responsibility for accuracy nor permit deviation from contract requirements

当评审结论和合同要求冲突时，必须以合同要求为准

Reviewed no Comments Reviewed with Comments ORE Engineer 设计工程师

Signature/Date

Aiping Sun 孙爱平

克隆密封安装使用指导 一． 适用范围 适用于旋转轴用机械密封安装，以卧式离心泵用机械密封安装为基准，机械密封为内装、接触式， 转速不超过 5000 转/分或端面速度≤25 米/秒，密封工作温度在-40℃~260℃或介质温度低于 400℃，其它 设备用机械密封安装可参考使用，如有特别要求或不详之处，请您与丹东克隆集团有限公司联系。 电话：0415-6225535，0415-6227162，传真：0415-6224424 6225536

二． 安全建议 安装人员要有一定的机械密封方面专业知识和技能，能理解所要安装机械密封的工作图，并且详细 阅读本《安装使用指导》 ，在《安装使用指导》的要求下进行机械密封安装，如对本《安装使用指导》有 不明确之处，请您与丹东克隆集团有限公司联系。 本《安装使用指导》仅对机械密封安装进行说明，对于需要防护及在危险环境中工作要求应按相关 安全条例执行，与本《安装使用指导》有冲突时，以安全条例为准，如无法实现，请您与丹东克隆集团 有限公司联系。 安装机械密封前，必须保证相关设备、系统均已停用和处于非工作状态，并且已达到环境温度，有 压部分已泄到常压，保证机械密封安装过程中人身安全。

注意： i）为了保证密封使用性能，应使用克隆公司专配的密封备件或经克隆公司书面允许使用的其它零部 件。 ii）凡使用克隆公司密封产品，应依照密封工作图配置机械密封辅助系统。

声明： i）机械密封只有安装到使用其设备中，或与相关设备装配到一起才能发挥作用，其单独使用并不具 备任何功能。 ii）克隆集团不对未经克隆公司书面允许而装配的非克隆集团提供的零部件或备件而导致的后果负 责。 iii）克隆集团不对没有按密封工作图配置机械密封辅助系统而造成密封失效等后果负责。

三． 安装步骤： 准备 1． 准备好所要安装的密封后，查阅密封工作图，注意拆泵时各件拆装 顺序。拆泵，将旧的填料或机封拆除。 2． 检查泵上与轴套、压盖相接触的金属件表面是否完好。 3． 为了避免非金属元件（如"○"圈）的损伤，应在有非金属元件滑过的 所有台肩部位加工出 2x30°倒角，所有尖角倒圆并修光滑（如图一） ， 在键槽或沉孔处倒掉所有棱角，有密封圈滑移的直径处金属表面粗糙 度 Ra 应小于 0.8μm，静密封圈处的金属表面粗糙度 Ra 应小于 3.2μm。 4． 清洁密封腔体，并检查各安装表面是否有损伤痕迹。 5． 检查与机械密封相关的安装连接尺寸是否与机械密封工作图相符。

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6． 校核密封腔体中旋转件及静止件的轴向及径向跳动，不超过国家标准规定极限值。 轴端部跳动小于 0.1mm, （如图二） 轴径向跳动小于 0.03-0.05mm., （如图三） 密封腔止口端面与轴的垂直度小于 0.05mm。 （如图四） 如果达不到上述要求，应更换轴承或调整相关部件。 7、擦净各部件，对滑移部位添加润滑剂，该润滑剂要与密封材料及介质相容。 推荐使用润滑剂：肥皂水、水、硅润滑脂、乙二醇或甘油。

装配 1．机械密封的装配要求在干燥、清洁的环境中进行。 2．拆开机械密封包装，注意密封端面不可与硬物相碰。 3．依据密封工作图，确定密封工作长度 L3（以符合 DIN24960 的 C8U 型机械密封为例）(见图五） 。 3-1、密封弹性组件（包括动环）的工作长度是经过计算的，即在规定的 运行寿命内能保持合适的端面比压及弹性补偿量的长度。工作长度与 其自由状态的长度差值，即是密封的压缩量，安装中，需计算得出实 际压缩量。可根据使用经验对密封压缩量进行少量增减，否则必须保 证密封工作图尺寸。盲目或过大增减压缩量、不按密封工作图尺寸安 装将导致密封不能工作或过早失效。 4、测量压盖尺寸 A（含止口垫）后(见图六)，将静环及静环密封圈装至压盖内，并注意静环后部的槽对 入压盖上的防转销。如果静环密封圈是“O”形圈，可将密封圈表面涂润滑剂后，套到静环上，再将 静环放平用手压入压盖。如果静环密封圈是聚四氟乙烯或柔性石墨，则先将密封圈装到静环上，平 放到压盖内，对准压盖上的防转销，注意密封圈内外圆上倒角 方向有利于安装。端面平垫软布，用压力机或钻床等类似能产 生压力的机械将静环缓慢压入压盖，端面加力必须均匀，并测 量尺寸 E 是否符合要求且一致（见图七） 。不可对静环局部用 力，不允许对静环敲击。如果压不动或压力很大，应立即停止， 测量压盖、密封圈及静环尺寸，对不合适的尺寸进行修整后再 装配。 5、 参照机封工作图，计算出 B（=L1K-A）值。 6、 在轴套上按 B 值位置固定动环组件(见图八)，其他类似机封亦 可按相同办法计算安装。

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注意：一些机械密封轴套上已刻有 B 值线或轴套上有定位台阶(图九)，这样机械密封安装时仅需校核 L3 尺寸即可。

7．清洁密封端面，将已安装动环及轴封的轴套和已安装静环及 止口密封圈的压盖小心合在一起，把端面贴和。如果是带限 位板的集成式密封，此时可将限位板安装固定好。再将剩余 零件安装，需要紧固的，应均匀拧紧螺钉。轴套紧固方式若 采用螺母（即传动环）紧固键传动形式（通常是双支撑泵） ， 要选准螺纹旋向，即轴套紧固螺母拧紧方向与轴的旋向相反 （见图十） ，注意此种情况必须有键传动轴套。 8．一般悬臂泵的轴套直接用叶轮压紧固定，用键传动。安装时， 可根据顾客习惯，先将整套密封套装到轴上，再装泵盖固定 密封压盖。也可以先将整套密封装到泵盖上并固定密封压盖， 再装到泵轴上。注意轴封垫和压盖垫要安装到位。将泵盖与悬架固定后，可装叶轮键、叶轮等其它件。 9、安装双支撑泵的密封，将整套密封从轴端套入缓慢推到密封腔中，注意轴套键槽要对准轴上的键，类 似图十七结构的密封，要将轴套推到位后固定压盖，轴封圈需待压盖固定后安装。类似图十六结构的 密封，将整套密封推到位，压盖进入止口并压住压盖垫后固定压盖。对于用传动环定位和传动的轴套 或用胀紧圈固定传动的轴套，均匀拧紧传动环上螺钉固定轴套。最后不要忘记拆移限位板。 10、安装带泵送环的双端面或串联机封时，先按密封工作图组装密封和分步安装密封，轴向螺旋泵送环 需注意旋向与工作图一致，在图十一中，从 A 向看，如果轴是顺时针旋转，应安装左旋泵送环，反之

为右旋泵送环。使用径向泵送环的机封，安装时注意压盖上缓冲液出口方向与轴旋向一致，应有利于 缓冲液流出。

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11．紧固固定压盖的螺母时，要均匀拧紧各螺母，以免压盖偏斜。紧固螺母后注意检查压盖与轴之间间 隙是否均匀，如果有干涉，需拆卸调整，以免导致密封损伤。 12．组装泵其余各件，安装完毕后。转动泵轴，检查静环、压盖与轴套之间和旋转件与密封腔之间有无 摩擦，泵轴转动一周应感觉用力均匀。如转不动轴或转一周局部用力很大，则应检查密封是否存在安 装问题，必要时应拆泵查找问题后重装。 13．依据泵或密封工作图，连接密封辅助系统管线，同时要保证管路系统清洁，保证机封工作环境整洁， 注意管路排布，防止局部滞留气体影响循环。

注意： 1． 机械密封的安装步骤与所使用设备的结构紧密相关，应结合设备特点安装。 2． 安装各部分零件时，应细致均匀的用力，以防止端面变形及脆性元件的损坏。 3． 不要对密封端面使用润滑剂。 4． 乙丙橡胶材质不可接触矿物油。 5． 安装聚四氟乙烯的密封圈时，应耐心细致并均匀用力，以 防其损伤。安装聚四氟乙烯 V 型圈时，应特别注意 V 型刃 口，避免折叠及翻转。刃口朝向压力高的方向（见图十三） 。 6． 安装柔性石墨轴向挤压密封圈或平垫类密封圈，需保证圆 周范围内轴向紧固力均匀。

四．操作 1． 将泵的入口阀打开，引入介质，在有一定静压情况下观察密封情况。 2． 缓慢转动泵轴，观察密封有无泄漏。如果出现较大的泄漏，则可能存在密封安装或其他问题，应拆 开密封仔细查找原因，排除后重装。 3． 如果情况良好，即可启泵。对于高温介质的泵，需按要求缓慢加温，待密封腔达到合适温度后才可 以启泵。注意打开辅助系统阀门，使辅助系统良好的工作。 4． 启动泵初期，可能存在微小的渗漏，但是渗漏逐渐减少则可正常使用，而渗漏不断增加则说明有安 装错误或密封有问题，应停止运行，拆泵查找原因，重新装配密封。

五．密封拆卸 密封的拆卸与安装步骤相反，可在密封上的拆卸槽或非密封面上用力，注意保护再利用的零部件， 不能敲击密封面，尤其密封端面。 为了分析密封失效原因，请注意妥善保管拆卸下来的密封件。

※在密封运行期间应注意以下条件，以保证密封的寿命： 避免介质压力波动； 避免频繁开停车； 避免泵抽空、汽蚀；如有抽空现象，应通知密封生产厂； 避免冲洗液、急冷水中断；定期检查密封辅助系统工作是否正常；避免用水质硬的急冷水；

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安装指导例一：标准安装尺寸及类似结构机械密封安装 一、适用范围 本例适用于符合 DIN24960 及 GB6556 安装尺寸的 U 型、B 型机 械密封（见附表一）及类似结构，主要包括 C50 系列波纹管密封或 类似旋转型波纹管机械密封（图十四） 、C8 系列小弹簧密封（图十 五） 、C4 系列波形弹簧密封、C45 系列大弹簧密封等标准安装尺寸密 封。弹性组件是旋转的，固定在轴或轴套上。静环通过密封圈装入 压盖。

二、安装方法 准备： 1、安装人员需先阅读《克隆密封安装使用指导》 ，并在《克 隆密封安装使用指导》指导下拆泵，检验密封腔上各零 部件表面及尺寸是否符合安装密封要求。有“O”圈滑 过的台阶要倒角 2X30°，所有尖角倒钝，并修光滑。 2、查阅所要安装的机械密封工作图，检验图中各安装尺寸，并注意是否有技术要求和安装要求。如果 有要求，请在安装过程中首先予以考虑。 3、打开密封包装，检查各件表面是否完好。 4、清洁各零部件，配齐顶丝。对于没有卡簧集成的密封，弹性组件与动环等各件不必组装，但对有卡 簧集成的弹性组件应组装，动环密封圈是楔形圈的，应先将卡钩都装好，拉住推环，使楔型圈不受 力。C50 波纹管密封或类似旋转型波纹管机械密封波纹管尾部内圈的密封圈要装上。

装配 1、参照机封工作图中 L1K 尺寸,计算出 B（=L1K-A）值。 2、在轴套上找到 B 值的位置，按 B 值固定弹性组件上的传动件，各顶丝拧紧力要均匀。动环密封圈 是契形圈的密封，弹簧盒固定后拆下卡钩。 3、对于非波纹管密封，要依据密封装配图将弹性组件上的剩余各件逐个小心装上。如果动环密封圈是 “V”形圈，应注意 V 型刃口安装及方向，避免刃口出现折叠或翻转。 4、按照《克隆密封安装指导》中装配第四条安装静环，如果静环是陶瓷类材料，安装时应格外小心。 5、将动、静环端面擦拭干净，端面上不要留有细微纤维状物或颗粒杂物，将轴套装入压盖，轻轻将动、 静环端面合到一起，如带有限位板，将限位板插入轴套的槽中并固定到压盖上。将其它件装到密封 的相应位置上，整套密封保管好，待装配泵。 6、装泵前依据密封工作图检查密封装配尺寸并核算调整密封实际压缩量，符合要求，即可在《克隆密 封安装指导》的相关要求下安装密封，装泵，操作检验。C8、C4、C45、BT1 系列密封动环与弹簧 组件之间没有集成，安装过程中要防止动环脱落或移位。

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附表一：符合 DIN24960 及 GB6556 安装尺寸的 U 型、B 型密封安装尺寸 （本表以 C8 系列密封安装尺寸为基础）

U 型密封 尺寸数据 D4 L1K L3 密封规格 D1 D3 10 20 22 32.5 22.5 12 22 24 32.5 22.5 14 24 26 35 25 16 26 28 35 25 18 32 34 37.5 25.5 20 34 36 37.5 25.5 22 36 38 37.5 25.5 24 38 40 40 28 25 39 41 40 28 28 42 44 42.5 30.5 30 44 46 42.5 30.5 32 46 48 42.5 30.5 33 47 49 42.5 30.5 35 49 51 42.5 30.5 38 54 58 45 32 40 56 60 45 32 43 59 63 45 32 45 61 65 45 32 48 64 68 45 32 50 66 70 47.5 34 53 69 73 47.5 34 55 71 75 47.5 34 58 78 83 52.5 39 60 80 85 52.5 39 63 83 88 52.5 39 65 85 90 52.5 39 68 88 93 52.5 39 70 90 95 60 45.5 75 95 104 60 45.5 80 104 109 60 45 85 109 114 60 45 90 114 119 65 50 95 119 124 65 50 100 124 129 65 50 110 138 144 65 50 120 148 154 65 50

D6 17 19 21 23 27 29 31 33 34 37 39 42 42 44 49 51 54 56 59 62 65 67 70 72 75 77 81 83 88 95 100 105 110 115 125 135

D7 密封规格 D1 21 10 23 12 25 14 27 16 33 18 35 20 37 22 39 24 40 25 43 28 45 30 48 32 48 33 50 35 56 38 58 40 61 43 63 45 66 48 70 50 73 53 75 55 78 58 80 60 83 63 85 65 90 70 92 75 97 80 105 85 110 90 115 95 120 100 125 110 136 120 146

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B 型密封 尺寸数据 D2 D3 D4 L1K L2 14 24 26 40 18 16 26 28 40 18 18 32 34 42.5 18 20 34 36 42.5 18 22 36 38 45 20 24 38 40 45 20 26 40 42 45 20 28 42 44 47.5 20 30 44 46 47.5 20 33 47 49 50 20 35 49 51 50 20 38 54 58 50 20 38 54 58 50 20 40 56 60 50 20 43 59 63 52.5 23 45 61 65 52.5 23 48 64 68 52.5 23 50 66 70 52.5 23 53 69 73 52.5 23 55 71 75 57.5 25 58 78 83 57.5 25 60 80 85 57.5 25 63 83 88 62.5 25 65 85 90 62.5 25 68 88 93 62.5 25 70 90 95 62.5 25 75 95 104 70 28 80 104 109 70 28 85 109 114 70 28 90 114 119 75 28 95 119 124 75 28 100 124 129 75 28 110 129 134 75 28 120 143 149 75 28 125 153 159 75 28

L3 30 30 32.5 32.5 33 33 33 35.5 35.5 38 38 38 38 38 39.5 39.5 39.5 39.5 39.5 44 44 44 49 49 49 49 55.5 55.5 55 60 60 60 60 60 60

D6 17 19 21 23 27 29 31 33 34 37 39 42 42 44 49 51 54 56 59 62 65 67 70 72 75 77 83 88 95 100 105 110 115 125 135

D7 21 23 25 27 33 35 37 39 40 43 45 48 48 50 56 58 61 63 66 70 73 75 78 80 83 85 92 97 105 110 115 120 125 136 146

安装指导例二：DM

系列固定法兰连结及类似结构密封安装

一、适用范围 本例主要适用于以 DM 系列为典型 的固定法兰联结结构，旋转（组）件和静 止（组）件通过平垫密封圈、紧固螺钉、 弹簧垫圈等零件分别与轴套和压盖法兰 形成联接并实现的密封。DM 系列包括 DBM-B-1、DTM-B-1、DTM-BV、DTM-BW （安装形式见图十六） 。

二、安装方法 准备： 1、安装人员需先阅读《克隆密封安装使用指导》，并在《克隆密封安装使用指导》指导下拆泵，检验 密封腔上各零部件表面及尺寸是否符合密封安装要求。 2、查阅所要安装机械密封的工作图，检验图中各安装尺寸，并注意是否有技术要求和安装要求。如果 有要求，请在安装过程中首先予以考虑。 3、打开密封包装，检查各零部件表面。 4、清洁各零部件，置于洁净的地方。

装配 1、参照密封工作图，将旋转环（组件）、静止环（组件）各加一个平垫装入轴套、压盖上，用专配的 圆柱头螺钉紧固，注意螺钉长度符合工作图要求，波纹管密封配有水套的，水套从压盖另一面装入。 拧紧螺钉时按对角线方向均匀将全部螺钉紧固。各螺钉的拧紧力矩应尽量一致，紧固力不均可能造 成端面变形，导致密封失效。 2、安装过程中注意不要把波纹管组件过度压缩，以免造成永久变形和损坏。 3、注意不能磕碰动、静环密封端面。 4、将动、静环端面擦拭干净，端面上不能留有细微纤维状物或颗粒杂物，将轴套装入压盖，轻轻将动、 静环端面合到一起，如带有限位板，将限位板插入轴套的槽中并固定在压盖上。将其它件装到密封 的相应位置上，整套密封保管好，待继续装配。 5、装泵前依据密封工作图检查密封装配尺 寸并核算密封实际工作长度 L3，如符合 要求，即可在《克隆密封安装指导》的指 导下安装密封，装泵，操作检验。如果压 缩量偏小，在 2mm 内，可增加动、静环 密封垫片数量，动、静环密封垫最多只能 各加一个。如果压缩量偏小较多，只能修 改轴套定位尺寸或重新设计制造密封。如 果压缩量偏大，但仍在 2mm 内，可增加压盖止口垫数量，最多只能增加两件，如果压缩量仍然偏

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大，也同样需修改轴套定位尺寸或重新设计制造密封。对于图十六那样有限位板的密封，可不考虑 密封压缩量问题，但应核实密封腔深度，避免动环固定螺钉与密封腔干涉。

三、注意事项 1、DM 系列密封部分规格弹性组件分 I、II 系列，即 II 系列弹性组件比 I 系列长（见图十六中 L3 尺寸） 尺寸见附表二，其它尺寸相同，但同规格二者不能互换。 2、安装前应对照密封装配图，测量弹性组件高度，弹性组件自由高度为 L3 加 5mm 偏差±0.5mm。

附表二：DM 系列密封安装尺寸（图示为 DBM-B-1 密封）

规格

d

d1

d2

d3

d4

d6

d7

d13

L3

L4

n

Mc

30

27

30

32.5

47

49

32.2

47

40

30

18

8

M4

35

31.5

35

36

51

53

35.7

51

44

30

20

8

M4

40

37

40

41.5

62

65

41.2

62

52

40

25

6

M6

45

41.5

45

46.5

67

70

46.2

67

56

45(52)

25

6

M6

50

46.5

50

51.5

72

75

51.2

72

62

45(52)

25

6

M6

55

51.5

55

56.5

78

80

56.2

78

67

45(55)

30

6

M6

60

53

60

61

83

85

60.7

83

72

45(55)

30

6

M6

65

58.5

65

66

88

90

67.5

88

76

45(55)

30

6

M6

70

67

70

72.5

97

100

72.2

97

84

50(55)

30

6

M6

75

73

75

77.5

98

100

77.2

98

88

50

30

6

M6

80

73.5

80

79.5

103

105

79.2

103

91

50

30

6

M6

85

78

85

85.5

108

110

85.2

108

97

50

30

6

M6

90

86

90

92.5

115

118

92.2

114．5

103

50(58)

30

6

M6

95

90

95

97.5

121

124

97.2

121

110

50

30

8

M6

100

95

100

102.5

124

128

102.2

124

113

50

30

8

M6

注：1、括号内尺寸为 II 系列尺寸 2、DTM-B-1 型、DTM-BV 型、DTM-BW 型密封无 30、35 规格

8

机械密封故障现象原因及解决措施 一、机械密封安装所致故障 所致现象 压盖过热

端面渗漏

冒烟或端 面发声

不正常 振动 密封泄漏 严重

机构破坏 偏磨泄漏

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

可能的故障原因 压缩量过大 静止部件与转动部件接触 辅助系统性能不良 泵抽空、气蚀 端面变形较大 螺丝拧力不均匀 压缩量偏小 密封端面有异物 密封腔抽空 静止部件与转动部件接触 安装对中不良 介质不足，操作不稳定 运行密封腔没有排气 压缩量大 密封装配后没有紧固 安装对中不良，精度不够 安装过程中，密封件损坏 密封没有压缩量 静密封点密封不良 密封端面变形严重 安装时端面没有处理干净，有异物 密封零部件安装时错位或安装错误 静止部件与转动部件接触 压缩量太大

a 泵轴与泵盖端面垂直度不够 b 密封部件安装倾斜

改进措施 按密封装配图尺寸要求调整压缩量 检验泵轴与泵盖之间的相对精度，保持足够的 安装精度，保证辅助系统工作良好 严格按装配要求检验相关部件的精度 按密封装配图尺寸要求调整压缩量 重新安装，按要求步骤均匀拧紧螺丝 重新研磨密封端面，达到要求的平面度，保持 端面洁净 避免抽空，装配密封前检查密封各安装尺寸 保证冲洗和冷却等密封辅助系统工作良好 检验泵轴与泵盖之间的相对位置精度，保证足 够的安装精度 避免装置操作不稳定 开泵前排出密封腔内气体 重新安装密封，注意螺纹联结的紧固，仔细调 整，保证较高的安装精度 拆卸密封，仔细检查各零部件，确定泄漏部位， 检查研磨端面达到要求的平面度，注意静密封点， 保证密封性能良好 更换损坏的密封部件，按密封装配图尺寸要求， 检测安装尺寸，保证正确的压缩量，仔细安装密封 拆卸密封，仔细检查各零部件，更换损坏的密 封部件，检验泵轴与泵盖之间的相对精度，检测安 装尺寸，保证正确的压缩量，仔细安装密封 检验泵轴与泵盖之间的相对精度，仔细安装密 封

二、其它问题所致故障 所致现象

密封 泄漏

不能运转

机构破坏

可能的故障原因 a 装置操作不稳 b 泵轴跳动或串动过大 c 密封辅助系统（冲洗、冷却）性能变 差 d 泵开停频繁 e 介质工况改变 a 介质凝固或结晶. b 环境温度过低，冷却水结冰 c 传动机构失效 a .介质出现凝固或结晶现象 b 介质温度波动过大，辅助系统不良 c 机件材料被腐蚀 d 出现抽空、汽蚀 f 泵轴跳动或串动过大

改进措施 避免装置操作不稳，保证辅助系统性能良好 检修泵轴承和泵轴，达不到使用要求的零部件 应及时更换 避免频繁开停泵，否则密封寿命将受影响 介质工况有较大改变，应提前同密封制造厂协 商，及时更改密封结构，以免造成密封失效 增加蒸气保温措施，改变密封结构 改善工作环境 检查密封安装是否正确 增加保温措施，开泵前给足够的时间暖泵，避 免介质温度波动过大，检修辅助系统，排除故障； 检修泵轴及支撑系统，更换性能不良元件 避免工艺操作中对密封使用不利的因素 正确提供介质成分及化学腐蚀性能，改进密封 结构或材料

9

a 辅助循环系统管路狭小或堵塞 压盖过热 b 缓冲液低于最小用量 密封处冒烟 c 密封传动机构损坏，旋转部分跳动过 大，磨压盖 a 出现抽空、汽蚀等现象 不正常振 b 端面液膜汽化(闪蒸)，润滑液膜不足 动或萧叫、 c 密封上有零件脱落或杂物落在密封 有磨损物 腔内 析出 e 未对中或叶轮及泵轴动平衡不良，汽 蚀，轴承有问题 a 介质中含有磨粒 密封 b 介质有结晶或部分固化 寿命短 c 泵轴串动造成压缩量大 a 密封辅助系统性能较差或冲洗口远 端面龟裂 离密封端面，端面摩擦热不能被及时 烧伤、软 带走 环高度磨 b 出现抽空，密封端面干摩擦 损 c 泵轴出现串动，使密封压缩量过大 a 介质温度过高，密封辅助系统性能变 差，降温不够 弹性元件 b 冲洗液流量偏少，密封腔内温差较大 失弹 c 安装偏斜较大 d 窄环外缘 a 压力波动汽蚀、喘振 破坏、 b 热冲击，急冷、急热\温差过大 端面变形 c 端面液膜汽化(闪蒸)，抽空

检查密封辅助系统管路是否畅通，及时添加缓 冲液，保证液面 检查密封各部件情况，更换损坏部件 检查泵轴及支撑系统，更换性能不良元件 改进密封辅助系统措施，如加外冲洗或增加端 面冷却，增加冲洗量 对密封仔细拆卸、检查、组装，清除密封腔内 杂物 检修泵的旋转部件 加洁净的外冲洗液 增加蒸汽保温，避免介质结晶 重新密封安装尺寸，核对泵轴是否有串动 重新检验密封辅助系统结构及性能，使其有效 发挥作用，不使密封端面急剧升温 检修泵轴及支撑系统 改变端面材料，减小摩擦系数，降低端面温度 检修密封辅助系统使其最好的发挥作用，均匀 降低密封腔温度 重新安装密封，仔细检验安装结果 避免装置操作不稳，提高密封辅助系统的性能 来抵消装置操作不稳的影响 重新仔细装配调整，更换损坏部件，研磨端面

注意：故障的正确诊断是预防和排除故障的基础，故障发生前的征兆或迹象，以及拆卸前后 的检查结果和对拆卸各密封元件的目测检查结果的详细记录是分析故障发生的重要 依据。请相关人员作好有关材料搜集和现象记录。 注: 如果不能确认故障原因并加以排除,请与丹东克隆集团有限公司的销售公司或技术部 联系。 联系电话：销售公司 TEL 0415-6227161 6227162 FAX 0415-6224424 技术部 ：TEL

0415-6225535

FAX

0415-6225536

6220417

公司主页：Http://www.colossusgroup.com 公司信箱：[email protected]

10

安装使用说明书 Ｄ、ＴＤ系列叠片挠性联轴器

无锡创明传动工程有限公司

ＷＵＸＩＴＲＵＭＹＴＲＡＮＳＭＩＳＳＩＯＮＥＮＧＩＮＥＥＲＩＮ ＧＣＯ．，ＬＴＤ． 地址： 无锡市新区华友二路８ 号 电话： ０ ５ １０－ ８５７０ １２２７传真：０ ５１０－ ８５７０ ６３３０网址：ｗｗｗ．ｔ ｒｕｍｙ ．ｃｏｍ

Ｄ系列、Ｔ Ｄ系列安装使用说明书 地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ

D、TD 系列安装使用说明书

１．技术资料 本安装使用说明书中提到的联轴器的基本尺寸、公称扭矩、峰值扭矩、最大 许用转速、补偿能力、使用温度等技术数据均可从产品样本查知。样本可向本公 司索取或者随时从网络上下载，网址：ｗｗｗ．ｔｒｕｍｙ．ｃｏｍ。 联轴器的具体设计可能与产品样本有差异，因此发货时提供了包含必要的技 术参数的安装图。 这些资料和联轴器的协议条款确定了它的既定用途。 危险环境下使用的联轴器应当限制其温度范围。

警告！为了保证持续、无故障的运行，联轴器选型必须有足够的工况系数。 如运行条件发生变化（功率、转速及主、从动机的变动），须复核设计。

２．总则 ２．１绪论 本安装使用说明书适用于Ｄ、ＴＤ系列叠片挠性联轴器的安装和使用。 所有参与安装、运行、维护、维修联轴器的人员应遵循本安装使用 说明书。我公司不负责违反本说明所引起的损害或破坏。

警告！未经我公司同意，安装和使用非我方提供的备件，可能改变设计特 性并由此影响安全。因使用非原装备件导致的任何损坏我公司拒绝承担任 何责任。 我公司将不断改进和完善我们的技术体系，本说明书如有更改，恕不另行通 知。 ２．２版权 本说明书的版权由无锡创明传动工程有限公司持有。 本说明书的内容不得以任何形式被复制用于竞争目的，未经授权，不得使用 提供给第三方。

３．交付状态 ３．１我公司出厂的联轴器零部件经过表面防锈处理。 ３．２叠片组件已厂内组装，不得分解。 ３．３联轴器按预装配状态交付。

４．运输和储存 ４．１供货范围 供货范围已在发货清单中列出。应当在交付时核查其完整性。如若发现运输 损坏或零件缺失，应立即书面告知我方以便处理。 ４．２运输

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 1/10

D、TD 系列安装使用说明书 须使用有足够承载能力的起重设备和操作设备。联轴器应使用适当的 运输工具运输。 根据运输途径和尺寸，联轴器采用不同包装。请注意包装上可能有的标识。 含义如下：

４．３储存 ４．３．１联轴器零部件的储存 联轴器零部件经过表面防锈处理，在室内干燥环境下可以保存不超过６个月。 如需保存更长时间，请联系我公司。 ４．３．２叠片组件的储存 ４．３．２．１总则 适当保存的叠片组件其特性保持不变。在不利条件下保存和不适当的处理会 对其产生消极影响并导致物理特性发生变化。如高温、高湿等条件都会产生影响。 ４．３．２．２储存环境 储存环境应当干燥无尘。叠片组件不能与腐蚀性化学物质、酸、碱性溶液等 保存在一起。

警告！潮湿环境（相对湿度大于６５％）不适于储存。需注意不能有水汽凝 结。

５．安装 ５．１准备工作 ５．１．１检查联轴器有无运输损伤、零部件是否齐全，并清洗零部件。 ５．１．２认真阅读安装使用说明书，理解安装程序。 ５．１．３准备适当的起吊、安装工具。 ５．１．４安装过程中，适当的起吊或支承零件，保护好法兰和止口，以防划伤。 ５．２安装盘的安装、找正 安装前须清洗孔、轴表面，不得有灰尘及各种防锈物质，如防锈漆。键必须 准确的装入轴和毂上的键槽中。键的侧面应符合规定的配合，顶部有少量间隙。 为了保持动平衡，键应当正好装入键槽中，不能太短或太长。 ５．２．１带键直孔安装盘的安装 轴端不得伸出安装盘。如果需要，可使用限位块限定安装盘到轴肩的间隙。 可用紧定螺钉或端板进行轴向固定。 如轴、孔配合为间隙配合，可直接将安装盘装在轴上，可用软质榔头轻击安 装盘。如轴、孔配合为过盈配合，则需将安装盘放在油槽或烘箱中加热使其膨胀，

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 2/10

D、TD 系列安装使用说明书 以便安装。加热温度视过盈量而定，一般为１２０℃～２５０℃。为避免安装过程中安 装盘冷却与轴抱死，安装必须迅速。如轴、孔配合为过盈配合，则可适当加热安 装盘，并在轴上涂润滑油。加热时不允许局部加热，以免变形。安装人员在安装 过程中当心被零件烧伤。 钢制安装盘所需加热温度θ（℃）的计算方法： δ θ=θ0 + 84000 × + 40 D 式中：θ0 ：室温（℃） δ：实际过盈量（可按孔径实测值与轴径实测值之差） （mm） D：轴和孔配合名义值， （mm）

５．２．２带键锥孔安装盘的安装 检查孔与锥度塞规的接触面积，接触率应满足相应的设计要求，再将安装盘 试装在轴上，用手推紧，记录轮毂在轴上的位置，作为锥孔安装盘轴向推进的 起 始 位置，然后将安装盘轴向移动至其工作位置。由起始位置移至工作位置的距 离称为轴向推进值。可通过加热安装的方法安装到位、或采用轴向推进器直接推 进到位、或通过拧紧轴头螺母推进到位。安装到位后，装上轴端螺母并锁死（如 果使用）。 轴向推进值＝孔与轴配合过盈量／锥度Ｋ 孔与轴的过盈值可在安装图或技术条件上查得。 ５．２．３无键圆锥面过盈联接安装盘的安装 圆锥面过盈联接安装盘一般采用液压装拆。 被连接设备的制造商会提供专门的联轴器安装盘液压安装说明书。下面给出 的安装要求仅供参考。必须保证设备制造商已提供了安装说明，并且得到了遵守。 ａ．清洁轴和安装盘孔，去除防锈油、灰尘等。检查孔与锥度塞规的接触面 积，至少应有８５％的接触率。检查时应确认Ｏ型密封圈及保护环已不在密封沟槽中 （如果使用）。不要在轴上配研以达到所需的接触面积。 ｂ．将安装盘试装在轴上并用手推紧，记录轮毂在轴上的位置，作为锥孔安 装盘轴向推进的 起始 位置。试装时应确认Ｏ型密封圈及保护环已不在密封沟 槽中（如果使用）。 ｃ．拧掉油孔上的防尘螺纹堵头，装入密封垫和保护环（如果使用）。 ｄ．将安装盘套在轴上并装上所需的液压安装设备。 ｅ．将安装盘推至 起始 位置，泵油以加大内压力，从而使安装盘胀开。 检查是否漏油。 ｆ．将安装盘按规定推进量及规定次数或时间沿轴向推紧。同时要控制和调 整孔内的压力，其值不能超过联轴器安装图或设备制造商提供的安装说明中规定 的范围。 ｇ．慢慢地释放孔内压力，使得液压油有时间从孔中泄出，此时推进器仍需 按规定留在原位足够的时间，以使轮毂保持在推紧位置。 ｈ．在孔内液压油已泄尽，并确认安装盘已完全胀紧后，移走推进器。然后 装上轴端锁紧螺母并锁死（如果使用）。拧上油孔上的防尘螺纹堵头（密封铜垫 不取出，如果有的话）。

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 3/10

D、TD 系列安装使用说明书 应保留足够时间让油从孔中排出，否则推进器移走时安装盘会以很 大的力从轴上弹出！ ５．２．４安装盘的找正 为了确保安装盘的正确安装，可利用百分表检测安装盘的外圆及端面，外圆 和端面的跳动均不应大于0.05mm，对外圆直径大于250mm或对锥孔配合的安装 盘，端面跳动在极限情况下允许为0.08mm。如果超出上述值，说明安装盘未被 装正，应找出原因并重新安装安装盘。

６．机组的对中 ６．１复核两安装盘安装面之间的轴向距离 将主、从动机转子置于运转位置，测取两安装盘安装面之间的轴向距离F（如 封面图所示）。测量时应在圆周向取4个读数，每隔90 测一次，取平均值。F尺 寸应当符合安装总图上的尺寸，误差控制在 0.8的范围内。 若机组热胀量较大，则联轴器在设计时采用轴向预补偿技术，以减小联轴器 运行时的变形，改善受力状况。此时联轴器中间传动段总长较机组冷态时的F值 短，安装完成后挠性叠片组件处于拉伸状态。机组热态运行时轴头距离缩短，叠 片组件的变形回复。 ６．２机组的角向、径向对中 对中是安装中重要环节，可根据机器设备的种类和调中要求，采用如下四种 方法之一来实现： ６．２．１采用专业对中仪对中 专业对中仪采用先进的激光技术进行轴对中，简单有效并能实时显示对中 值。 ６．２．２端面及外圆对中 采用千分表分别对联轴器安装盘的端面和外圆测取跳动值，通过对测得的数 值进行计算分析，确定两轴在空间的位置，得出调整量和调整方向。如图6.1所 示。 这种方法应用较广，但对轴向有窜动的机组，盘车时端面读数会产生误差。 为消除轴向窜动对端面读数的影响，提高对中精度，可采用与轴心等距分布的两 个千分表同时测量端面跳动。

图６．１ ６．２．３双表法对中 采用两个千分表在联轴器安装盘的外圆上同时测得数据，如图６．２所示。

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 4/10

D、TD 系列安装使用说明书

图６．２ 驱、从动机的轴同步转动，两端安装盘的相对位置保持不变。千分表测头应 尽量靠近安装盘的端面。 此法好而快，它无需考虑轴端的变动，可同时实现轴线在水平面和垂直面内 的重合。特别是在现场可简便而快捷地完成测量工作，图解法计算调整量简单， 便于掌握。 ６．２．４采用直尺和内卡钳对中 如图６．３所示，用直尺检查安装盘外圆各方向上的对中情况，用内卡钳来测 定两安装盘端面的距离，从而调整对中。 此法误差较大，仅用于低速、对中要求不高的场合。

图６．３ ６．３表杆下垂量对不对中值的影响。 采用 ６．２．２、６．２．３两种方法对中时，若机组需要（例如轴头距离较长，或 对中精度要求特别高），应计入表杆下垂量对不对中值的影响。可预先按下面步 骤测出标杆的下垂量，并作记录。 ａ．按实际找正所需的表杆长度固定好表架，然后将磁力座安装在刚性较好 的平板上。 ｂ．把平板先正放，再反放，读取千分表读数之差值，如图６．４所示。

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 5/10

D、TD 系列安装使用说明书

图６．４ 安装时许用的不对中数据，应由各种设备制造厂提供，如联轴器用户没有得 到相关数据则角向和径向不对中值（安装盘端面跳动、径向跳动）推荐采用表１ 的数据或共同协商给定。轴向安装尺寸按联轴器安装图。 表１ 千分表指示 千分表指示 型 号 型 号 (mm) (mm) 端面 径向 端面 径向 D4-4 0.10 0.10 TD8-840 0.15 0.15 D4-6 0.10 0.10 TD8-1700 0.20 0.20 D4-14 0.15 0.15 TD8-2700 0.20 0.20 D4-22 0.20 0.20 TD8-3300 0.25 0.25 D4-44 0.25 0.25 TD8-4200 0.30 0.30 D4-112 0.25 0.25 TD8-6600 0.30 0.30 D4-142 0.30 0.30 TD8-8400 0.35 0.35 D4-220 0.35 0.35 TD8-9011 0.35 0.35 TD6-66 0.10 0.10 TD8-9015 0.40 0.40 TD6-150 0.15 0.15 TD8-9021 0.45 0.45 TD6-210 0.15 0.15 TD8-9026 0.45 0.45 TD6-370 0.20 0.20 TD10-5300 0.30 0.30 TD6-470 0.20 0.20 TD10-8400 0.30 0.30 TD6-523/ TD6-840 0.25 0.25 TD10-9011 0.35 0.35 TD6-1300 0.25 0.25 TD10-9013 0.35 0.35 TD6-2100 0.30 0.30 TD10-9019 0.40 0.40 TD6-2700 0.30 0.30 TD10-9023 0.45 0.45 TD6-3300 0.35 0.35 TD10-9033 0.45 0.45 TD6-4200 0.40 0.40

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 6/10

D、TD 系列安装使用说明书

７．叠片组件及间隔轴的安装 ７．１将叠片组件、间隔轴放在两安装盘之间，然后分别将两端的螺栓、衬套、自 锁螺母（或槽形螺母）装入。各零件安装位置如图 ７．１所示。

图 ７．１ 注意：螺栓穿向应按图纸要求，不应反穿；衬套应垫在螺母下方，不能垫在其它 地方。 注意：轴头距离较短时螺栓可能需要预先装入间隔轴并与叠片组件一起放入（如 图 ７．２所示）。

图 ７．２ 注意：经过动平衡的联轴器零件必须按照联轴器上的相对位置标记安装（如图 ７．３所示）。同一套联轴器上相同规格的紧固件经过称重，可互换。

图 ７．３

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 7/10

D、TD 系列安装使用说明书 7.2 先拧紧一端螺母（螺母安装时，应涂少量中性润滑油），拧紧时要尽量注意 使螺栓不要跟转。严格按规定的拧紧力矩（Ｄ系列见表 ２，ＴＤ系列见表 ３）、用力 矩扳手至少分两次按对角顺序均匀拧紧。 自锁螺母允许多次使用，但若用手能自由地将自锁螺母锁紧部位拧入螺栓或 自锁螺母收口部位有裂纹等缺陷时应报废，严禁再使用。对槽形螺母，拧紧后应 穿上开口销，并翻边紧固，保证运转时不松动或脱落。 表２ 拧紧力矩 拧紧力矩 拧紧力矩 型号 型号 型号 （Nm） （Nm） （Nm） D4-4 4 D4-6 4 D4-14 5 D4-22 7 D4-44 10 D4-112 25 D4-220 80 表３ 拧紧力矩 拧紧力矩 拧紧力矩 螺栓规格 螺栓规格 螺栓规格 （Nm） （Nm） （Nm） M6 8 M16 100 M27 500 M8 15 M18 150 M30 700 M10 25 M20 180 M36 1200 M12 45 M24 350 M42 1900 保证拧紧力矩。拧紧力矩不够将导致叠片组件的加速磨损和联轴器 损坏。 ７．３慢慢地转动机组 ２～３转，确认它转动自由。 ７．４安装联轴器保护罩。

８．投入使用与运行 ８．１投运前复核所有螺栓的拧紧程度，如有必要需重新拧紧。对中也应当复核， 如有必要需重新对中。 任何旋转部件都有潜在的危险，必须用护罩将联轴器防护起来，危 险环境下使用的防护罩至少须达到防护类型ＩＰ２Ｘ的要求。 ８．２运行期间，请留意： 运转噪音的变化。 突然发生的振动。 如噪音突然变化或振动值超过许用范围，应停机检查原因。

９．拆卸 警告！ 防护好需拆卸的联轴器零件！当心联轴器零件跌落造成人身伤害。 9.1 拆卸前应熟悉联轴器的结构和装拆程序。观察各零部件之间是否有相对位置 标记，螺栓、螺母、衬套是否齐全，以便于再装配。拆卸时应注意保护好膜片的

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 8/10

D、TD 系列安装使用说明书 表面，以防碰伤。 9.2 先将两端螺栓、螺母拆出，然后将片组与间隔轴从两个安装盘的中间卸下。 最后拆卸两个安装盘。 9.3 对于有键安装盘，可利用安装盘上提供的拆卸孔装入拉拔器，利用拉拔器将 轮毂从轴上拉出（必要时直接对轮毂加热）。 9.4 对无键液压装配安装盘，装上液压设备将轮毂从轴上拆出，此过程与安装程 序相反。拆卸油压不能超过总图或设备制造商的安装说明中规定的许用压力。

警告！ 如果用加热的办法拆卸，则必须直接快速对轮毂加热。温度应控制 在 ４００℃以下。

１０．故障、起因及排除 １０．１总则 以下所列故障仅能作为查找故障原因的线索。 对于复杂机组，所有零部件都须包含在查找范围内。 在所有运行阶段，联轴器应当运行噪音低且无过大振动。不正常的运行反应 应当视作故障，必须立即排除。

警告！ 以下情况创明不受质保条款的约束或承担责任：联轴器的不当使用、 未经创明同意做出更改或使用非创明提供的备件。 １０．２可能的故障 表４：可能的故障 现象 原因 解决建议 停止驱动机 对中变化 改善对中变化的原因（例如松、紧基础螺栓） 噪音水平突然 检查磨损情况 变化和（或） 停止驱动机 突然振动加剧 拆下联轴器并拿掉残余的叠片组件 叠片组件损坏 检查联轴器零件并更换损坏件 检查对中情况，如有必要纠正它（见第６章）

警告！ 严禁使用叠片组件损坏的联轴器。 １０．３不正确的使用 经验表明以下错误可能会导致联轴器的不正确使用。因此除了遵守本使用说 明中的其它规程，必须注意避免这些错误。 损坏的联轴器有爆裂飞出的危险。禁止在危险区域使用有损坏元件 的联轴器。

警告！ 联轴器的不正确使用会导致联轴器损坏，进而导致整个系统中断。

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 9/10

D、TD 系列安装使用说明书 １０．３．１选用联轴器时可能的错误 描述驱动机和使用环境的重要信息未传递给供方。 系统冲击扭矩太高。 系统转速太高。 工况系数选择不正确。 化学腐蚀环境没有考虑。 环境温度不在许可范围。 １０．３．２联轴器安装时可能的错误 有损坏的零部件被安装。 加热安装联轴器零部件时过热。 轴径超出指定公差范围。 联轴器零件被互换。 指定的拧紧力矩或旋转角度未遵循。 对中或轴不对中值不符合安装使用说明的规定。 被联接的机构没有正确地与基础紧固，由此机组产生移动，比如基础螺栓联接 的松动导致联轴器零件的过大偏移。 叠片组件未被正确安装（见各系列安装使用说明书）。 使用的联轴器护罩不适于爆炸防护要求。 未经同意改变使用条件。 １０．３．３维护时可能的错误 维护周期没能遵循。 未使用创明原配叠片组件和紧固件。 使用损坏的创明叠片组件和紧固件。 联轴器附近的泄漏未发现由此化学腐蚀介质在破坏联轴器。

１１．维护 应当根据工厂的维护计划定期对联轴器进行外观检查，但最少一年一次。必 须特别注意以下情况： 叠片组件的外层表面是否有碰伤、裂纹、过度的永久变形等缺陷。 螺母是否有松动。 开口销是否有折断或缺损。 联轴器法兰是否损坏。 螺栓配合段表面是否有明显揉伤。 机组轴对中是否已变化，若不对中数值已超过规定，应重新进行对中调整。 未经动平衡的联轴器允许单独更换损坏的叠片组件和紧固件。

无锡创明传动工程有限公司

Ｗ Ｕ Ｘ ＩＴ Ｒ Ｕ Ｍ ＹＴ Ｒ Ａ Ｎ Ｓ Ｍ Ｉ Ｓ Ｓ Ｉ Ｏ ＮＥ Ｎ Ｇ Ｉ Ｎ Ｅ Ｅ Ｒ Ｉ Ｎ ＧＣ Ｏ ． ， Ｌ Ｔ Ｄ ．

地址：无锡市新区华友二路 ８号 电话：０ ５１ ０－ ８５ ７０ １２ ２７传真： ０５ １０－ ８５ ７０ ６３ ３０网址： ｗｗ ｗ． ｔｒ ｕｍ ｙ． ｃｏｍ 10/10

操作说明书

MC

苏州苏尔寿泵业有限公司

目录 1. 总论 1.1 1.2 1.3

关于本说明书 保修 操作说明书型号

2. 安全 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

操作说明书中的说明符号 人员资质和培训 不遵守安全规则的危险 安全指导工作 用户和操作者安全说明 保养、检查和装配工作安全说明 严禁未授权的改装措施或更改 不允许的运转模式 防爆装置

3. 运输和贮藏 3.1 3.2 3.3

到货验收 运输和起吊 保存和贮藏

4. 描述 4.1 4.2 4.3 4.4

概述 泵的描述 轴承支架和润滑 轴向推力吸收-平衡鼓

5. 安装 5.1 5.2 5.3 5.4 5.5

泵组的安装 联轴器校正 吸水和排水管道工程 辅助设备 最小流量装置

6. 运行 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

概述 试运行 泵启动和运行 不允许的运转模式 关闭 重启程序 使用控制 运行故障

7. 保养 7.1 7.2 7.3

泵概述 轴封 轴承/润滑

8. 维护 8.1 8.2 8.3 8.4 8.5

泵的拆除 易损件检查 泵装配 工具 螺丝拧紧转矩

附件 操作说明书附表

4000/e0-1-00-000

1. 总论 1.1 关于本说明书 本操作说明包括如何安全、正确并且有效的操作泵的重要信息。遵守这些说明可以帮助避免危险，减少修理成本 和停机时间，并可以增加泵的可靠性和使用寿命。

如何使用本说明书 本操作说明书必须在泵使用的地方随时可以获得。任何负责与泵相关工作和操作泵的人员必须阅读和应用这些说 明，例如：运输、贮藏、安装、运行和保养。 本说明书应该和所有其他机器的文件结合起来一起使用，以便获得关于泵的准确信息。在没有完全理解 泵系统和所有辅助系统（例如：驱动器，冷却装置、密封冲洗等）之前不要启动或运行泵。

1.2 保修 按照合约协议，应提供保修。 一般苏尔寿的保修包括生产或材料缺陷，但不包括由于不合适的贮藏环境、不正确的安装、操作以及不按照指 定用途使用而导致泵损坏。 在保修期内，维修或改装只能由我们的服务人员或经过我们书面同意的情况下进行。

1.3 操作说明书型号 (按照DIN 8418和VDMA 24 292) 颁发时间: 2012 我们保留本说明书和其所包含的信息的所有权力。在未经我们许可的情况下，严禁第三方复印、使用或披露信 息。

修订记录 3 2

2015-02-12

增加试运行和辅助管路信息

1

2014-05-08

增加最低转速和最大启动时间的限制

Yan

0

2012-03 内容描述

签字

修订

日期

Amanda

备注 如果有进一步的疑问、配件订购和其他函件，请注明苏尔寿序号和泵型号。这两者可以从泵的铭牌中获得。

0000/e1-0-00-000

2. 安全注意事项 本操作说明书包含基本的信息，在安装、试运行、操作和保养时都必须遵守。因此，本操作说明书应常备在现 场以便维修人员使用，且在试运行/或者装配/拆除泵之前必须阅读本说明书。 不仅要遵守“安全注意事项”下面所列出的一般安全说明，而且还要遵守操作说明书中所列出的特殊安全说明。

2.1操作说明书中的说明符号 安全说明包含在这些操作说明中，如果不遵守，可能会对人员造成伤害。 这些安全说明用一般危险标志 或电压警告标志 或特殊的防爆标志 如果不遵守安全说明，可能会对机械和其运行 带来危险，在此将插入 注意 标志。 直接贴在机械上的标志（例如：转动传感器箭头，液体接口标记等）应保持完好，清晰，因为这些必须经常遵守。

2.2 人员资质和培训 维护、保养、检查和装配的人员必须持有相关的资质证书。用户应清楚地划分人员的责任范围、任职范围和监控 范围。如果相关人员不具备所要求的知识，则应对他们进行培训和指导。如果用户要求，这些培训可以由机械生 产厂商进行。另外，用户应确保相关人员完全理解生产厂商说明书中的内容。

2.3 不遵守安全规则的危险 如不遵守安全规则，则可能会对人员、环境和机械造成危险，并可能导致完全失去任何关于损坏的索赔。 例如，不遵守安全规则可能会导致如下的危险： -机械或设备重要功能出现故障 -保养和维修所要求的程序出现故障 -由电、机械和化学的影响对人员造成危险 -危险材料的泄漏对环境造成危险

2.4 安全指导工作 必须遵守本操作说明书中所列出的安全规则，包括事故预防国家规定以及由用户制订的公司内部工作、操作和安 全规定。

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2.5 用户和操作者安全说明 -

为了防止高温或低温下机械部件可能导致的任何危险，用户必须对这些机械部件进行防护，避免接触。 在机械运行过程中，不能将传动部分（例如：联轴器）的安全罩从机械上拆除。 对危险性液体（例如：具有爆炸性液体、有毒液体和高温液体等）泄漏的处置必须防止对人员和环境造 成危险。必须遵守相关的法律条例。 必须杜绝电危险（例如：详细内容参见电气工程师协会和当地电力供应部门的相关规定。） 必须遵守本操作说明书中以下段落中的特殊安全说明。

2.6 保养、检查和装配工作安全说明 -

用户必须确保所有保养、检查和装配工作只能由经授权的技术熟练的人员进行，这些人员必须通过仔细 阅读操作说明书完全了解情况。 一般来讲，在机械上所进行的任何工作都只能在机械关闭的情况下进行。应严格遵守本操作说明书关于 机械关闭步骤的说明。机械必须锁住，以避免未经授权或无意的启动。 长头发的员工必须将头发扎在后面。不能穿宽松的衣服或戴首饰，包括戒指。因为这样会有受伤的危险， 例如：有可能将这些物品夹住或拉入。 泵或装置输送的对健康有危害的的介质必须对其进行净化。 所有安全和防护装置都必须相应的重新装配上，然后再投入使用。 在反复启动时，必须再次遵守最初试运行段落中所列的所有重点。

2.7 严禁未授权的改装措施或更改 -

只有在经过生产厂商同意的前提下才能对机械进行更改或改装措施。由生产厂商授权的原装配件和辅助设备 可以保证安全。使用其他配件可能会导致丧失生产厂商对于其后果应承担的责任。

2.8 不允许的运转模式 -

在任何情况下都不能超过数据单表中所列出的限值，请参考泵数据表中泵的相关数据。

2.9 防爆装置 -

泵上任何的标志仅限于泵上的部件。联轴器、驱动马达（例如：电动机）和辅助系统（轴封、润滑油系 统等）必须分开。 应避免由于不正确的操作方法而导致的超过规定温度（超过或达不到运行数据，达不到最小输送流量， 冷却水或循环输送的减少或出现故障等）的情况。

-

在启动泵之前，应确保泵系统（吸入管、泵壳和轴封）完全充满输送液体。这样可以防止系统中出现任何潜 在爆炸性空气。

-

经常监控泵的运行（仪器，例如：压力计、温度计、速度计和电流表等）。

-

对泵进行正确地保养。机械只有在完好的技术环境下才能保证安全运行。

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3. 运输和贮藏 3.1 到货验收 在装运之前，应对泵装置的完整性进行最终仔细的检查。根据装箱单检查所有项目，以确保部件没有丢失。 所有部件应小心起吊。

损伤 检查起吊期间所导致的任何损伤。对泵/或者配件的任何损伤都应进行拍照，包括运输包装的损伤。

缺失部件 应立即向承运商、保险公司和苏尔寿泵业代表报告缺失部件。采用到货检查报告R 0000/1-0-00-000。

报告

名称:

到货检查

工厂/位置:.......................................................................................................................................... 总规格:................................................................................................................................ 泵型号:............................................................... 驱动器:......................................................... 序号:................................................................... 型号/编号:.................................................... 到货日期: ...................…………………………….. 备注:............................................................. …………………………………………………. 检查日期: ………………….……………………… 1. 运输方式: 备注:............................................................. …………………………………………………. □ 卡车 …………………………………………………. □ 铁路 …………………………………………………. □ 海运 …………………………………………………. □ 空运 …………………………………………………. □ 其他…………………………………….. 2. 缺失部件: □ 是 □ 否 备注:............................................................. …………………………………………………. □ 泵、附件、工具 ................................. …………………………………………………. □ 其他 .................................................... 3. 损伤: □ 是 □ 否 备注:............................................................. …………………………………………………. □ 包装 …………………………………………………. □ 泵 …………………………………………………. □ 驱动器 …………………………………………………. □ 管道系统(冷却、循环 ...) …………………………………………………. □ 其他……………………………………… 4. 关于损伤所采取的措施: 备注:.............................................................. □ 拍照 …………………………………………………. □ 登记 …………………………………………………. □ 向承运商报告 …………………………………………………. □ 向保险公司报告 …………………………………………………. □ 向供应商报告 …………………………………………………. □ 其他………………………………………. 5. 意见: .……………………………………………………………………………………………………………..

R 0000 / 1-0-00-000 日期:

签字:

第1页

3.2 运输和起吊 A. 总论 对于所有运输工作，必须严格遵守工程的一般规则和预防事故法规，尤其包括以下内容： VBG 1 - 一般法规 VBG 5 - 电动作业设备 VBG 8 - 起吊装置 VBG 9 - 起重机 VBG 9a -带有升降和输送设备的载荷悬挂装置 在其他国家应遵守相关的法规。应有合格的指导者监控起吊和运输工作。

B. 运输 应检查运输装置（包括车辆）的容许载荷。关于运输物品的总重量，应参考发货文件。在运输过程 中应确保安全，防止移位。

C. 起吊 检查起吊重物的装置和绳索 必须检查起吊装置所能承受的重量，必须经过允许、确定无危险的绳索才可使用。承载的重物的质量必须 适合起吊的装置或绳索所能承受的重量。提供货物的总重量在安装图上给出，有的在递交资料上给出。

不要站在悬挂重物的下面

固定板条箱吊索 在封闭的板条箱上标记出固定吊索的位置，参见图3.2-1。因为不能在封闭的板条箱中觉察到重心，因此 吊索必须在标记的位置进行固定。板条箱可以通过叉车提升和运输，参见图3.2-2。

吊索如图中板条箱标记所示

图 3.2-1 板条箱上吊索的位置

图 3.2-2 采用叉车提升和运输

裸泵的固定位置

图 3.2-3 裸泵的固定位置 泵壳可通过缠绕在壳体上的绳索吊装，参见图3.2-3。

泵组单元的固定位置 如果底板上有吊环或提升杆，则在这些点上应用吊索将未包装的泵组单元固定起来，参见图3.2-5。 泵组单元达到一定重量时，绳索可以缠绕在泵部件（例如：泵法兰、轴承支架、点机外壳等）位置上提升起 来，参见图3.2-6。

图 3.2-5 具有吊环的底板固定点

图 3.2-6 没有吊环的底板固定点

泵部件上或泵组其他部件的吊环不能用于泵起吊或整机起吊，每个部件的起吊环只能用于部件安装 或者拆卸时单独起吊用。

3.3 保存和贮藏 A. 总论 此信息可以让你更安全有效的贮藏泵。如果需要更进一步的信息或者本说明中没有充分包含所出现的特殊问 题，请和最近的苏尔寿代表联系。 以下的贮藏说明仅适用于泵，并不适用于所提供的辅助设备。应遵守泵系统所有其他部件的生产厂商说明。 贮藏所需要的保存方法取决于发货保存。泵装置可以贮藏在清洁干燥的库房中，在发货保存所规定的时间内 不需采取保养措施。

B. 发货保存 标准包装: 当运输泵时，在光滑的外表面应喷防腐防锈涂料Tectyl506，在泵内表面喷Mobilarma524（或同类产品）。 注意：此方法不适用于长期保存，最长的容许贮藏时间是6个月。 航运包装: 泵在发货时，如果采用聚乙烯泊塑封，并带有防潮剂包装的泵如果其包装没有损坏，则最长可以贮藏一年， 并且不需要任何特殊的保养。 特殊包装: 如果有特殊要求，则泵可以用铝箔（带有防潮剂）包装。这此情况下，保存时间最长为2年，且不需要特殊 的保养。 注意：如果不采用航运包装或其他特殊包装，只有标准保存有效，例如：如果未采取任何措施，则最长贮藏 期限是6个月。

C. 中期贮藏 交付后没有立即安装和试运行的泵可根据发货保存期限贮藏。 注意：要防止变形和腐蚀，（尤其有缝隙的地方），轴承的损坏或污染。必须选择干燥的房间、恒温和干净 无振动的贮藏空间。 注意：在所有情况下，不利的气候环境将对适宜的保存时间有一定的负面影响。 如果装置没有或不再保存在特殊包装内时，则应遵守以下规定： 注意：如果遇到不利的周围环境的影响，例如：潮湿大气、(白天/昼夜)温差很大，酸或碱环境、具有污染的 危险（污物、砂等），则必须塞住泵的连接法兰保持密闭。

D. 长期贮藏-保存 概述 注意：泵应该总是以其机能性位置贮藏，也就是说，卧式泵应该水平贮藏，立式泵应该竖直贮藏。按照要 求对泵进行校准和支撑。 如果是长期贮藏，必须遵守预防措施，以免损坏泵。建议将所有贮藏检查和贮藏方法进行记录。 长期贮藏可能需要： 1. 没有进行过试运行的新泵。 可以按照中期贮藏的要求贮藏泵。在发货防腐期过后，采取措施防止其受到腐蚀损坏。

2. 备用泵或被长期关闭的泵 长期贮藏程序取决于在泵结构所用的材料（铸铁、钢、不锈钢、特种合金）。中期交付和环境条件（冻 伤）参见下表： 结构材料 输送的介质 中性 侵蚀性 碳氢化合物… 水… 海水… 酸… 铸铁 B A 钢 B A 不锈钢 B B A 特种合金 B B A A. 和泵送液体相接触的泵部件必须清洗干净,并干燥后涂上防锈剂保护起来。对于水力部件进行防护处理时 非常必要的。按照以下第I节到第IV节的描述采取完整的保护程序。 B. 如果没有冻伤的危险，可给泵灌满介质。按照以下章节的描述对轴承箱采取保护程序。 警告：防锈剂可能刺激皮肤，导致眼睛发炎。应遵守生产厂商规定的所有安全预防措施。

I 未涂油漆的泵外面部件的保护 泵的外面部件：例如：

- 法兰凸面 - 泵轴 - 联轴器 - 小管道连接等

我们强烈建议不能将普通的润滑油当作防锈剂。关于光亮泵部件的保存，矿物油行业生产出了一种特殊的防 锈剂。首先，这种防锈剂是液体，可通过刷子、喷嘴或喷漆器手工涂上。在溶剂蒸发后会留下一层蜡状覆盖 层。 此类保护层可以通过溶剂或碱洗剂清除掉。 我们推荐采用重型防护油或蜡状物 - 美国埃索石油公司的防锈剂397 - 壳牌安施之水性防锈剂K - 胜牌防锈防腐涂料506 同时也可以采用其他相同质量的防锈剂。平均防护期为1~3年。防锈剂是防止生锈的物质，然而不能除锈。 基于此原因，所要防护的部件必须是清洁并无锈的，这是应用防锈剂的先决条件。在使用相应的防锈剂之前， 应仔细清理部件的表面。

II. 泵内部的保护 如果液压泵部件（泵壳、叶轮、磨损环…）为不腐蚀的不锈钢或特种合金，则不需要采取任何的防护措施（代 替A冲洗方案）。注意：轴承箱和轴承应一直进行保护。 泵内部部件：例如： -泵壳 -填料函 -轴承箱、轴承… 2

对于这些部件，应采用粘度约为60~70 mm /s的矿物油液体防锈剂。 我们推荐的防锈剂 注意：泵内部的防锈剂必须根据所用的密封垫、密封材料选择。 密封垫或密封材料：

防锈剂

丁腈橡胶（NBR），氟化橡胶（FPM），特氟隆（PTFE）： -美孚公司的美孚防锈油拉玛524 -美国埃索石油公司的MZ110

-壳牌安施之机油30 乙烯丙烯橡胶（EPDM）：

-kluer syntheso D220

III. 长期防护处理过程 概述 采用聚氯乙烯尼龙油布保护泵及其附件。 将油布铺平以进行排水，不要形成小水坑。保持充分的空气流通，油布和泵部件间至少留10cm间隙。 保护泵免受风沙、污垢或（海）水的影响。 轴封 机械密封： 完整的机械密封在填料函中，不建议使用任何的预防措施。 软填料: 注意： 如果泵同时配备有填料的填料函，则必须去除原填料，并用特殊填料代替。在存放期间，该特殊 填料只能放在填料函中。 推荐的保护填料材料：含聚四氟乙烯的合成纤维（例如：Chetra1711 GS或Hecker 1820）。填料腔用单独的 填料环填充。 泵壳 泵的进出口法兰：首先，必须彻底地清洗泵法兰的凸面，并采用第I节中所提到的防锈剂进行保护。在光滑 法兰和带有环状T字形槽的法兰上放平垫片；如果是带槽的法兰，则应在槽口内放2个垫片，且所有插口应用 金属封盖密封严实。盲板应最少用4个螺栓固定。 冷却水管和循环管路等的连接也应通过钢旋塞封住。 保护程序：将防锈剂（参见第II节）灌入（或喷入）到泵壳中，将防护油彻底排出，并且每6个月重复一次。 如果是喷在壳体的内部，应该每3个月重复一次。 管道系统: 如果将泵连接到管道系统，在吸水管和排水管连接之前应采取保护程序。我们建议在泵和管道间 安装一个镀锌（或不锈钢）金属片，且该金属片应在试运行之前一直保持在原位上。 轴承箱 如果有：彻底排出了润滑油，去掉轴承箱顶部的注入塞，并向轴承箱中注入防锈剂（参见第II节）直到适当的 油位上。同时也向恒位油杯中注入防锈剂（如果有）。手动转动泵轴到合适的位置。

E.长期贮藏泵的保养 外观检查: 贮藏的泵装置外表面应每30天进行一次检查，检查表面是否有损伤、污物或泵附近区域是否有动 物。

注释：如果水、凝结水、砂、灰尘或其他污物通过包装或破损的防水帆布或密封不合适的封盖进入到泵装置， 则必须消除产生此类问题的原因，并且在重新贮藏前应将整个装置进行彻底地清洁和干燥。 手工转动泵转子: 为了避免轴承处发生腐蚀损坏，应每3个月将防护油排出一次，然后从轴承箱顶部重新灌入 新的防护油，同时用手转动泵转子，以便防护油均匀的涂在轴承的转动表面上，而且，泵转子在合适的转动 方向上应至少转5圈。 保养防锈涂层: 如果发现任何铁锈，则应采取相应的措施去除铁锈并进行防护。 充满防锈剂的泵部件: 对于注有防锈剂的部件（泵壳/轴承箱），应每6个月清理一次液体的浓缩物；如果需要， 则应加防锈剂。 注意： 根据生产厂商的说明，每6个月应将之前的防锈剂清除后重新加入新防锈剂。如果在此期间内没有 更换新的防锈剂，则贮藏人员有一定的危险。为了确保保养说明的正确实施，我们建议制订出保养 单。 如果是大型泵，且只有内部喷涂了防锈剂，则应在之后的3个月之内重复喷涂防锈剂。

F. 去除防锈剂的程序 表面受防锈剂保护的零件 在大多数情况下不可去除保护膜。如果需要，采用下列清洗剂去除防锈剂：石油精（挥发油），酒精，石油、 丙酮，同时也可以采用碱性清洗剂。

警告: 清洗剂是高度可燃物，并且对皮肤有刺激性。请遵守生产厂商所规定的所有安全防护措施。 注释:严禁使用硝基稀释剂！

泵壳 彻底排干泵壳，可能需要将泵提升起来充分排干泵壳（参见工作详图）。如果需要，应对泵壳进行冲洗。在 多数情况下，有必要拆除泵的液压部件，以便完全清洗。

轴封 机械密封: 填料函中保持完整的机械密封。弹性体密封取决于材料特性和时间变化（老化），这些都有可能 降低密封的效果，因此，我们建议在贮藏3年后应更换密封环。 填料: 在进行试运行之前，应确保去除了防腐填料，替换为工作质量的填料环。

轴承箱 放油孔下放托盘，以安全接收整个油量。除去螺旋塞，彻底排干油。用润滑油清洗轴承箱，允许排干 处理。安装上恒位油杯（如果卸下），按照泵使用说明书重新注满润滑油 按照法令法规处理防锈剂，无论如何不能将其倒入废水中。

G. 附加说明 当把泵从仓库移走时，必须特别注意。将泵和设备（管道、联轴器、驱动器...）表面清理干净，并进行 检查： 最少检查项目 额外的检查 检查完整性 检查轴承（是否发现任何 检查所有压力容器（紧塞）开口和 污染物，更换轴承) 连接的紧密度 检查轴封并更换所有 检查是否有裂纹或损伤的痕迹 弹性密封圈 检查泵的旋转，并检查固定部件和转动 安装附加的入口过滤器 部件间的缝隙是否正确 检查校正联轴器 检查所有紧固件的紧固程度 检查运转数据（泵是否合适） 注意： 如果泵贮藏超过3年，我们建议在启动前应至少打开并检查轴承和轴封。如果泵贮藏超过5年，我们 建议拆开泵，并更换所有垫圈和密封圈。

名称：

报告

保存和贮藏

工厂/位置:.......................................................................................................................................... 总规格:........................................................................................................................................ 泵的型号:........................................................... 驱动器:.......................................................... 序号:.................................................................. 型号/编号:..................................................... 出货日期: .........…………………………….. 备注:.............................................................. …………………………………………………. 到达日期: ……….……………………… …………………………………………………. 负责人: ……………….…………………………... 1. 发货保存: □ 标准（6个月）

□ 特殊包装（2年）

□ 航运包装（1年）

□ 其他..........................................................

2.

包装损坏:

□ 是

3.

如果航运包装或特殊包装被去除或损坏了，则只有标准保存（6个月）是有效的。 贮藏:

□ 否

□ 在包装箱内

□ 贮藏地方应无振动

□ 室外（采用防水帆布保护）

□ 贮藏地方应没有腐蚀性气体、吹沙或污染物

□ 室内

□ 应对贮藏的地方进行加热

4.

贮藏期间所采取的措施:

间隔时间

□ 检查喷漆并修复

按要求

□ 没有遮盖且光亮部件的检查和重新上涂层

6 个月

□ 壳体内注入防锈剂或清除浓缩物重新 □ 拆除管嘴盖，并在内部喷防锈剂 □ 轴承箱清理和重新加润滑油

6 个月

□ 清除腔室的润滑油，重新加入

12 个月

日期:

签字：

3 个月

□ 其他 ...................................................... 注释: …………………………………………………………………………………………………………….. …………………………………………………………………………………………………………….. …………………………………………………………………………………………………………….. …………………………………………………………………………………………………………….. 备注：发货保存时间从出货日始 R 0000 / 3-0-00-000

5.

日期：

签名：

页码：

4. 描述

图 4.1-1 标准视图

4.1 概述 苏尔寿MC泵是卧式、多级、高压、径向剖分式泵，设计用于锅炉给水和其他的高压用途。 注意: 这些泵适用于泵送干净和轻度污染的液体。容许工作压力和容许工作温度取决于材料规范。 注意: 结构材料是按照订单中的指定的介质选取的。在使用其他介质或其他的温度条件下运行时，必须向生产 厂商咨询。 防爆装置 根据欧洲联盟规章94/9/EC(防爆指令)和泵的设计意图，泵可以用于以下范围中： II 组 第2类别

第3类别

G(区域1) D(区域21) G(区域2) D(区域22) G – 潜在的爆炸性气体环境 D –潜在的爆炸性粉尘环境 温度等级 确保泵是根据其组别分类且提供有相应的证书。 o 每组都是由周围的气体或周围的灰尘和温度等级决定的，最高的外界环境温度为40 C。 所输送的材料容许的最大温度必须遵守正处于讨论中的温度等级。观察传输材料温度的责任通常落在操作人员身 上。 T1 T2 T3 T4 T5 T6 温度等级 o

300 C

o

280 C

最高温度

450 C

介质最高温度

430 C

泵组件标识举例 组别 类别 温度等级

4330/e4-1-00-000 第1页

o

200 C

o

135 C

o

180 C

o

100 C

o

115 C

o

o

80 C

o

II

o

85 C o

65 C

2G

T3

4.2 泵的描述 泵壳 泵壳为径向剖分泵，由进口段、中段（环形截面壳体）和出口段组成。各部分由O型圈依靠外部的穿杠螺栓联 接密封。 叶轮 叶轮通过键联驱动，中段和导叶上有可更换的磨损环，通过导叶逐级引流。 轮轴 精密的机加工为安装和操作提供合适的间隙。轴肩为部件提供了正确的安装位置。 轴封 泵内部的液体由填料函或机械密封密闭，具体见7.2或密封厂家的资料。 注意： 密封箱体根据需要可带冷却腔，为了防止轴密封处汽化，冷却水流量必需确定，否则会导致密封失效。 联轴器 必须使用挠性联轴器，使得允许轴有轴向、径向和角度串量。

4.3 轴承支架和润滑 轴承箱 轴承架安装在泵的两侧，采用飞溅润滑。在联轴器端头的轴承可以吸收径向力，而对面的轴承决定转子的轴向 位置。关于润滑油量，可见公共能耗清单。 注意： 根据工作环境，轴承箱可以根据需要水冷却以保持可接受的轴承温度。在这种情况下，冷却水量可参 见公共能耗清单。 耐磨轴承 驱动端使用圆柱滚子轴承，非驱动端使用可承受轴向力的双列圆锥滚子轴承。 风扇 非驱动端装配有风冷轴承架的风扇。 恒位油杯 每侧轴承架都安装了恒位油杯，它可以维持轴承支架的油位并且起到自动补油的作用，参见第7.3节。

4330/e4-1-00-000 第2页

4.4轴向推力的吸收-平衡鼓 概述 当泵运行时，由于叶轮前后盖板面积不同而产生的轴向力，方向指向吸入端，对于多级泵，轴向力是每个叶轮 产生的轴向力的总和，可通过水力平衡装置平衡轴向力。 工作原理 平衡装置包括随轴一起旋转的平衡鼓（603.01）和固定在出口段上 的 平衡鼓套（605.01）。平衡鼓是末级叶轮后盖板处产生的压力（约等 于泵出口压）“a”和平衡腔产生的压力（等于入口压力+平衡管路损失） “b”造成的作用在平衡鼓上的压力差“F”，以此来平衡轴向力。压力差“F” 是由平衡鼓的端面“A”产生的，每个规格泵的平衡鼓都能保证泵在工 况点完全平衡轴向力。推力轴承平衡残余轴向力，由于“a”腔和“b”腔 的压力差，介质经过平衡鼓和平衡鼓套间隙“c”流入“b”腔平衡装置才 能无故障的运行。要想平衡轴向力，通过平衡流量的控制，来防止平 衡腔内压力过高。

轴向推力 图4.4-1 平衡鼓工作原理 平衡管 注意：

若不严格对待平衡管路的配置，泵有可能会造成严重的损坏。

注意：

为防止平衡腔的压力过高，必须控制排放液的流量。（位置在尺寸图上标出）。

平衡管路的规划根据运行工况形式。它或者： 引回到入口端的罐中 或者 引回到泵吸入段壳体 -

具体数据见随泵提供的安装图。 注释： 当回流到入口端的罐中，必须注意下列项： 注意： 平衡管的摩擦阻损失不能超过0.8bar，选择相应的名义直径。 注意： 为了便于维修，在管路上应该设置阀门，阀门设置锁死装置，防止未经允许而关闭或偶然关闭。 平衡设备的损坏可能会导致平衡介质加热，在平衡管内引起难以承受的压力。因此必须在管内安装安全阀。 调节出口压力高于进口压5 bar。

4330/e4-1-00-000 第3页

5. 安装 5.1泵组单元的安装 A. 概述

(参考工作外形图、安装图等)

用于具有潜在爆炸区域的机械装置必须满足防爆要求。核对关于机械和附件（和铭牌）的文件。 要使泵机组快速、简洁、正确的安装，需要周密的计划和充分的准备工作，同时使得泵机组安全运行，当准 备安装泵机组时，必需注意下列事项： 地脚螺栓的联接位置和尺寸见外型尺寸图/安装基础图。 在进行安装或检修工作时，必须有适当的起吊装置，具备良好的光线和手提灯插座是必要的，安装的泵在各 个方向便于接近。 泵的基础和安装设计保证在运转状态和停机状态下振动值为最小，否则将减少泵的寿命。 必须提供排放管路，以便于密封泄漏液、冷却水（开放系统）和大修时排出的介质排放。 对于有毒、爆炸、热的或其他危险介质的排泄要特殊处理，防止对操作人员和环境造成危险。 根据生产要求，在管路安装以前，法兰和外接口由至少5mm厚的金属封尾带弹性垫圈保护，在整个安装期间， 泵必须盖住泵。 基础或任何其他必要的建造工作必须完成。将基础弄粗糙并进行清理。所有装配的准备工作都必须完成。对 于大型装置，需有合适的门窗洞口用于到安装现场的运输。 水泥浆的选用 2 选择抗缩的水泥浆可以更好的适合于高温和低温。选用一家混凝土最终强度为25N/mm (B25) 或强度更好的 混凝土公司的混凝土。 如果混凝土公司没有有效技术，下面所给的数据可作为参考。 适合于用机械底座灌浆的混凝土，每1 m³必须含有300 至350Kg 水泥。每1m³成品混凝土（1.2 m³混合物） 中沙子和石子的比例如下所示： 地脚螺栓的灌浆 65%细砂 粒径 1-5mm(0.04-0.2英寸) 35%粗砂

底座灌浆

粒径

5-10mm（0.2-0.4英寸）

根据需要加水 这种称为“快速凝固水泥”的使用可以缩短安装时间。 40%细砂 粒径 1-5mm(0.04-0.2英寸) 60%粗砂

粒径

5-15mm(0.2-0.6英寸)

水：100-140升（7-10加仑） 表5.1.1 注意： 只有清洁的、被洗过的沙子可以使用，水和水泥的比例对混凝土的最终强度起决定性影响。 通过高标号的水泥、低的水和水泥比例及成型时的震动可获得高强度的混凝土。

4330/e5-1-00-001 第1页

B.机械竣工和安装程序检验清单 参考段落

内容

□

5.1 A-G

□

5.1 C

泵和驱动器的安装

□

5.1 D

找平，底座板的水平校正

□

5.1 E

地脚螺栓灌浆

□

-

□

5.1 G / 5.1 D

紧固的地脚螺栓和重复检查找平

□

-

装上驱动器（如果是现场安装）

□

5.2 A-H

□

5.2 D

检查较软的脚点、泵和驱动器

□

5.1 F

底座灌浆

□

5.1 G

砂浆养护后地脚螺栓的最终固定

□

5.3 A-H

□

5.3. C

检查无应力管道连接

□

5.3 F

清理管道

□

5.4 A-H / 8. A-B

□

5.5 A-B

□

-

□

5.2 A-I

现场安装说明

混凝土凝结

将驱动器和泵对准

安装主要管路

安装辅助设备 安装最小流量装置（如果有） 泵系统注入和排出 最终定位（安装联轴罩）

表 5.1.2 □

当完全满足时打勾

C.泵和驱动器的安装 在作业前和作业期间，应确保气体不会有潜在爆炸的危险。如果发现任何危险，应立即停止所有工 作。 注释：对于具有单独底座的泵和驱动器，先安装泵，再调直驱动器。 前提 - 位置必须具有充分的刚度以防止泵振动。特殊的底座设计将取决于位置和外部管路力的要求。 位置和表面检查 - 检查安装表面。所有用于安装泵装置的位置表面都必须清理干净，去除铁锈、污物或其他外来杂质。 - 将基础弄粗糙并清理干净。灌浆孔洞壁必须具有粗糙表面，且应没有污染，去除任何松散颗粒、污物或油 浸的混凝土。所有将和混凝土接触的底座板表面都应清理干净，并去除铁锈、油漆或其他外来杂质。 - 安装 - 将钢丝绳吊索拴到泵装置上（参见3.运输和吊装），并将泵装置小心提升起来。把地脚螺栓安放在底座的 螺栓孔中，用螺母粗固定。 - 将底座小心地放在基础的位置上。地脚螺栓必须放到位。

4330/e5-1-00-001 第2页

D. 水平调整 使用机械安装报告 TC 0000/5-1-00-000. 把钢片垫在调节螺栓下，借助调节螺栓调整泵机组的水平，底座和基础预留适当的间隙（见安装基础图） 注意： 在垂直法兰上用水平仪沿着泵轴方向检查泵的安装。泵侧面的法兰必须是垂直的，参见图5.1.1。 最佳误差 :每1 m误差为0.2 mm (0.003 in./ft.). 最大容许误差: 每1 m误差为0.5mm (0.006 in./ft.). - 在基础地脚螺栓孔两侧安放钢片，要有不同厚度的垫片，便于调整底座与基础的间隙，参见图5.1-2。 - 拧开调节螺丝，并检查是否水平。如果需要，应调平。

图 5.1-1 装置调平

图 5.1-2 地脚螺栓灌浆

E.浇注地脚螺栓 - 浇注前，先将地脚螺栓孔弄湿，用混凝土添满地脚螺栓孔，参见图5.1-2。 - 浇注后，将地脚螺栓拧紧（参见表5.1.3），再次检查水平校准。如果泵位置已经改变了，则应调整校准。 注意： 应避免底座变形，以免泵运行时产生振动和噪音及联轴器调整产生困难。 - 在浇注底座前，按照第5.2节（校准报告）的规定调节对中联轴器。

4330/e5-1-00-001 第3页

F.完成灌浆 (正确校正后) 注意：

浇注基础是安装过程非常重要的部分。水泥质量如果有问题，将会导致过早的失效。

-

在基础设置围堰，要有足够的强度承受水泥的压力，同时围堰 四周有斜边，参见图5.1-3。

-

按照相应的安装平面完成底座板的灌浆。通过灌浆孔向底座板 浇灌较薄的一层混凝土，并应确保底座板完全灌满混凝土，如 有必要应进行振捣。

注意： 混凝土在最初48小时内既不要变硬，也不要结冰。在此期 o o 间，基础温度不要低于10 C（50 F）。混凝土凝结过程中的最佳 o o o 温度为20 C +/-10 C (65 +/-15 F)。 -

必要的话，可给灌浆孔涂漆或用灌浆孔盖盖上。

浇注后，重新拧紧地脚螺栓（参见表5.1.3），并检查联轴器校准对 中（校准报告） 图5.1-3 底座板混凝土灌浆

G.地脚螺栓拧紧力矩 螺纹规格（外尺寸，英寸） 拧紧力矩 Nm(lbf.ft)

M 12(0.04)

M 16 (0.60)

M 20(0.80)

M 24( 0.95)

M 30 (1.18)

灌浆前力矩

15 (10)

30 (20)

70 (55)

140 (105)

280 (210)

灌浆后力矩

20 (15)

50 (40)

100 (75)

185 (135)

350 (260)

表5.1.3

4330/e5-1-00-001 第4页

名称:

测试证书

机械安装

工厂 / 位置:...................................................................................................................................... 总规格:........................................................................................................................................... 泵型号:................................................................ 驱动器:.......................................................... 序号:................................................................... 型号/编号:..................................................... 方法 证实 1. 基础施工 是 □ 否 □ 日期: 签字: 主要尺寸和连接检查 2.

底座板调平 调平

日期:

方向

签字:

纵向

横向

测量值:

.................

.................

规定值:

每米误差在0-0.5 mm 间 最小值: 最大值:

检查底座板和基础间的距离

尺寸 X

地脚螺栓 地脚螺栓混凝土灌浆

是 □

否 □

日期:

签字:

是 □

否 □

日期:

签字:

3.

混凝土凝结后拧紧地脚螺栓

4.

底座板混凝土灌浆 方向

调平检查

纵向

横向

.................

.................

日期:

签字:

□

日期: 日期: 日期: 日期:

签字: 签字: 签字: 签字:

否 □ 否 □ 否 □

日期: 日期: 日期:

签字: 签字: 签字:

测量值: 底座板应灌满混凝土

是 □

5. 管道连接 联轴器校准检查 泵支脚和驱动器紧固 主要管路的应力控制 管路清理和连接 (主要和辅助部分)

6.

是 是 是 是

□ □ □ □

否 □

否 否 否 否

□ □ □

附属检查和连接

电气连接 (主要及辅助部分) 润滑检查(泵、驱动器 ...) 驱动器试运行, 转动检查 (泵未装联轴器) 系统检查 系统清理 系统注入和排出

是 □ 是 □ 是 □

7.

压力测试

是 □ 是 □ 是 □

日期：

4330/e5-1-00-001 page 5

否 □ 否 □ 否 □

返工: 是 □

测试结果 接受: 否 □ 是 □

否 □

TC 0000 / 5-1-00-000 签字：

页码

5.2.联轴器校准 A. 概述 如果苏尔寿供货范围中不包括联轴器/联轴器保护，应确保在潜在爆炸区域只能采用批准的材料和设计。 驱动器“空载”运转 在没有安装联轴器前，检查电机的旋转方向和泵的旋转方向是否一致。 辅助设备的装配和电动机电气连接必须按照生产厂商的要求完成。关于详细内容，请参考驱动器的生产厂商 手册。 “空载”驱动器测试将检查驱动器运转情况，并在驱动器连接到泵之前提供最终的设备调整机会。 注意： 挠性联轴器需要将轴非常仔细的进行校准，通过调整机械支脚下垫片的厚度，调整轴的中心，对中 不当，将会破坏联轴器、泵及电机的轴承。 注意：

如果适用的话，应确保在转子准备运转之前拆掉转子的任何锁扣装置。

注意：

在转子准备运行之前必须对轴承进行润滑，应避免机械转子的任何不必要的运转。

注意：

每当实际使用时，在用手转动泵之前必须将介质注入泵内。

注意：

不锈钢装配的泵在拿起时特别容易受影响，只要可能应避免用手转动。

范围 本节描述了所供应的泵装置的调整发动机（主动机）和泵（从动机）的建议程序。 1. 当用作参考机器（标准泵）时，确定哪台机器需要正确调平和定位。此机器的位置应保持不变，如有必要， 应将附件的机器移动和其对准，参见图5.2-1。 2. 确保参考机器（泵）正确调平和定位。 3. 从参考机器向外进行，定位下一台机器A，使其和连接法兰或轴端（根据情况）间的缝隙一致，并将轴和参 考机器的轴对准。 4. 如果在驱动机构中包括另外一台机器B，将机器A作为参考机器定位并校准B，使其和A对齐。采用同样的 方法，定位和校准C，使其和B对齐，以此类推。

图 5.2-1 参考机器 – 下一台机器

4330/e5-1-00-001 第6页

B. 不合理的安装形式 泵和电机轴不合理的三种结构形式：

图 5.2-2 角度偏移 轴线在某一点交叉

图 5.2-3 轴中心线偏 移 轴线平行，但偏移

图5.2-4 轴向距离偏移 轴线平行，但错位

C. 安装 根据联轴器安装手册仔细安装泵端联轴器和电机端联轴器。参见维修手册。

D. “软机械支脚”的检查 在联轴器校准之前，泵和驱动机必须对“软支脚”进行定位检查。 如果在机器支脚与底座之间存在空隙，先后松开机器支脚的固定点并用测隙规检测。如果空隙大于0.05mm （0.002英寸），则空隙必须用薄垫片补偿。 如果底座还没有被灌浆，“软支脚”也可以通过重新调整底座得到补偿。 如果泵或驱动机没有正确的安装在底座上，那么会产生由于管口载荷引起的间歇振动和过大的不对中程度。

E. 泵底座拧紧力矩 为了传递力及力矩，紧定螺栓必须拧紧在泵支脚上。为了弥补由于泵的热膨胀可能产生的松动，非驱动端不 必像驱动端拧的那样紧。驱动端和非驱动端系紧螺钉的拧紧力矩见下表。 标准螺纹直径

拧紧力矩 驱动端

mm

in.

非驱动端

Nm

Ibf.ft

Nm

Ibf.ft

M 16

(0.6)

60

44

40

30

M 20

（0.8）

120

88

80

60

M 24

（0.95）

220

160

140

100

M 27

（1.05）

350

255

220

160

M 30

（1.18）

480

350

320

230

M 33

（1.30）

680

490

450

325

M 36

（1.42）

900

650

600

435

M 42

（1.66）

1500

1080

1000

725

M 48

（1.88）

2400

1740

1600

1160

M 56

（2.20）

3900

2820

2600

1900

M 64

（2.21）

5900

4270

3900

2800 图5.2-4 底座拧紧力矩

表5.2.1

F.热增长的补偿 温度会产生比较大的影响，因此在校准中应该考虑到。每台泵的轮轴和驱动器的中心线当其达到运行温度 时将会升高。因此，这两者预期增长间的差值应该包含在冷校准中，以便当达到运行温度时轴仍然对齐。

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根据装置热增长间的差别，热增长较大的装置在安装时必须比其他装置低。 泵的热增长 注意：

对于底部支撑的泵（不是中心支撑）和运行温度在80℃以上时，

应按照以下表格考虑热增长。 泵尺寸 MC 40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400 X =中心支撑

H 160 185 240 275 325 360

> 80 0.10 0.11 0.14 0.17 0.20 0.22

热增长 ⊿H 单位mm o 运行温度 C > 100 > 130 > 150 0.13 0.18 0.22 0.15 0.21 0.25 X 0.20 0.28 X 0.23 0.32 X X 0.27 X X 0.30

热增长△H

> 170 0.25 0.29 X X X X

热增长 X 可 忽略

图 5.2-5 驱动器热增长 泵的热增长 注意： 驱动器设备的热增长必须从生产厂商的说明获得。 热增长跟温度、载荷和周围环境而变化。对于齿轮或蒸汽轮机驱动设备，应考虑附加的横向和/或者轴向热 增长。

G.轴向轮轴间距 半联轴器之间的间距必须遵守，请看安装图和附录中联轴器的安装提示。 在轴间的距离调整之前，不带止推轴承的驱动器轴必须固定在合适的运行位置上，参考驱动器生产厂商的说 明。 半联轴器间距 注释：联轴器法兰面和轴端面不对齐时，联轴器法兰面间（DBCFF或DBFF）的距离通常在相应的图纸上有 规定，而且应作为设置机器间正确间距的参考尺寸。轴端（DBSE）间的距离可能也会在图纸上有示意，但 不能将其作为参考尺寸。 联轴器端面和轴端面对齐时，联轴器法兰面间的距离DBSE通常在相应的图纸上有规定，并应该作为确定机 器间合适间距的参考尺寸

H. 校准 概述 任何高度的改变可以通过在设备支脚和底座板基架间加垫片来实现。垫片最多为4个。在校准后，根据所给 力矩（参见泵脚点拧紧力矩）拧紧泵脚点紧固件，并重新校准。 在每次校准检查/程序（参见下页）中都应填入联轴器校准证书TC 0000 / 5-2-00-000。 注意： 每次校准检查/控制都必须在泵处于冷态并考虑泵和驱动器的热增长的情况下进行。不允许停机后热 作业下进行热校准程序。 在管道连接期间必须监控联轴器的校正，并在管道连接后重复检查以确保管道连接对校准没有造成不利影响。 如果影响到校准，应重新进行管道连接直到校准合适为止。 注意： 不要调整驱动器或者从动机位置来纠正管路连接引起的对中误差。

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联轴器校准程序 每次对中检查必须先测量跳动，并将结果记录在联轴器校准测试证书上。 先检查垂直对中，进行必要调节。然后再检查水平对中，进行必要调节。 拧松活动机械上的压紧螺栓，提升机器，并向安装脚下面插入足够的垫片以使得轮轴和参考机器的轴对齐， 同时应考虑冷态偏移（热增长）。必须使用至少和安装脚相同尺寸的带槽垫片。垫片最好是不锈钢的，且有 各种不同的厚度。大多数情况下，对于水平校准，应提供定位螺旋千斤顶。根据需要拧紧或拧松螺旋千斤顶 以便使得轴和参考机器的轴对齐。 在用垫片填补和水平校准后，紧固参考机器和活动机器的压紧螺栓直到合适的力矩值，重新校准。如果需要， 应校准对齐。 公差 直径上最大允许轴向错位为0.05mm（0.002英寸），但最好 ≤0.03mm(0.0012英寸)。 直径上最大允许径向错位为0.1mm（0.004英寸），但最好 ≤0.05mm(0.002英寸)。 千分表校准 径向和轴向都应该采用千分表进行校准（参见图5.2-7）。确 保每个指示器的支撑具有足够的刚度以消除由于任何的下垂 导致的虚假读数。所有径向和轴向偏差的读数在仪表位置确定： o 顶面、底面、右边和左边。例如：每90 ，而两个轴同时转动。 光学对准 可使用光学（激光）对中设备来取代使用千分表装置 。光学对 中是最精确的轴对中方法。发射机是一个激光二极管，安装在 联轴器一侧，棱镜安装在另一侧。激光产生的激光束由棱镜反 射到定位器。 偏差可以通过旋转轴测得。 S k e t c h 5.2-8 光学对准

I. 联轴器安全罩 泵必须在安装联轴器罩后方可工作。每次校准对中检查之后联轴器罩必须立即重装。检查罩的正确 安装、是否牢固和与联轴器的距离。

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名称：

测试证书

联轴器校准

工厂/位置：........................................................................................................................... 总规格：............................................................................................................................... 泵型号：……………………………………… 驱动器：……………………………………… 序号：………………………………………… 型号/编号：………………………………….. □ □ □ □

管道连接前校准： 管道连接后校准： 试运行前校准： 试运行（维修）后校准：

备注: …………………………………… ………………………………………….. ………………………………………….. …………………………………………..

1. 轴向间距检查

联轴器间隙（mm） 规定间隙: 公差:

泵

驱动器

带加长段的联轴器

泵

驱动器

实际间隙

不带加长段的联轴器

联轴器型号：………………………. 2. 径向偏差检查（参见2.1）

否 □

径向偏差（mm） 测量位置

左

测量值: 规定值: 泵

是 □

加长段：……………mm

右

上

下

0…0.1(最佳值0.05)

驱动器

2.1 轴线位移的检查 (仅适用于驱动器和从动机间热增长差而引起的 偏差)

轴线位移（mm） 位移

水平方向

竖直方向

测量值 规定值

泵

驱动器

0…0.05

驱动器安装在…………………………mm 以上/以下 驱动器安装在距离右侧/左…………...mm处

3. 轴向偏差的检查 （平行） 轴向偏差（mm） 测量位置

左

右

上

下

测量值: 0…0.05(最佳值0.03)

规值: 泵

驱动器

4. 螺栓紧固检查 （校准后） 泵底座检查： 是 □ 否 □ 驱动器底座检查： 是 □ 否 □ 锚固螺栓检查： 是 □ 否 □

测试结果 返工： 是 □

接受： 否 □

是 □

否 □

TC 0000/5-2-00-000 日期: 4330/e5-1-00-001 第10页

签名:

页数:

5.3.吸入和排出管路 A. 概述 焊接、烧灼和打磨工作应当只在泵上经特别批准的地方实施，否则可能存在火灾和爆炸风险。

管的直径在设计阶段已经确定，泵制造商已经把很多未知的因素考虑进去。通常吸入管路中介质的流速不超 过2m/s，排出管路中介质的流速不超过3m/s。 一般泵吸入管路法兰的公称直径大于（或等于）泵排出管路法兰的公称直径，这样可以减少由于摩擦造成的 扬程损失。基于同样的原因，管路敷设时应尽量少用弯头，而且即便使用弯头，也应该尽可能为大半径弯头。 下面给出一些在安装管路时应该考虑的实际问题。 注意： 泵停车后可能发生倒流，因此必须在管路上设置防止回流的装置（止回阀）装配。

B.安装 注意： 管路必须有足够的支撑，以确保不能因为管路的自身重量或由泵法兰传递过来的热量所引 起的热膨胀而使管路产生弯曲力矩或压力（可以安装一膨胀节）。 所有的支撑和膨胀设备在和泵联接前安装。保证法兰连结处垫片的正确使用，并注意对中。

C. 无应力管路联接 无应力管路联接按以下方式检查（凉泵，空泵）：  管路必须悬挂在泵法兰上端，并预留足够的空间紧固密封。  支撑装置设计时必须考虑到管路和液体的重量，不允许其对泵支口施加过高的压力(参见管口载荷图)。 高于给定的最大许可管口载荷可能会导致输送介质的突然泄漏和对生命造成危险。 

如果管路支撑（特别是固定点）不在泵的附近且有 1 或2 个弯管接头（45° 或90°变向）的管路可以看 作是挠性的。这种情况下，以下偏差可以应用“无应力联接”。

\

/

S 图 5.3-1 径向偏移

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图 5.3-2 角度偏移

挠性吸入和排出管路无应力联接（凉泵状况） 管道公称直径 径向偏差 A 角度偏差 S

小于或等于200（8英寸）

大于200（8英寸）

最大0.5mm（0.02英寸） 最大0.2mm（0.008英寸）

最大0.4mm（0.016英寸）



如果管道是非挠性的，可采用挠性管道容许偏差的50%。应确保不能超过最大允许管口载荷（参见安装 平面图）。 注意： 如果偏差超过允许量或对管路损坏，应及时调节管路。

D. 管路安装 出口管路 出口管路止回阀和截止阀应安装在泵出口管路上。止回阀应放在泵和截止阀之间，用来防止倒流 和承受反压。当泵停车时起用截止阀作用。 入口管路 吸入管路在管路上应安装截止阀，以利于泵停车、维修和残液的排放。在运行期间，截止阀必须 完全开放，且一定不要用于泵的调节。 注意： 应使用相同公称直径的管路。如果泵支路的公称内径比配件的公称内径小，则应安装合适的变径管。

E. 吸入管 在吸入端淹没的情况下，吸入端卧式管道部分管径朝泵的方向应该是由大变小的（泵端为小），在吸入端提 高的情况下，卧式管道部分管径应该朝泵的方向平稳上提，防止空气滞留。

图 5.3-3 倒灌 (吸入扬程) 图 5.3-4 吸上 变径管路的设计应不妨碍流体的自由流动。从小管径到大管径应该是逐渐的变化过程。同心锥管（变径管路） 的长度一般是管两端管径差的5～7 倍。 应该避免管的横截面积突然减小和过尖的弯角，尤其在吸入端不应该出现此类变化，因为这些变化大大增加 了管路的摩擦阻力。吸入端高的摩擦阻力将使泵入口压力减小，太低的压力将导致叶轮入口处产生汽蚀。 不要将截止阀放在吸入管路和吸入口之间，以免产生紊流。入口阀应手柄水平或垂直朝下，以防止气囊产生， 在流动扰动间安装将其作为配件或弯头，直管长度为管径的5~8倍。 注意： 在安装几台泵的情况下，除备用泵外，每台泵必须提供单独的吸入管路。备用泵与对应的泵可用一 根共同的吸入管，这是因为在使用过程中始终是一台泵在运转。

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F. 管道的清洗 在泵开车前，必须认真清洗管路系统中的所有污物和杂质，管路焊接处的焊渣等杂物必须被清除

G. 入口过滤器 为了防止杂质进入泵内，可以在入口管路安装不锈钢过滤器。插入的过滤 器应包含支撑吸滤器圆孔板，圆孔尺寸为5~8mm（0.2~0.32英寸），在 圆孔板上焊接金属丝，金属网格尺寸为0.315X0.2mm（0.0125X0.008英 寸）。此吸滤器通过的有效面积必须至少为管径的1.5~2倍。 用压力表监测通过滤网前后的压力变化。当吸入压力减小时，应将过滤器 拆下清洗。 注意： 当压差≥0.35 bar（5psi.） 时，开始报警（清洗过滤器）。最大 在0.5 bar（7psi.），泵应停车；高的压差可能导致过滤器损坏，严重的 可能损坏泵。 图5.3-5 过滤网 注意： 过滤器的载荷是有限制的。因为过滤器的最大允许压差降低了吸入支管的有效汽蚀余量，然而，有 汽蚀余量一般大于规定必须汽蚀余量，因此应将警报/关闭的控制限值相应地设置低一些。

H. 压力试验 注意：

管路应按照规范的要求进行水压试验。

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5.4. 辅助设备 A. 概述 辅助设备是用来对泵进行监控（如：压力、温度等测量设备）和对运行进行维护保养（如：冷却、冲洗、密 封等）。所需的辅助设备应根据装置运行需要来确定，辅助设备管路的位置和尺寸见安装图。 任何辅助装置(如：冷却、循环)的失效都将导致泵内的压力超过允许值，这样用户必须安装适当的安 全装置(如：报警器、紧急停车或其它类似的装置） 1.

注意： 不要混淆管路，管铺设（或修理）完毕后应检查管的走向。所有设备内的冲洗管路和电缆桥 架等辅助管道，均不得踩踏，攀登等方式，避免管道损坏及事故发生。

下面的说明可以作为泵辅助管路和辅助设备的指导。

B. 电气连接 电机和控制设备的电源连接只能由专业技术人员来完成。认真阅读电器设备制造商的使用说明书、 电器装置的国家规范和有关当地供电商的法律规范。 应遵守和终端连接相关的相应标准和指导。如果底座板已提供接地线耳，则必须连接。

C. 压力测量设备 - 泵操作点的启动和监控通过使用压力计而变的相对容易些，可参见第6条和第6.7条。压力计应安装在普通 仪表板上，并用带有膨胀圈的液压管连接到泵分支或者附近管道的丝锥上。在管道上安装隔离阀和排气阀 以便于维修保养。 - 如果轴封外流，则在此管道上安装压力计用于监控压力。

D. 温度测量仪器 - 如果泵在邻近汽化点运行，则应用温度计控制液体温度，也可参见第5.4节“最小流量装置”。在管道上安装 温度计时，温度计应插入到液体40mm以下。如果压力大于16bar，则使用保护套管（DIN43763） - 如果有技术要求，可控制密封循环液温度，以避免在密封附近汽化。 - 热载体加热至最大温度时，一定要注意控制。 - 推荐测量冷却水出口温度，调节出口温度小于40 ℃。防止冷却水管堵塞。 - 如果泵使用高载荷轴承，需要控制轴承或油温。如果有必要，可用接触式温度计。按装和测量点参见管路 配置图或安装方案，关于限值，参见第7.3节。 - 按照泵油温或轴承温度的各自值不超过限制值为准。 E. 轴承的监测 (振动测量) 采用冲击脉冲的测量方式（可能含滚动轴承）、轴承箱振动或轴振动测量方式。 - 轴承损坏和其他机械故障可以通过电子传感器测量方法得知和探测。电子（计算机化的）振动系统可用于 不断测量和监控各类监管参数，从而防止意外的机械故障。关于更多的信息，请参考生产厂商的详细说明。

4330/e5-1-00-001 第 14

页

F. 流量指示或流量计 - 按照技术要求，流量指示器安装在供给管回流处。在辅助管路打开之前不要启动泵。液体是否流动可以由 流量指示器确定。 - 过低的循环流量可对密封造成危险，将流量指示器安装在循环管路上。流量计将在循环量下降时发出警报 或将泵关闭。

G. 过滤器/过滤网/旋液分离器 这些装置用来清除机械密封冲洗液中的杂质。 注意： 如果使用过滤器或滤网应注意（不适用于旋液分离器）。如果更换过滤器时泵不能停车，可以安装 可转换的并联的过滤器。如果密封压盖的温度不断升高或过滤器前后的温差过大，应立即更换或清洗过滤器。 为操作安全起见，推荐用带远距离指示器、转换功能的过滤器。

H. 辅助管道工程 - 排残 泵体残液可以通过一根管引到底座上的残液收集盘或收集管中。排残液管路上必须配置一个公称压力 不小于泵额定压力的阀门。 泵送有毒、易燃易爆、过热或有其它任何危险介质的排残液不应该对操作人员和环境产生任何危险。 - 密封泄漏：密封的泄漏液也可以通一根管引到底座上的残液收集盘或收集管中。 危险介质的泄漏液必须排走或急冷冲掉，这样可以对操作人员和环境不产生任何危险。 - 冷却：在布置图或独立的冷却水系统图表中指出需要冷却的地方，不要混淆进、出口管路，冷却水管应该 按照从冷却腔的最低点进入，从冷却腔的最高点出，为调节冷却水量应在进口管上安装流量调节阀，在开式 系统中排出的冷却水引到排放渠中。 - 加热：接口和位置参见各自的安装方案图。不要混淆出、入口（入口高，出口低）。在供给管路上安装调 节阀。引导回流到一个收集管，如果必要的话，可流经汽水分离器。 - 轴封的冲洗和密封：在布置图或独立的密封冲洗和（或）冷却水系统图将指出需要的冲洗和（或）冷却 必要时要连接换热器，压力源或在最高点设有排气孔的密封液罐。如果需要虹吸，那么要用尽可能长的管 子，管路必须是连续的并且不能突然拐弯。 - 急冷：如果需要对机械密封进行急冷，详见公用工程消耗清单中急冷介质和急冷液流量的介绍。

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5.5.最小流量装置 注释： 按照当地的安全标准，这些说明必须作为每一本操作说明书中的一部分。这是关于泵在部分载荷区域运行的安 全说明。如果所提供的泵从来不在部分载荷区域运行，则可忽略以下说明。

概述 注意： 泵在局部负荷工况内运行时（当泵接近零流量时），几乎把所有的能量以热能的形式传递给泵送介质。 如果这个流量小于某一个最小值，液体将被加热直至汽化，结果会导致平衡装置、叶轮和泵体口环的损坏， 最终导致泵的损坏。为了避免发生上述现象，一定要确定泵的最小流量。 如果输送管道的关闭装置在泵运行期间节流或处于关闭状态，在较短时间内，泵内的输送液体会变热， 这可能会导致泵壳的表面温度超过许可的温度等级。如果需要的话，应在设备上安装合适的安全系统 （例如：远程温度控制，带有紧急切断装置）。 对于多级泵带水力平衡轴向力装置，会有下列两种情况： 1. 平衡液流量比较大 这是指电机功率相对比较低的情况下，吸入状态合适，平衡液流量比较大，这种情况下的泵，最小流量与平 衡液的流量相同，则平衡管路不要联接到泵吸入腔，必需引回到入口端的罐中。 2. 平衡液流量比较小 最小流量装置必需设置在系统出口管路上（靠近泵出口法兰），在泵出口阀关闭的情况下，为保证最小流量， 下列设备必需提供： a) 自动排气止回阀 随着流量减少，最小输送管路自动打开，由整体的节流阀部件控制最小流量。反之， 会增加流量。最小输送管路直接接到自动排气止回阀上，并接回到吸入槽中。 b) 连续旁通管 在泵和排放阀间安装有旁通管，旁通管也接到吸入槽中。在管道中安装节流阀可以决定其 流量。在此种情况下，旁通管内液体在排放阀开启的情况下流动，这降低了泵的效率。必须慎重考虑是 否值得购买自动排气止回阀。 最小流量管路或旁通管 注意： 泵制造厂不提供最小流量管路，必需由使用 者 提供此套装置，管路必需由泵引回到入口端的罐 中，为了关闭和维修拆卸方便，关闭阀设置在最小 流量管路上，但试车时必需关闭阀门，若许多泵集 中在一起，则最小流量管路可联接在一起。单每个 支管路必需设置逆止阀。 注意： 如果最小流量管路和平衡管路要求引回到入 口端的罐中，这两个管路必须分开。 注意： 一定不要让泵在低于泵的最小流量时运转。 24 小时内，泵在最小流量点的运转都不要超过2 小时。 图 5.4-1 典型最小流量阀管路布置图 Minimum flow valve 最小流量开关，minimum flow line 最小流向线 Suction tank 吸入槽

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6.

运行

6.1 概述 以下所建议的启动和运行程序只适用于泵。关于任何设备（驱动器、联轴器、轴封系统等）的信息，请参考生产厂 商说明。

安全说明 在未进行以下操作前严禁启动或运行泵, - 已证实安装是正确的，且已检查了所有的安全和控制功能。 - 已经完全了解泵装置整体所有部件的位置和功能，包括阀门、可能影响流到或流自泵的介质流量 的上下游设备。 - 已完全了解所有辅助机械、电气和液压系统以及所有监控仪表和报警装置的功能。 当启动泵时，如果泵或辅助系统出现故障，应紧急关闭。

6.2 试运行 在工作之前或期间，应确保气体不会有潜在爆炸的危险。如果发现任何危险，应立即停止所有工作。 注意： 单独介绍的事项如果适用，在使用过程中必须逐步执行。在设备试压或运行前，所有管路上的紧固件（含 法兰，螺栓，阀门，活接头等）需要根据现场情况进行检查及拧紧，避免现场发生泄漏。

必须确保合格的人员操作电力传动装置，而且需有必要的保护措施。接地、重新设置、剩余断 电操作装置等必须准备好，并应获得经验丰富的专业人员的批准。

试运行前 a. 连接 检查螺栓连接和螺塞，检查辅助管道安装是否正确。 b. 润滑油 采用轻油清洗轴承箱，并排干净。注入润滑油，参见7.3和表中推荐的润滑油。 c. 校准 检查联轴器的校准（参见5.2） d. 轴封 检查轴封（参见7.2）。如果是双机械密封，注入和排出密封系统（参考生产厂商的说明） e. 灌注泵 注意: 如果是热（或）冷介质：当在环境温度下灌注泵时应特别小心。为了防止温度急增，应缓慢灌注，且灌 3 注流量应控制在0.3~0.5 m /h （1.2~2加仑/分），以便泵壳和内部部件均匀升温或冷却。 灌注泵 – 供给运行 灌注泵- 吸上 • 缓慢打开吸入管路的截止阀 • 完全打开吸入管道的截止阀 • 如果有（参见安装平面图）排气孔，应打开 • 如果有（参见安装平面图）排气孔，应打开 （泵体设排气孔是不正确的) （泵体设排气孔是不正确的) • 如果用机械密封时：机封腔应设排气孔 • 如果是用机械密封时：机封腔应设排气孔 （参见第5.4节冲洗和密封） （参见第5.4节冲洗和密封） • 当泵送介质没有气泡时关闭排气阀 • 灌注泵(吸入管道必须有底阀) • 完全打开吸入管路的截止阀 • 当泵送介质没有气泡时关闭排气阀 注意: 注意: f.

在启动泵之前，吸入管路、泵壳和轴封腔体必须充满液体。 如果有霜冻的危险，则应保护泵壳、轴承箱和冷却室防止冻伤。 最小流量管(如果安装) 打开和关闭最小流量控制管路上的阀门（参见第5.4节-para. 最小流量装置）。

g. 平衡管路 如果平衡管路返回到入口端罐中，同时应打开并锁紧此管路上的阀门。（参见安装平面图或P & I 图示）

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6.3 泵启动和运行 泵运行是基于以下假设：即假设泵系统总是完全充满输送液体。这防止了在泵内存在任何潜在的爆炸混合 物。如果这点不能保证，则在设备上应安装合适的安全系统（例如：液位检测器或电动机负载控制器）。 a. 辅助设备 如果存在，打开辅助设备（例如：冷却、加热、密封压力等），打开辅助管路上的阀门（在泵启 动后打开急冷管路）排放压力表中的气体（也可参见第5.4节） b. 无压系统开启 . 关闭出口管路上的截止阀（最小流量必须保证）。 . 启动驱动器，将泵转子加速到运行速度。 . 缓慢开启出口管路上的阀门，直到压差达到 数据单表中所列处的值。

有压系统开启 (前提条件是在出口管路上安装有止回阀) • 打开出口管路上的阀门，启动驱动器，将泵转 子加速到运行速度。

注意:

当运行低于最小转速（1400转/分钟）时，例如：经常变化的速度传动或涡轮传动，会对泵造成严重的 损坏。最大允许的至最小转速的启动时间为10秒。 注意: 当一达到额定运行速度时，泵就产生压力。如果没有的话，应立即将泵关闭并使泵系统保持畅通。 警告: 压差不允许的低于设计点压力，并且在装置中应保持稳定的系统压。出口压力表的示值为出口与入口 压差之和。 c. 观察电表读数 绝对不能超过电动机铭牌上显示的满载安培数。 d. 调整 泵流量可以通过出口阀门进行调整。 注意: 不要在低于最小流量时运行泵（参见第5.4节最小流量）。在泵运行期间，吸入管路上的阀门必须完全打 开。 不遵守说明可能会导致不可接受的温度增高，并使得泵干运行。在最极端的情况下，泵壳可能会发生爆 炸。

启动备用泵或启动平行工作泵 注释: 如果备用泵需要代替另一台（运行泵）的功能，在两台泵应同时运行一段时间。 a. 进行第6.1节 概述和第6.2节 试运行所述到的关于备用泵或平行工作泵的准备工作。 b. 按照第6.3节启动泵，检查出口压力。同时平行运行两台泵。 c. 备用泵 当运行完全达到正常情况时，可以将第一台运行的泵关闭，参见第6.5节 关闭 平行工作泵 两个泵都在运行。每台（相同的）泵 只输送一半的流量，参见以下的泵曲线图。不相同 的泵也可以平行运行，但在选择时必须非常仔细。 两台相同的泵平行 运行

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6.4 不允许的运行模式 • • • • • • • • • • • • •

必须避免过载的发生，因为过载而引起的严重机械损伤将导致零部件的损坏。如果泵在超过它自身的 性能范围情况下运行，将发生过载现象，例如： 超过最大允许转速 低于最低速度（低速转动，例如：涡轮传动，穿过泵高速冲洗，出口止回阀损坏导致泵的严重损坏） 超过或低于介质的粘度 超过最大允许入口压力 超过最大允许温度 超过或低于泵的运行范围 运行泵时没有排净泵体内气体 在没有安装规定的安全装置（安全阀、电子过载保护等）情况下运行泵 在出口管路上的截止阀关闭且没有安装最小流量装置（启动时例外） 在关闭入口阀的情况下运行（干运行） 泵的材质不适用于输送介质（化学、固体、气体等）的情况下运行 运行泵时的旋转方向错误 使用不正确的轴承润滑方式或错误的润滑油情况下运行泵 以上所列的运行模式和其他不允许的运行模式可能会导致对泵和设备的其他部件造成严重的损坏。承 压部件的爆炸所引起的碎片或热的、腐蚀性的及有毒介质都将对人或环境造成重大的危害，这些危险 一旦发生那将是致命的。

6.5 关闭 (注意顺序) 备注: 如果出口管路上安装有逆止阀，当是短期停车时，出口阀可以继续开着。当长期停车、维修或没有安装逆 止阀时，必须关闭出口管路上的关闭装置。 a. 关闭出口阀以及电机，同时注意转子是否是平稳、缓慢的停止。 备用设施 辅助系统如冷却、急冷、密封）是可正常运行，备用泵需要定期间隔启动，以便于可以立即投入使用，建议 每个月运行一次，时间为30分钟。 延长关闭 b. 如果在吸上运行，并不准备启动，则吸入阀应该关闭。 c. 如果有，应关闭急冷管路 d. 如果安装的话，关闭辅助管道的阀门，但冷却水例外，冷却水只能在泵已经冷却下来后关掉。 冰冻损坏和储藏 e. 如果有冰冻的危险，应防止液体在泵内冻结。需要排干泵体内和冷却水腔中的液体，包括外部热交换器和管 道。

泵的紧急关闭 a. b.

如果万一泵或任何辅助系统发生故障，则应立即关闭驱动器。 在重新启动装置之前，请遵守第6.6节中的重新启动程序

6.6重新启动程序 如果泵是在紧急情况下关闭， 在紧急事件原因发现和消除之前不能重新启动。 a. 在重新启动之前，检查泵转轴处于停止状态。如果排放管道的止回阀泄漏，由输送的介质回流，泵转轴转 向相反的方向。 注意: 在泵轴以相反的方向旋转时，禁止启动泵，因为这样可能会损坏机械。 b. 按照第6.3节 启动和运行，重新进行启动。

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6.7 运转控制 概述 必须观察和认真监控泵，确保无故障运行。 在运行的第一阶段（ 24小时）应进行密切监控。每隔一小时读取和检查运行参数。在运行的下一阶段（第一周） 每24 小时应进行监控工作。在正常使用中，应至少一周一次定期检查。 注意： 如果观察到有任何振动，不寻常的噪音或故障，立即停止运行。 参考章节“运行故障” 启动次数 泵正常的设计是连续的工作。太多和太频繁的启动会加速设备老化，并导致异常高度磨损和减少使用寿命。如 果启动次数太多，我们建议强化监管，并且应缩短维修间隔时间。所建议的启动次数如下： -试运行阶段：

不超过200次启动/停止（最多：6次启动/天）

-正式运行：

不超过3次启动/天

累计启动的最多次数： 600次启动/年 备注：如果启动/停止周期多，我们建议在运行6年后对水泵进行全面检修。 检查水泵的工作点（设计点） 在初次启动时，尤其重要  检测转速  读取出口压力并减去吸入压力 按下列公式计算后的差压值换算（产生的压力）成扬程，换算后的扬程与给定转速下泵铭牌上规定的扬程 值进行比较。

注意： 所产生的压力，不得低于泵数据表中限定的值，否则将超过最大允许流量，电机将过载或泵入口压将 低于所需的最小值。 流量检查 流量是由泵性能曲线和以上算出的扬程（米）来确定。 在性能曲线的纵坐标上，找到所产生的扬程的值.* ，通过这一点，画一 条水平线，水平线与曲线的交点所对应横坐标（水平轴）上的值就是要 确定的流量。 *如果特性曲线仅包括一级的压力，则将扬程除以泵级数。

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6.8运行故障 水力或机械的原因可严重影响泵的运行。工厂中还有其他常见的运行故障。 通常不同类型的故障之间都有一定的联系。所以，把症状和可能的原因列表并对比是有帮助的。实际情况中， 个别运行故障可找到原因。 故障/可能的故障原因/处理办法 故障

泵不工作、出 1 口无压。（启 动时的故障）

2 泵启动后出口 压力降低

3 水泵流量太小。差压 太低。效率损失

4 泵振动或噪音大

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可能的故障原因

处理办法

电机没有工作，转速太低

按照操作手册检查

转子卡死

检查并调整

旋转方向错误

根据泵转向箭头检查

泵没有准备好

泵排气

吸入阀/管路堵死

检查并调整

底阀堵死或损坏

检查底阀

叶轮流道堵死

检查泵内部

吸入管路没有完全充满介质

系统充满介质

泵送液体含气量大

检查运行数据

空气漏进入口管路

检查并调整

吸入和排出阀没有完全打开

检查阀门，调整到合适的位置

吸入端过滤网堵死

拆卸并清洗过滤网

最小流量管线敞开，最小流量阀 损坏或旁通孔板磨损

检查最小流量管路、最小流量阀和旁通 管孔板（4.4）

泵内部流道或管路粗糙

清理并冲洗管路 拆卸和清理泵内部流道

叶轮流道堵死

拆卸和清理叶轮内部流道

泵内部零件损坏（间隙）

拆卸并检查泵内部间隙（8.）

联轴器部不对中

检查联轴器对中(5.2)

联轴器损坏

检查联轴器并更换

吸入阀没有完全打开

检查阀并调整（完全打开）

吸入端过滤网堵死

拆卸和清洗过滤网

泵发生气蚀

检查运行参数，提高吸入口压力

管路疲劳，管口法兰承受力和力 矩过载 基础太单薄，底座没有灌浆或灌 浆不合理

给管路提供支撑，防止管路承受的力传 递给泵

叶轮损坏或堵死

拆卸并检查泵内部流道

轴承损坏

拆卸并更换轴承（8.）

转子不平衡

检查联轴器，驱动器和泵旋转部件

轴弯曲

拆卸和检查轴跳动（8.）

检查基础的地脚螺栓底座灌（ 5.1 ）

症状

可能的故障原因

补救办法

5 轴封温度高、 机械密封泄漏 量大、轴封寿 命短

密封冲洗液（流量）不充足或泄漏

检查流量要求

孔板规格不对或孔板已损坏

检查孔板规格和流量要求

密封面或弹簧处有固体颗粒

拆卸并清除固体，重新使用

密封面处发生汽化

检查循环流量和冷却装（7.2）

密封液不适合（密封面磨损）

设置过滤器或旋液分离器，重新使用

密封环、辅助密封（O型圈）或弹簧 拆卸和更换损坏的密封（8.） 损坏

6 轴承温度高、轴承 寿命短。

密封干运行，密封系统提供冲洗 液不充足或没有排气

密封腔体和系统充满液体 并排气

密封面材料不适合

咨询密封生产制造厂

轴弯曲

检查密封处轴的跳动

泵没有在工况点上运行

检查运行参数

联轴器不对中

检查联轴器对中(5.2)

轴承润滑油或脂太多

检查和纠正(7.3)

油位太高或太低

检查和调整油位(7.3)

润滑油质量差

更换润滑油，使用已鉴定和推荐的润滑 油（7.3，T3）

安装时，轴承受力

安装时检查轴承和相关零件（8 .）

检查进风量 不合适的轴承冷却（空气冷/水冷） 检查冷却水量

7 润滑油泄漏

8 泵内部磨损严重 -腐蚀 -冲蚀 -材料的损坏

轴承损坏

拆卸并更换轴承（8.）

轴向力过大

检查平衡装置和平衡管路 拆卸并检查泵内部间隙（ 8.）

轴弯曲

拆卸泵并检查轴跳动（8.）

油位太高

检查并调整油位（8.）

折流盘或密封环安装不正确

检查安装（折流盘泄漏眼在最下部）

轴承压盖垫片或者密封损坏

拆卸并更换密封（8.）

通气孔堵塞

检查并清洗通气孔

泵不在工况点上运行 入口压力不合理. 输送介质与要求的不同（温度、 特性、比重）

检查运行参数 必要时，重新设计 重新更换零件 清洗系统，安装过滤器或旋液分离器

材料不适合介质的输送 9 泵 温度过高/卡死

e6-0-00-000 page 6

小于最小流量点下运行（泵干运行）

检查最小流量（5.4） 在卡死的情况下，拆卸并更换部件

7 .维修 7.1 维修- 概述 在工作之前和工作期间，确保气体不存在潜在爆炸危险。如果产生任何危险，立即停止所有工作。 作业人员应经常检查机器。检查的目的是要彻底让人员熟悉使用的装备。如果出现异常现象，则应及时纠正。 检查主要应包括以下内容： 1．泄漏 * 检查泵吸入口和排出口处的主要接口 * 检查轴封处的泄漏，辅助连接 * 检查轴承外壳处的漏油 2. 仪表

* 检查压力表（泵吸入口，排出口， ... ） * 检查温度（流体，轴承，驱动器， ... ） * 检查电表（机动）

3．轴承

* 检查轴承温度 * 检查轴承振动（测量SPM值）. * 检查油位，向恒位油杯内加油

4 .振动，噪声

* 检查机器 * 检查不正常振动 * 检查是否有不寻常的噪音

5 . 紧固件

* 检查所有的螺丝钉是否都被正确的固定

如果机组保持在良好的技术条件，那么安全运行才能保证。这只能通过不断的监测和适当的维修才能实 现。 注意:

如有任何振动，不正常的噪声和缺陷，应立即停车。查明原因并矫正（见运行故障）

在操作过程中，监控辅助设备（如果有的话） 仪表：

定期监测压力，温度和电流

冷却：

流量和温度

冲洗/密封：

压力，温度， （数量）

任何不是更改或整修管路引起的泵性能的下降都可能是泵内部部件磨损造成的，此时，应停车进行大修,见第8 章节，检修水泵的有关详情。 注意: 平衡腔的压力保持恒定，若压力增大2-3bar，则必须检查平衡装置，若需要，可更换平衡装置。管路摩 擦损失也是造成压力提高的原因。 轴承 有关润滑油的信息，见第7.3 章。 轴承外壳，必须保持外部干净，因为散热量会由于灰尘或污垢而减少。 轴承监控：检查运行期间轴承的振动。 耐磨轴承采用振动冲击方法。按照操作手册定期检查仪表。第一次启动的最初值一定要记录，以便于以后测量 打偏离。测量结果不同的标示代表不同的意义。 • • •

绿色盖子 黄色盖子 红色盖子

= = =

一切正常 应引起注意 轴承开始损坏 o

用正确的保养和不受阻碍的散热，在表面的环境温度不超过+ 40 C时，在滚动轴承区保持温度等级为 o o o T4（ 135 C）时完全可能的。当在更高的环境温度下, 或温度级T5 （最大100 C）和T6（最多85 C） 时采取特别措施（冷却）。

0000/e7-1-01-000 第1页

振动 这些可以用手或用电子设备（频率或振幅分析仪）来检测。 卧式泵，：通过地脚螺栓固定在基础上的卧式泵，不应超过下列表格中给定的振动速度。

运行速度 连续运行 报警 停止运行

轴承振动等级未过滤的有效值/ 10到1000Hz -1 -1 达 3000 最小值 达 3600 最小值 4.5 mm/s (0.18 In/s) 5.6 mm/s (0.22 In/s) 7.1 mm/s (0.28 In/s) 9.0 mm/s (0.35 In/s) 11.0 mm/s (0.43 In/s) 11.0 mm/s (0.43 In/s)

注意： 此数据表仅适用于工况点运行/优先运行范围的运行范围（锅炉给水泵流量从>70 ％到<120%）。 流量< 70 ％BEP-部分负荷运行验收标准：+1.5mm/s（ 0.06In /s）参考优先运行范围取值。 测量值过高也可能是由于仪表、管路、辅助设备或其它（机械）振动源所引起。为了确定引起高振动值的原因， 对振动进行分析是有必要的。 噪音 有些不正常的噪声可以用耳朵听出来，像由于滚珠缺陷，不正确的安装等。噪声往往是各种破坏的前兆。 校正 在关闭（根据运行需要）期间，检查联轴器对中（至少每年一次）。如有必要，重新校正（见5.2 ）。 运行记录 泵在运行期间，建议运行日期、润滑和维修等情况都详细记录在运行记录表中。运行中的记录有助于解决故障， 分析机械运行规律。泵手册中的各种报告单应复制使用。 配件 以下备件推荐常备。这些适当的投资可以防止由小故障导致大麻烦。以下备件应必备：  滚动轴承，如果是滑动轴承（包括轴瓦及衬垫）  平衡鼓和平衡鼓套（平衡盘）  耐磨环及固定螺丝钉  垫圈和O型圈  机械密封 鉴于泵是同一装置中同类机械中极其重要的设备，建议在工作现场应备有整机设备。 配件的订单中应始终包含以下信息： 

泵的型号（铭牌或操作说明书）



订单编号（铭牌或操作说明书）



数量及指定零件号码（零件清单）



零件编号（零件清单或剖面图） 维修只有由专业人员使用原装配件进行更换时才能保证泵的安全。

0000/e7-1-01-000 page 2

检查和检查清单

压力

温度

•输送泵 (吸入和排出)

6.3

•平衡室

4.2 / 7.1

•输送介质 •泵轴承/集油槽

精细检查期 间

➊

年

X

月

(压力计、温度计、电表，存在但不受自动报警器/紧急装置控制)

周

测量装置

日

关于更进 一步的建 议，参见

6个月

每次必须的检修的时间间隔可能会有很大不同，因为不同的运行环境对机械部件的使用寿命都有着重要的影响。 在正常操作，且在定期保养和维护的情况下，建议按照以下的时间间隔进行检修：

➊ X

7.3

➊

进一步检验和检查 油位

•视油窗/恒定油杯

7.3

X

泄漏

•轴封 / 机械密封盖

7.2

➊

•法兰密封 (主连接)

-

X

•轴承箱润滑油

-

X

•振动测量

7.1

➊

•轴承振动

5.4 / 7.1

➊

换油

•轴承箱

7.3

联轴器

•检查校正

5.2

一般 检修/磨损检查

•轴承、平衡鼓和垫圈 轴封、叶轮、磨损环...

7.4 / 7.5 / 7.6 / 7.7

振动

保养工作

➊ ➋

➊ ➊ ➋

这些参数应记录在运行记录上面，并将其作为维修保养工作的依据。 检修需要检查磨损、及早发现任何损坏的迹象并及时更换有缺陷的部件。所有使用的磨损件和配件应 记录在运行记录上。

0000/e7-1-01-000 第3页

名称：

报告

检验单

工厂/位置:...........................................................................................................................…… 总规格:................................................................................................................................. 泵型号:.......................................................... 驱动器:...................................................... 序号:............................................................. 型号/编号:.................................................

启动

正常

异常

备注:……………………………….…………

运转

□

□

………………………………………………

噪音

□

□

………………………………………………

振动

□

□

………………………………………………

注释:……………………………………………………………………………………………………….. .……………………………………………………………………………………………………………. ……………………………………………………………………………………………………………… 时间 仪表 轴承 泵 启动

关闭

进口段

出口段

温度 oC 平衡

备注:

非驱动端

驱动端

非驱动端

R 0000 / 7-0-00-001 日期：

0000/e7-1-01-000 第4页

驱动端

油位

签名：

页数

报告

名称：

检验单

工厂/位置:......................................................................................................................................... ………… 总规格:...................................................................................................................................................... 泵型号:......................................................... 驱动器:........................................................... 序号:................................................................ 型号/编号:......................................................... 1. 泄漏

正常

异常

备注:.................................................................

泵进口 泵出口 轴封

□ □ □

□ □ □

……………………………………………………… ……………………………………………………… ……………………..............................................

2. 仪表

备注:..................................................................

泵进口 泵出口 平衡腔

.............. .............. ..............

bar bar bar

3. 轴承

正常

异常

温度 油位 加油 漏油

□ □ □ □

□ □ □ □

正常

异常

□ □ □ □

□ □ □ □

4. 振动/噪音 轴承箱

驱动端 非驱动端

泵壳 噪音

……………………………………………………… ……………………………………………………… ……………………………...................................

................................ oC 驱动端/非驱动端 ................................. 确认 是/否 ................................. 加油量 ................................. 是/否

备注:.............................................................. …………………………………………………. …………………………………………………. …………………………………………………. …………………………………………………. ………………………………………………….

注释:.................................................................................................................................................... .............................................................................................................................................................. .............................................................................................................................................................. 备注:

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0000/e7-1-01-000 第5页

签名：

页数

名称：

报告

保养单

工厂/位置:................................................................................................................................................... 总规格:................................................................................................................................................ 泵型号:......................................................... 驱动器:........................................................ 序号:................................................................ 型号/编号:...................................................... 保养间隔编号: ..................

运行时间: ................小时

启动次数: ...................

轴承: □ 更换润滑油

润滑油型号 : ...............................................

□ 泄漏检查

油量: ............................................................

绿色

黄色

红色

驱动端:

□

□

□

非驱动端:

□

□

□

一切正常

注意

损坏

轴承监控:

通过冲击脉冲测量

注释：……..........................................................................................................................................

机械部件: □ 联轴器校准对中检查（报告） □ 拆开轴承检查 □ 机械密封检查 □ 拆开平衡装置并检查 □ 一般检查，打开泵液压部件检查 □ 转子调整（轴向、径向中心位置）

更换部件: □ 机械密封-驱动端/非驱动端 □ 平衡装置 □ 轴承-驱动端/非驱动端 □ 轴 □ 磨损环 □ 其他： ..........................................

注释:................................................................................................................................................................ .............................................................................................................................................................. ……. ....................................................................................................................................................................... 备注：

R 0000 / 7-0-00-003

日期：

0000/e7-1-01-000 第6页

签名：

页数

轴封保养

7.2

单作用式机械密封 (关于制作、类型和尺寸，请参见剖面图) 总论 用于潜在爆炸区域的机械密封必须满足爆炸防护要求。

对于机械密封，是靠两个平行的密封面依靠弹簧和介质压力作用，紧压在一起形成密封面防止介质的泄漏。密封环 （静环和动环）同时像弹性支座一样和邻近的密封件（如O型圈）封住介质。

条件 注意：

为了机械密封无故障的运行，必须在两个密封面间形成液膜，则冲洗液必须满足下列要求： - 充分的润滑性能 - 气化温度高于工作温度 - 在密封环周围没有杂质

如果需要以下功能的辅助设备达到所要求的运行条件，则应遵守第5.4节要求和泵的安装平面图 - 冲洗 - 缓冲 - 冷却 - 加热 - 旋液分离器/过滤器 (如果输送含杂质的介质) 辅助设备（冷却、循环等）的故障可能会导致壳体表面温度升高而不可接受。如果必要的话，应给设备提 供合适的安全系统（例如：远程温度控制，并带紧急切断装置）。

保养 机械密封的保养限于控制泄漏和温度，如果适用，也可用于辅助设备。 注意： 机械密封通常存在小的泄漏量。关于密封泄漏的特殊说明仍然是有必要的，密封的泄漏量取决于很多 不同的因素（如：尺寸、材料、泵送介质、温度等）。当密封液有较大泄漏时， 可断定密封件已损坏，应立即 停车检修，损坏的部件必须更换。在每次装拆密封时，辅助密封件（如：O 形圈）必须重新更换，动静环也必 须一起更换。

0000/e7-2-01-001

7.3 维修-轴承/润滑油 飞溅润滑的耐磨轴承 概述 注意： 离心泵处于连续重载荷（轴向、径向）下工作，合适的润滑油质量决定了轴承的寿命和安全运行。油不 要含杂质、酸性物质及其它脂类。润滑油的最低要求详见DIN 51 511, API-SF/CC, MIL-L-46152 B。 因此，所有润滑油供应商应能够相应地划分其产品分类，并且建议能满足这些标准的产品。 由于润滑油导致的故障（例如：缺少保养，采用不合适的润滑油或油量，泄漏等）可能会导致壳体表面温 度升高而不可接受。如果必要的话，应给设备提供合适的安全系统（例如：远程温度控制，并带紧急切断 装置）。 油的粘度 在滚动轴承下，由于轴承完全运行时所引起的轴承自热扮演很重要的角色，另一方面，当轴承达到运行温度时， 要确保充分的润滑油膜，油的粘度应至少为12 mm2/s。应按照以下规定选择油的粘度： 注意： 应采用多级液压油SAE 15W-40.关于最大的许可温度值，请参见以下表格。如果有偏差，应联系服务 o 商。如果在检修后温度高于连续运行所给定的值（在油槽中的温度大于90 C）时，则首先应采取的措施是检查 止推轴承的轴向间距（参见第8章）

换油间隔和油量 在泵首次试运行或轴承检修的情况下，在泵运转了10～15 个小时以后，应排放并净化所有润滑油。如果油被外 来污染并且含水量低，更换周期为6个月： 泵尺寸

40 - 180

50 -220

80-260 100-300 150-360

油量（升） 驱动端

0.1

0.15

0.2

油量（升） 非驱动端

0.15

0.2

0.25

如果是自动恒位油杯，则应注意向储油槽（加油器油槽）里加油

最大允许温度 观测点 模式 轴承附近轴承箱外侧

4330/e7-3-01-001

o

< 110 C

o

> 120 C

o

> 130 C

连续运行

< 100 C

警告

> 110 C

停止运行

> 120 C

定时检查测量点的温度。

轴承滚道外部

油浴

o

< 90 C

o

o

> 100 C

o

> 110 C

o

o

推荐的润滑油 合适的润滑油对于离心泵的安全运行非常重要。 如果正确使用合适的润滑油，可以获得最佳性能，并可以避免出现问题和其 导致的后果。作为操作说明书的补充，以下表格列出了关于离心泵所推荐的 o o 润滑油，且其周围环境温度在-10 C ~+40 C间。 所列的润滑油是按照字母顺序排列的，与其质量无关。

4330/e7-3-01-001

供应商

多用途机器润滑油SAE 15W-40

AGIP ARAL BP CASTROL DEA ELF ESSO MOBIL OIL SHELL TEXACO WINTERS-HALL

F1特级机油, SINT 2000 特级柔性机油 1540 BP SB机油, VISCO 2000 GTX 2, GTX 3, TXT SOFTEX CASTOLITE REGIS多级通用, TORUS 15W40 PRESTIGRADE, SPORTI T, MULTIPERFOR. 3C 润滑油MHC 1540, MHX 1540 特级配方, DELVAC SUPER 15W40 螺旋标准, ROTELLA MX 1540, RIMULA TX 金富力, URATEX 多级通用 15W40 TFE 10W40, MAGNUM SL, 多记录 15W40

油位 注意： 监控恒位油杯瓶中的油位。瓶中应保持2/3的油量。油位突然下降意味着出现泄漏，应停止运行，并检 查装置。

换油 润滑油对皮肤油刺激性，并可导致眼睛发炎。必须遵守生产厂商所规定的所有安全注意事项。 换油应按照以下程序进行： 关闭泵。

1.

2. 在放油口下面放置一托盘以便让所有油安全地流入到托盘里（关于放油口的位置和尺寸，请参见安装平面图 或尺寸详单） 3.

拆除螺旋塞，让油彻底排出，然后再将螺旋塞拧紧。

4.

按照说明向轴承座里注入新的润滑油。 按照法律法规处理废机油。无论如何不能将废机油倒入到废水中。

恒位油杯加油（阿达姆斯型） 通过轴承箱体上的注油孔将其中加满油。直到恒位油杯中的油开始上升为止，然 后在恒位油杯中加油，并把它装回原位置。重复上述各步骤，直到油箱中至少充满2/3的油。应经常检查油杯中的 供油情况并根据需要及时补充油。

恒位油杯工作原理 若轴承箱体内的油位开始下降时，恒位油杯排出管的斜面上部边沿会首先露出液面，此时油液将从油杯中流到轴 承箱体内，直到达到先前的油位高度，此时排出管的斜面杯口便又 浸在油中。（见下示意图） 油瓶向后摆

注意:

正常工作时的油瓶位置

应确保玻璃瓶密封牢固，如果必要的话，应更换垫圈，将玻璃瓶用手拧紧到螺纹盖内。

4330/e7-3-01-001

8. 检修 8.1 泵的拆卸 在作业前和作业期间，应确保作业环境无潜在爆炸性。如果出现任何危险，要立即停止所有作业。 注：在保修期内，维修或改装只能由我们的服务人员或经过我们书面同意的情况下进行。 当泵需要检修，最好在检修前采购所有的必需零备件，以减少停车时间。订购零备件时，必需注明零件的准确名 称、数量、泵型号和规格。（见机器铭牌） 参考

参考特定图纸(剖面图、零件清单、安装平面图)。

注：此泵只可由合格的专业人员采用适当工具严格按相关说明进行拆卸。必须尽可能小心地进行所有组装作 业。疏忽会导致泵过早失效。

准备工作 -

关闭进出口阀门，并保证在未经许可之前，不得打开阀门。 在拆卸前让高温泵件冷却到室温。 使电机绝缘，防止电机启动。 对于电动驱动器：释放剩余电流(取下保险丝)。对于高压联接要由电工处理。 - 泵排残液(排残孔的位置见安装平面图) 对于排放有毒、爆炸、热的或其他危险介质，防止对操作人员和环境造成危险，同时注意法律 的相应规定。

如果泵输送腐蚀、有毒或其它危险介质，必须对它进行认真冲洗，如果具有放射性，必须在室外清理和去污染。 如果将泵送交制造商修理，在运输前必须进行清理/去污。必须包括一份证明泵绝对安全的证明。 尽管如此，相关的操作人员也必须注意安全，因为充分的冲洗与清洁工作也会残留有害的物质，应谨防泄 漏。 - 拆下联轴器护罩和分开联轴器各半部分(拆下加长段)。 - 拆除任何仪器和配套管。 - 如果是油润滑：放掉轴承箱的油。 要按相关法规处置旧油。切勿将其放入污水系统。 在拆卸时应注意危险情况，即注意站稳，固定好组装件以防坠落，支撑好松动的零部件等等。

-

如果轴密封是集装式：松开密封盖集装式机械密封的装配杆，并将其拖入轴套槽再次紧固。 拆下泵驱动侧的联轴器(见示意图8.1-1)，取下键(940...)。 为了避免损坏轴承或轴中心螺纹孔损坏，应采用适当的拉拔器 和保护螺纹孔的圆盘。轴承切勿受任何压力或震动。

圆盘

示意图 8.1-1

4330/e8-3-01-001 page 1

非驱动侧轴承的拆卸 -

拆下固定风扇罩(832.01)的螺丝(900.01)并取下风扇罩。用弹簧环钳将弹性卡环(932.01)从轴槽取出，取下风 扇(831.01)和键(940...)。

-

拆下轴承盖(360.02)的内六角螺丝(914.03)。清理并润滑轴，小心地将轴承盖与迷宫密封(423...)一起推离轴。

-

在需要时：将迷宫密封(420...)推出轴承盖孔。注：虽然迷宫密封由两个零件组成，即定子和转子，但却按一

个单元进行组装。不得将转子与定子分开。 -

移除锁紧螺母（920.16和920.15） 锁紧螺母（920.16）：轴承锁紧螺母（920.16）靠调整螺钉将锁紧销压在轴上。由于锁紧销与锁紧螺母为紧 配合，故而松开调整螺钉后锁紧螺母依然紧紧地抱在轴上。轻轻敲打锁紧螺母靠近调整螺钉的地方，使锁紧 销松开，这样锁紧螺母就能轻松的旋下。 圆螺母（920.15）：止动挡圈通过压紧力压紧在轴承的圆螺母(920.15)槽中，把止动挡圈(931.01)从圆螺母 槽中扳出来，旋下圆螺母,取下止动挡圈和垫片(551...)。

注意： 在拽出非驱动侧的轴承支架前止住轴，以防止损坏机械密封。为此应在驱动侧安装固定装置，以借助轴 孔将转子紧固到它上面，见示意图8.1-2。 -

拧下轴承支架的紧固六角螺母(920.02)，安装拉拔器(见示意图)并将轴承支架与耐磨轴承(320...)一起拽出。

-

将中间轴套(525.02)与迷宫密封(423...)一起从轴上拽下或从轴承支架孔将其取出。从轴承支架拆下耐磨轴承。 用拉拔器将轴承支架拽出

止住驱动端的转子：

将轴承支架与耐磨轴承一起均匀的从轴

用固定装置更换轴承盖的2个彼此相对的紧固螺

上推下。

丝并通过轴中心螺纹孔固定转子。 固定装置

轴 轴

轴承托架非驱动侧

轴承托架驱动侧

图8.1-2

机械密封和水力平衡装置的拆卸

集装式机械密封: 拆下机械密封盖的紧固螺母(920.05)并从轴密封室拔出整个机械密封(集装式)。当心： 剩余 介质流出。 在松开组装杆并将其移出轴套槽后，可以将机械密封拆成单件。警告：机械密封盖受内部弹簧预应 力作用。

标准机械密封: 拆下密封盖(471.01)的紧固螺母(920.05)，并将密封盖与机械密封的固定部件一起取下。当心：剩 余介质流出。轴套 (523.01) 与紧固在其上的机械密封的旋转件一起从轴上拽下 (轴套开有便于使用工具的槽) 。

4330/e8-3-01-001 page 2

- 拧下紧固轴密封壳(441...)的内六角螺丝(914.01)，松开并拔出轴密封壳。当心：残余介质会流出。 - 安装专用工具将平衡鼓 (603.01) 、平衡鼓套 (605.01) 以及轴套（520.02）从轴上拉出。见示意图8.1-3。取 下键(940.02、940.04) 。

输送盖(163.01)

平衡鼓(603.01)

平衡鼓衬(605.01)

图8.1-3 平衡鼓和平衡鼓套的拆卸

驱动侧轴承的拆卸 - 拆下固定装置 (为拆卸非驱动侧轴承安装) 可以拆下轴承支架驱动侧。 警告：如果非驱动侧的轴承支架已被拆下，切勿使转子沿轴线方向移动，以免轴密封部件受损。 - 拧下轴承盖(360.01)的内六角螺丝(914.02)。清理并润滑轴，小心地将轴承盖与迷宫密封(423...)一起推离轴。 - 将锁定垫圈扁尾弯出轴承螺母(920.17)并拧下轴承螺母。取下锁定垫圈(931.02) 和分隔圆盘 (551.01) 。 - 拧下轴承支架的紧固六角螺母(920.02)。松开轴承支架并将轴承与其一起拆下。将抗摩擦轴承外圈与滚动 件一起压出。 - 将隔套(525.01)与迷宫密封(423...)一起从轴上拽下，抗摩擦轴承内圈也将自动被一起取出。在需要时可采用适 当的拉拔器。

轴密封 – 驱动侧的拆卸 -

集装式机械密封: 拆下机械密封盖的紧固螺母(920.05)并从轴密封室拔出整个机械密封(集装式)。当心： 剩 余介质流出。在松开装配杆并将其移出轴套槽后，可以将机械密封拆成单件。警告：机械密封盖受内部弹簧 预应力作用。

-

标准机械密封: 拆下密封盖(471.01)的紧固螺母(920.05)，并将密封盖与机械密封的固定部件一起拆下。当心： 剩余介质流出。将轴套(523.01) 与紧固在其上的机械密封旋转件一起从轴上拽下 (轴套开有便于使用工具的 槽) 。

4330/e8-3-01-001 page 3

泵水力部件的拆卸 由于在重新组装时要求各部件必须回到原先的位置，因此在拆卸时应给每级中段，导叶和叶轮按拆卸顺序做标记。 -

将螺母(920.01)从穿杠螺栓（905.01)上拧下，并将穿杠螺栓取下。 用橡胶锤轻敲，取下出口段(107...)。注意：残留的液体会流出来。 将末级导叶(177.01)从出口段取出。 将叶轮(230...)从轴上滑下，取下键 (940.01)。 导叶(171...)从各中段(108...)中取出。注意：残留的液体会流出来。 将下一个叶轮 (230...)从轴上滑下，取下键(940.01)。 接下来各级中段的拆卸如上同。在拆卸过程中一定要将轴充分支撑，以防止轴弯曲。 在从首级中段取出第一级叶轮后小心撤下轴，将叶轮从轴上滑下并取下键。 将导叶(171...)从各级中段中(108...)推出来。 在需要时(如果发生磨损，见8.2)：可以更换进口段/中段和级间衬套(541...)的耐磨环(502...)

拆卸后 所有零件必须清理并对非不锈钢表面做防锈处理，做短期的贮存。在第3条下给出推荐的防锈剂。 泵轴要轻拿轻放，轴尽可能的垂直保存。 检查所有泵件是否磨损或损坏，见8.2

4330/e8-3-01-001 page 4

8.2 易损件的检查 注意： 要尽可能小心进行全面检查。应检查所有零件的磨损情况并视情况进行更换和重新机加工。必须尽可能 小心地进行所有组装作业。疏忽会导致泵过早失效。

叶轮 检查叶轮是否磨损或损坏。查找抽吸区域(尤其是第一级叶轮) 的气蚀痕迹 (蚀坑) 、叶片腐蚀和护罩裂缝。用 细锉或金刚砂纸磨平微小起伏，在必要时更换叶轮。

耐磨环和间隙 检查口环是否有槽道和不均匀磨损。检查叶轮间隙。下述给出了最小(新的)直径向间隙。 当泵性能降到系统合格标准以下或达到或超过建议最大间隙时，应更换叶轮和耐磨环件。 说明：每当间隙加大时都会造成泵效率损失。 间隙测量: 见示意图8.2-1。测量旋转部件和固定零件之间的间隙。应在几个测量位置上测量， 然后按以下所述计算间隙。 示意图8.2-1 最大口环内径ID – 最小叶轮 外径 = 直径方向间隙 叶轮- 和口环，级间衬套 泵尺寸 最小间隙 (对于新件) 最大间隙 (对于磨损件)

80-260

材料指数

0.3

0.35

铸铁或软氮化钢

0.45

0.5

不锈钢

0.6

0.7

铸铁或软氮化钢

0.9

1.0

不锈钢

40-180

50-220

* 与直径相关的间隙

耐磨环的更换 泵壳口环：见示意图8.2-2。拆下定位螺丝并将固定的口环压出其位置。导叶装置： 在口环与其座位插入拉拔工具或撬棒并加压。中段： 注意隔套一侧。 施加适当压力。 安装：确保口环和及其座位干净和无毛刺。谨慎安放进新口环，槽向内，用锤轻按 或施压压力。检查口环周边是否完全合实（支撑件）。钻孔并螺旋新的锁定螺钉孔， 一半在中段 ，一半在口环上。用锤敲击安装并确保螺钉稳固。 图8.2-2 叶轮口环：(如果有的话) 见示意图8.2-3。通过移除固定螺丝移除叶轮口环， 并 对口环进行均匀加热以方便移除。对旧的口环进行打磨（注意不要损坏座）利用 凿子对裂口进行打磨。安装：确保新的口环及轴座干净无毛口。在电炉内加热口环 或采用热油浴方式，将其加热到约100°C并安装，对叶轮的内角进行斜切。可施加 适当压力。检查安装的磨损环是否与叶轮的肩四周相接触。钻并螺旋出新的螺丝锁 定孔，一半在叶轮上一半在口环上。利用锤子锤击固定螺丝。

图8.2-3

级间衬套：见示意图8.2-4。通过移除定位螺钉将级间衬套移除，并将其轻敲出其 座位。可以施压力。检查其座位去除任何毛口。将新的衬套组装上。 为定位螺钉 穿钻孔。用锤敲击安装并确保螺钉稳固。 图8.2-4

4330/e8-0-01-001 page 5

平衡 建议叶轮单独在平衡机上做动平衡检测。不平衡量按VDI 2060，ISO 1940，Q = < 2.5进行。 组装后的转子不是稳固单元。这是受到液压轴以及径向轴承在水泵内形成很小的间隙所影响，转子在空气中平衡 时偏差不同。

轴 轴要轻拿轻放轴和受均匀支承，以保持平直。应避免轴受到撞击、敲打或弹跳。应检查轴座和轴肩是否洁净、是 否有划痕和毛刺；并在必要时予以更换。 轴的正确运行：将轴支承在轴承区域上(采用V形块或滚子)并检查同心度。最大允许跳动如下表所示。如果最大 跳动超过允许值，应更换轴。

≤ 3000转/分

工作速度

0.025mm(0.001英寸)

最大允许径向跳动

> 3000至4000转/分 0.020mm(0.0008英寸)

轴封 备注：集装式机械密封要作为完整的一个单元进行更换。对损坏的集装密封进行修理时，要将其送回厂家 或厂家的服务中心 集装件的拆卸：在松开装配杆并将其移出轴套槽后，可以将机械密封拆成单件。警告：机械密封盖受内部 弹簧预应力作用。 密封环(运行面)前侧不得有划伤迹象。要及时更 换带有划痕或裂纹的转子和定子，要一起作为一个单元 更换，不要只更换一个。检查轴套的表面是否完好，尤其是轴座内的转动单元，若有必要可更换新部件。 组装：在重新组装时，应采用新的密封垫和O型密封圈。我们建议采用新的转子和定子密封圈。 注意： 要严谨进行组装，清洗要按规定进行。密封件绝不可以受到任何压力或碰撞（破裂危险）。密封件的表 面不能添加润滑油或润滑脂，这会妨碍密封液体在运转时的导入。

轴承 耐磨轴承 用清油清洗轴承。如果是大修或损坏，应更换轴承。

说明：在更换推力轴承时：只可使用成对轴承，切勿只更换单元的一个轴承。轴承设计号如泵零件清单所示。

平衡鼓 / 平衡鼓套 在泵性能下降到系统合格标准之下或达到或超过建议最大间隙时，应更换平衡鼓和平衡鼓套。 检查平衡鼓的外径、平衡鼓套的内径精度以确定尺寸(还可见示意图8.2-1)。应按单元更换平衡鼓和平衡鼓套。

泵尺寸

40-180

50-220

材料

80-260

最大间隙，mm*

0.3

0.4

铸铁或软氮化钢

(对于磨损件)

0.5

0.5

不锈钢

* 直径间隙

4330/e8-0-01-001 page 6

转子同轴度检查(带旋转部件的轴) 在不承受载荷与承受载荷两种情况下，分别检查轴的同心度。在装配完转子部件期间，最后一级叶轮与平衡鼓之 间放一个合适的垫片（Washer），用一个适当长度的轴套来代替轴向轴承。见示意图8.2-5。

示意图8.2-5 转子同心度检查

定位轴承时不要拧紧轴承锁紧螺母。在轴承安装区域（使用V-型铁/滚筒）支撑轴。在不受载荷条件条件下检查 同心度，测量点分别是：叶轮直径处间隙、叶轮轮鼓、轴套、平衡鼓，联轴器处轴端。最大允许跳动0.05mm。 如果在非载荷情况下，转子部件的同轴度检查结果是令人满意的，那么在受载荷的条件下也要同样的测量，通过 拧紧锁紧螺母把转子部件固定在轴上。在相同位置上，再次检查转子的同轴度，假如此时转子的径向跳动超过允 许值，垂直于轴中心线的用来传递轴向力的各端面，例如轴肩、叶轮轮毂、平衡鼓、轴套，必须仔细检查。 旋转心轴（不固定心轴情况下），在轮毂和轴套长度等处减小尽量碾磨量，然后在轴外径（轴肩、平衡鼓、 轴套等）处的检查同轴度，最大允许偏差不超过0.01mm。如果超过这一数值，必须重新加工。 按上面所述重新检查转子的同轴度，直到有了满意的检测结果为至，然后移走检查、修整同轴度所用的特殊 工具，再拆解转子部件，及拆解过程中必须按先后顺序在叶轮上做标记，为以后在泵的组装过程中按同样顺序组 装叶轮做准备。

4330/e8-0-01-001 page 7

8.3 泵的组装 参考

见特定图纸(剖面图、零件清单、安装平面图)。

这些泵只可由合格的专业人员采用适当工具严格按相关说明进行安装。必须尽可能小心地进行所有组装作业。疏 忽会导致泵过早失效。

初步工作 -

清理泵件 准备润滑剂(例如，油、Molykote、Never Seez) 对于O型密封圈，只可以使用甘油或"Klüber PROBA 270" 更换密封环和密封垫 注意在安装过程中可能的危险情况。例如，注意固定的支撑以确保部件不会坠落，支撑松动部件等等。

组装液压泵件(在重新组装时参见匹配号) 注意：40-180泵从9级起，50-220泵从10级起，80-260的泵从8级起，由于泵的中段级数较多，中段要对轴的偏 差线进行调整。通过安装一个或多个楔形中段。这样很容易就调整到准确位置。楔形中段上标示有 “OBEN"以及 并要标示段数 (从入口末端数起) 。见示意图8.3-1。

示意图8.3-1

如果泵是卧式组装，在安装穿杠前应在下面支撑中段，使中段“悬空"。 -

清理轴、叶轮孔，在接触表面上稍微涂点润滑剂。

-

插入第一个叶轮的键(940.01)，并将叶轮(231...)推装到轴(210...)上。

-

在第一个中段（108…）上安装导叶（117…）– 在必要时可用胶皮锤敲打。将O型圈(412.01)放在沟槽中， 以便密封。

-

插入键(940.01) 从非驱动端装入下一级叶轮(230...)。

-

安装另一个预组装中段(带有导叶) – 在必要时可用胶皮锤敲打。安放O型圈。

-

用同样的方法安装剩余的中段和叶轮。

-

将末级导叶(177.01)和O型圈（412.12）置入最后一级中段(108...)后，装入出口段壳体(107...)止口上。

-

驱动端：将O型密封圈(412.01)安放在导叶(170....)的止口上并安装出口段(106...)。 注意：在光滑钢板上调整的泵的进口段和出口段支脚。

-

安装穿杠螺栓 (905.01) 、垫片 (550.01) 和螺母 (920.01) 将整个液压组件沿横向均匀地连接起来。紧固扭 矩见表8.5。

4330/e8-0-01-001 page 8

组装平衡装置 -

将键(940.02)插入轴。将O型密封圈 (412.08) 装入平衡鼓 (603.01) 槽里，并将平衡鼓推装到轴上。 将带有O型密封圈(412.07)的平衡鼓(605.01)推入出口段，并将用于防止旋转的定位柱销(561.02)装入孔。 将键(940.04)插入轴并将分半环(501.01)放入轴槽。滑动轴套并盖住(520.01) 。

轴密封箱体的组装 -

非驱动侧：将O型密封圈(412.02)装入轴密封箱体(441...)的槽里。用内六角螺丝(914.01) 固定密封箱体在 出口段 (107...)上的位置。注：密封腔的排气孔要设在顶部。 驱动侧：将键(940.09)插入轴，并将隔套(525...)滑靠在叶轮上。将O型圈 (412.14和412.02) 装入轴密封箱体 (441...)的槽里。用内六角螺丝(914.01) 固定密封箱体在进口段 (106...)上。

转子部件轴向位置的测量和调整 如果泵件的安装长度在修理期间未因重新机加工而发生改变，则无需测量，但如果安装了新件(轴、叶轮、中段 等)，则必需测量矫正，否则按"轴密封非驱动端的组装"小节继续进行。 为了获得最好的水力效率，叶轮和导叶必须置于相对正确的位置上，以避免发生转子的扭曲与偏移。由于制造 上允许的公差，使得需修正的转子偏差值较小。 注意:

不要转动转子，尽量避免轴向移动转子

说明：在不设O型密封圈的情况下安装测量所需的所有零件。 -

驱动侧: 将轴的轴套(523.01)和隔套(525.01)推到不动为止。 组装泵两侧的轴承支架(330...)并用螺母沿横向均匀紧固。 推动转子，直到沿非驱动侧方向不动为止。 在非驱动侧：可用深度规确定“A”值，从轴承支架孔中的推力轴承挡圈面与轴肩之间的距离(见示意图8.3-3)。 隔环长度(525.02)应比测量值"A"大"B"。"B"值见下表中 泵尺寸 尺寸

-

B=

40-180

50-220

80-260

5.3 ± 01

6 ± 0.1

6.5 ± 0.1

尺寸单位 mm

在提供新的隔环时，应保证足够长的长度尺寸，在安装时才将其加工到实际所需的尺寸值。

注：在机加工后，隔环轴肩之间的平行度必须在0.01mm范围内。

图8.3-3 转子轴向位置的测量

4330/e8-0-01-001 page 9

- 在驱动侧：将转子推到非驱动端，测定隔环（525.01) 的尺寸的长度尺寸。为此要用深度规测量轴承支架(轴 承挡圈)的面与隔环端面间的距离尺寸C。测量结果应与下表所述的尺寸相一致。

泵型号

40-180

50-220

80-260

尺寸 C=

3 ±1

3.5 ± 1

4 ±1

单位，mm

说明：由于公差大，因此很少需要重新加工驱动侧的隔环。 -

在测量后，重新拆下两侧的轴承支架，还要拆下非驱动侧的隔环和轴套。

轴封的组装 - 非驱动侧 注意： 在拆卸液压泵部分后：不要安装轴密封件，应组装轴承支架和轴承，并接着进行“转子自由运转状态检 查”。如果自由运转检查合格，拆下轴承和轴承支架并接着进行“轴密封-非驱动端的组装”。 集装式机械密封的设计 -

将轴封的转子部件安装到轴套上。若有必要也可以在轴封内径上安置密封圈。

-

将机械密封固定件置入机械密封盖并推装在轴套上。通过在机械密封盖上加压在机械密封弹簧上施加预应力， 直至可以将组装杆推入轴套槽为止。

-

整个预组装机械密封(集装式)推入密封室(轴密封箱体)

-

说明：拧上轴密封盖的紧固螺母 (920.05) ，但不要紧固。

标准机械密封 -

将轴密封的旋转件安装到轴套上。将O型密封圈插入轴套孔槽并将轴套推装到轴上。

-

将机械密封固定件置入机械密封盖。安装O型密封圈并将其滑装到带有预组装轴密封固定件的密封盖上，用 手拧上螺母，但不要紧固。

轴承的组装 - 非驱动侧 -

润滑隔套表面(525.02)并将轴上迷宫密封(423...)推装到隔套上。注：为了防止损坏，应在迷宫密封转子处于

定子内时将其按压就位。 -

将隔套(525.02)(与迷宫密封一道)滑装就位到轴上。

-

轴密封箱体需要冷却时：将一个O型密封圈(412.02或412.03)安放在密封箱体的止口上，将另一个O型圈 (412.04)放入用来密封轴承支架槽内。

-

在安装轴承支架(330...)时，应将轴上的迷宫密封(423...)推入轴承支架孔。注：迷宫密封的回流开口向下。 润滑螺纹并支承螺母表面(920.02) 和沿横向均匀紧固紧固件。紧固力矩见表8.5。

-

组装推力轴承：将轴上圆锥滚子轴承(320...)的外圈与轴承的中间环置入轴承支架孔(确保一个轴承中间环孔 o

朝下)。用油浴将圆锥滚子轴承内圈和滚动件加热到约80-100 C，并将其推装到轴挡块为止。然后再安装轴 承 -

外圈。

注意： 在更换圆锥滚子轴承时：只可使用成对轴承，切勿只更换单元的一个轴承。轴承设计号如泵零件清单所 示。 -

安装隔环(551...)、止动垫圈(931.01)和轴承螺母 (920.15)。在止动垫圈和轴承螺母的接触面上涂上润滑剂。

-

紧固轴承螺母。将止动垫圈扁尾弯入轴承螺母槽。 注意:

不要过度紧固轴承螺母。

4330/e8-0-01-001 page 10

-

将O型密封圈(412.06)装入轴承支架槽。安装轴承盖并用内六角螺钉(914.03) 沿横向均匀拧紧轴承盖。紧固 力矩见表8.5。注：在紧固时，转子应达到最终轴向位置。

-

润滑轴表面并将迷宫密封(423...)推装到轴上和推入轴承盖孔。注： 迷宫密封的固定部分带有泄漏槽或向下

的孔。注：为了防止损坏，应在迷宫密封转子处于定子内时将其按压就位。

轴封和轴承的组装 - 驱动端 轴封 集装式机械密封的设计 -

将轴密封的旋转件安装到轴套上。如果有的话，将密封环安放在轴套孔槽内。

-

将机械密封固定件置入机械密封盖并推装在轴套上。通过在机械密封盖上加压在机械密封弹簧上施加预应力， 直至可以将组装杆推入轴套槽为止。

-

将整个预组装机械密封(集装式)推入密封室(轴密封箱体)

-

说明：将紧固螺母 (920.05) 拧到轴密封盖上，但不要紧固。

标准机械密封 -

将轴密封的旋转件安装到轴套上。将O型密封圈插入轴套孔槽并将轴套推装到轴上。

-

将机械密封固定件置入机械密封盖。安装O型密封圈并将其滑装到带有预组装轴密封固定件的密封盖上，用 手拧上螺母，但不要紧固。

轴承支架 -

润滑隔套表面(525.01)并将轴上迷宫密封(423...)推装到隔套上。注：为了防止损坏，应在迷宫密封转子处于

定子内时将其按压就位。 -

将隔套(525.01)(与迷宫密封一起)滑装就位到轴上。

-

轴密封箱体需要冷却时：将一个O型密封圈(412.02或412.03)安放在密封箱体的止口上，将另一个O型圈 (412.04)放入用来密封轴承支架槽内。

-

在安装轴承支架(330...)时，将轴上迷宫密封(423...)推入轴承支架孔。注：迷宫密封回流开口向下。润滑螺 纹并支持螺母表面(920.02) 和沿横向均匀紧固紧固件。紧固力矩见表8.5。 o

- 组装径向轴承：在油浴中将滚子轴承 (320.01) 的内圈加热到约80-100 C并将其推装到轴挡块为止。在滚动件 处于轴承支架孔内时置入耐磨轴承(320.01)外圈。 -

隔圈(551...)和止动垫圈(931...)安装到轴上，拧上轴承螺母(920...)。在轴承螺母和止动垫圈的接触面上涂上 润滑剂。

-

紧固轴承螺母，并将锁定垫圈扁尾弯入轴承螺母槽之一。 注意： 不要紧固轴承螺母。

-

将O型密封圈(412.05)装入轴承盖凹槽内 (360.01)并用内六角螺丝(914.02)拧紧轴承盖。紧固扭矩见表8.4。

-

润滑轴表面并将迷宫密封(423...)推装到轴上和推入轴承盖孔。注：迷宫密封回流孔向下。为了防止损坏，应 在迷宫密封转子处于定子内时将其按压就位。

4330/e8-0-01-001 page 11

检查转子的自由运行状态 注意： 由于泵部件是按照给定的公差加工制造的，转子部件理论上应处于中间位置，也就是说通常可以用手盘 动。为了这样做，也可以在联轴器端装上鸡心夹头检查自由运转状况。 - 转动转子并查找在运行停止时是否接触。 接触转子的原因和纠正措施 由于螺纹和螺母之间存在不同的摩擦力，所以按通常的方法把紧螺母会形成不同的预紧力。不同的预紧力会使连 在一起的壳体产生变形，这会使转子部件和固定的壳体产生碰撞，随着级数的增加这种现象会变得越来越明显。 注意： 如果发现转子部件盘车很困难或者根本盘不动车，这时壳体的变形需要通过调节把紧连接螺栓的力矩来 实现。由于没有一个适当的方法可以计算出壳体间的预紧力，连接螺栓的把紧程度应该由试验得到。

注：在这些情况下可以最多超出表8.4所述扭矩50%。 在检查自由运转后 -

如果自由运转转子检查合格，应检查轴向间隙并进行最终组装。

检查和调整推力轴承的轴向间隙(端部游隙) 注意： 为了能够在轴承件之间形成油膜和热膨胀，必需提供正确的轴承端部游隙。必须在每次拆卸推力轴承后 检查轴承端部游隙。 - 在轴非驱动端的前面放置一块千分表，把转子部件移动到最终位置来检查轴向间隙见示意图8.3-4。用锤子轻轻 敲打轴承支架（非驱动端）来拉直弯曲的滚动部件。 将转子移到最终轴向位置，使用如图所示装置。拧紧六角螺母①(不要太用力)，② 松开、读取千分 表，松开①，拧紧②并读取正常的间隙。

0.04至0.06mm

图8.3-4

圆盘

-

如果没有明显间隙，可以扭动轴承件(圆锥滚子轴承)，沿两个方向慢慢转动转子并再次测量。

-

如果测量轴向间隙小于0.04mm，可以通过拧紧推力轴承的轴螺母(920...)来纠正这个纠正问题。

-

拆下轴承端部游隙测量装置。 o

注意： 在检修后，如果圆锥滚子轴承的温度升到90 C以上，应首先检查轴承端部游隙。

4330/e8-0-01-001 page 12

最终组装 轴密封 -

集装式机械密封：如果有的话，紧固锁紧装置(轴/轴套)。沿横向均匀紧固机械密封盖的螺母(920...) 。紧固扭 矩见表8.6。松开密封盖集装式机械密封的组装杆，将它们从轴套槽抽出并重新连接。

-

标准机械密封：现在应通过沿横向均匀紧固紧固螺母(920.05)紧固非驱动侧和驱动侧的轴密封盖。紧固扭矩见 表8.6。

风扇冷却 -

非驱动侧轴承箱：将风扇 (831.01) 键 (940.05) 插入轴，装上风扇并将卡簧 (932.01) 嵌入轴槽。安放好风扇 盖(832.01)并用圆柱头螺丝(900.06)紧固。

联轴器：安装半联轴器。见示意图8.3-5。 - 清理联轴器孔和轴的延伸段，插入将联

螺母

半联轴器

轴器推入轴的键。建议在轴表面和毂孔薄薄地涂上一层油，不得使用二 硫化钼或类似产品。 - 拆下热敏件(例如，胶皮缓冲装置和密封环等)并以均匀干燥的热源(例如 o

电炉或加热板)将半联轴器加热到约80 C。将半联轴器装到轴上，并在其 冷却后再次安装其他部件。也可以与相应附件一起冷安装带有直径不超 过50mm孔的联轴器。

泵轴

图 8.3-5 注意： 轴承绝不能受到任何压力或撞击。 配套设备 -

连接配套管道(平衡管、密封循环管...)和仪器(温度计、恒位油杯、压力表...)

注意： 不要搞混接头。要仔细检查管路系统。 驱动装置 - 耦合驱动装置，检查联轴器是否对中 (见5.2) 。 - 安装联轴器护罩。 电动机和控制装置的电气安装/连接只可由合格电工进行。 注意： 在重新调试时，重复第6小节的所有步骤。

4330/e8-0-01-001 page 13

杆

螺柱

8.4 工具 平衡活塞和推力轴承箱的拆卸设备

件号 1

零件

泵尺寸

40-180

50-220

1 法兰 图号 物料号(整套工具)

2

4 螺柱(轴承箱拆卸)

3

2 螺柱(平衡活塞拆卸)

4

4 圆盘

5

4 螺母

6

1 六角螺丝

7

1 滚珠

M201.5(长140或180) 直径12mm

图8.4-1 推力轴承箱的拆卸

图8.4-2 平衡鼓(鼓套)的拆卸

转子同心度检查 (还可见8.2) 数量

用于平衡管和末级叶轮之间 垫片尺寸（mm） 内径x外径x厚度

1 数量

泵型号

40-180

50-220

80-260

尺寸

S 50x62x3

S 65x85x3.5

S 70x90x3.5

替换推力轴承 轴套尺寸（mm） 内径x外径x长度

2

泵型号

40-180

50-220

80-260

尺寸

40x52x46

60x75x62

55x68x58

4330/e8-0-01-001 page 14

80-260

壳体密封

8.5 螺丝紧固扭矩 拧紧扭矩(Nm) 件号： 905.01

泵尺寸 40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400

O型圈

工作压力(巴) > 80至120 1030 1580 940 1450 2250 3110

< 80 710 1090 650 1000 1550 2100

> 120至150 1260 1940 1160 1780 2770 3850

以下各项的拧紧扭矩(Nm) 泵尺寸 轴承支架紧固件号：920.02 40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400

105

205

注：只有螺母的螺纹和支承表面(分别是螺丝头支座)受到润滑，紧固扭矩才有效。

均匀载荷 建议按照推荐的扭矩值选用工作压力合适的接头，使螺母、螺栓或螺柱断裂或 松脱的可能性最小。 拧紧螺栓时，应采用正确的拧紧顺序以避免可能发生的变形。

螺纹润滑 除非润滑剂与紧固件的应用场合不相容，否则应采用石墨和油、二硫化钼或其 它质量相当的防卡润滑剂润滑螺母的螺纹和支撑面。

扭矩形成 在形成所需扭矩时，按交替顺序紧固相对紧固件。 润滑和安装手紧紧固件。应以至少三步形成所需的紧固件扭矩，其中第一步最 大施加33%扭矩值。

螺母920.02

系紧螺栓 905.01

螺母920.02 螺丝914.02

螺丝914.03

注：泵支脚的紧固扭矩还可见5.2

4330/e8-0-01-001 page 15

轴承盖螺丝件号： 914.02 / 03 20

30

栓接顺序

附件 操作说明附件表 泵 性能数据表 性能曲线 尺寸图纸 安装平面图 设备图纸 P+I 图 装置明细 剖面图 离心泵 零件清单-泵 轴封 轴密封系统 轴密封图 说明 隔障系统 说明 附件 驱动器 联轴器 驱动器 阀 最小流量规定

OPERATING MANUAL

MC

Customer/Contractor:

-

Cu. Order No.:

-

End User:

-

Plant:

-

Site:

-

Item No.:

-

-

Sulzer Equipment No.:

-

-

Sulzer Order No.:

-

Pump type:

MC

BA/e 4330 W ä

Sulzer Pumpen (Deutschland) GmbH

Ernst-Blickle-Straße 29 D 76646 Bruchsal Tel. (07251) 76-0, Fax 76329

Content 1. GENERAL REMARKS 1.1 1.2 1.3 1.4

About this manual Guarantee Type of operating manual Service data - Service control

2. SAFETY 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Marking of instructions in the operating manual Qualification and training of personnel Danger on non-observation of the safety regulations Safety-guided working Safety instructions for user / operator Safety instructions for maintenance, inspection and assembly jobs Prohibition of unauthorized rebuilding measures or alterations Inadmissible operating modes Explosion protection

3. TRANSPORT AND STORAGE 3.1 3.2

Transport / Lifting Preservation and storage

4. DESCRIPTION 4.1 4.2 4.3 4.4

General Description of the pump Bearing bracket and lubrication Absorption of the axial thrust - balance drum

5. INSTALLATION 5.1 5.2 5.3 5.4 5.5

Mounting of the pump Alignment of coupling Suction and discharge pipework Ancillary equipment Minimum flow device

6. OPERATION 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

General Commissioning Pump start-up and operation Inadmissible operating modes Shut-down Restart procedure Service control Operating faults

7. MAINTENANCE 7.1 7.2 7.3

Pump general Shaft seal Bearing / Lubrication

8. OVERHAUL 8.1 8.2 8.3 8.4 8.5

Dismantling of the pump Inspection of wearing parts Assembly of the pump Tools Screw tightening torques

ENCLOSURES Table of enclosures for operating manual

4000/e0-1-00-000

1. GENERAL REMARKS 1.1 About this manual The operating manual contains important information on how to operate the pump safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the pump.

How to use this manual The operating manual must always be available wherever the pump is in use. These instructions must be read an applied by any person in charge of carrying out work with and on the pump, such as transport, storage, installation, operation and maintenance. This manual should be used together with all other machine documentation in order to have accurate information of your pump. Do not start or operate this pump unless you have complete understanding of the pump system and all auxiliary systems (driver, cooling, seal flushing ...).

1.2 Guarantee Guarantee is assumed according to the contractual agreements. The normal Sulzer warranty covers manufacturing or material defect, it does not cover the damage caused by improper storage conditions, incorrect installation, operation and using against designated use. During the period of guarantee, repairs or modifications only can be made by our service personnel or with our agreement.

1.3 Type of operating manual (Acc. to DIN 8418 and VDMA 24 292) Documents no.: see cover sheet Service address: see cover sheet Issue: 2005 We reserve all rights in this manual and in the information contained. Reproduction, use or disclosure to third parties without our approval is strictly forbidden.

Revision history 3 2

2015-02.12

Add fasteners & auxiliary piping info

Amanda Gu

1

2014-05-08

Add min. speed and max. run up time limit

Yan

0

2005-11-25

First issue

E. T.

Revision

Date

Description

Sign

Remark In the case of further questions, of spare part orders and other correspondence please mention always the SULZER Serial No. and pump type. Both can be gathered from the rating plate of the pump.

0000/e1-0-00-000

1.4 Service Data – Service Control Sulzer Order-No.: Item-No.: 1.4.1 Main Data rated

Operating Conditions Discharge Capacity Suction pressure Discharge pressure Differential pressure Differential head NPSH – available @ Rated Flow

min. normal

m /h bar G bar G bar m m min.

Liquid Data Liquid (medium delivered) Pumping temperature Vapour pressure Density Viscosity

max.

3

normal

max.

o

C bar A 3 kg/m cP

Performance Speed Rated Power Efficiency @ Rated Capacity Min. Cont Flow Thermal Min. Cont Flow Stable Preferred Operating Region Allowable Operating Region Max. Head @ Rated Impeller Max. Power @ Rated Impeller NPSH – required @ Rated Flow Est. Max. Sound Pressure Level

rpm kW % 3 m /h 3 m /h 3 m /h 3 m /h m kW m db(A)

Min. Speed 1400rpm

to to

1.4.2 Lubrication Oil (according to DIN 51 511) Oil temperature Quantity of oil per bearing housing

o

C Liter

SAE 15W- 40 see also 7.3 40 - 90 (drive side) / (non drive side)

1.4.3 Cooling Total Cooling water requirement Pressure normal / max. Temperature outlet max. Parts to be cooled Cooling water requirement

3

m /h bar o C 3

m /h

1.4.4 Heating Heating medium Pressure normal / max. Temperature entry max. Parts to be heated Heating medium requirement

0000/e1-4-02-000

2/7 40

not required bar o C 3

m /h

1.4 Service Data – Service Control 1.4.5 Flushing (shaft seal) Flushing / Sealing medium Quantity min. Pressure Temperature of flushing medium

3

m /h bar o C

1.4.6 Flushing (wear ring) Flushing / Sealing medium Quantity min. Pressure Temperature of flushing medium

not required 3

m /h bar o C

1.4.7 Quench Quench medium Quantity min. Pressure Temperature of quench medium

3

m /h bar o C

1.4.8 Safety technical limit data Design Pressure suction / discharge Design Temperature Max. Allowable Working Pressure suction / discharge

0000/e1-4-02-000

bar o C

/

@

o

bar

/

@

o

C

C

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 ATTENTION 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

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

3.

TRANSPORT AND STORAGE

3.1 Transport / Lifting A. General remarks For all transport jobs the general rules of engineering and regulations on the prevention of accidents have to be strictly observed. These are especially VBG 1 - General regulations VBG 5 - Power-driven working devices VBG 8 - Lifting devices VBG 9 - Cranes VBG 9a - Load suspension device with hoists and conveyors The above regulations are applicable in the area of the Federal Republic of Germany, in other countries the appropriate regulations have to be observed. For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.

B. Transport Transport devices (including vehicles) have to be checked for the admissible load weight. Total weight of the delivered goods see dispatch documents. The load has to be secured during transport against shifting.

C. Lifting Check of the load suspension devices / ropes It has to be assured that admissible, undamaged ropes and lifting devices will be used. The loading capacity of the lifting devices and the ropes has to be suitable to take up the weight of the goods to be lifted. Load weight indications of the delivered units are given in the installation plan respectively the dispatch documents.

Sling rope as market on crate

Never stay within the range of suspended loads. Fastening of the sling ropes on crates The points for the fastening of sling ropes on closed crates are marked. As the center of gravity (mass) cannot be recognized in closed crates, the sling rope fastening has always to be done at the marked spots. See sketch 3.1-1. Fastening of the sling ropes on bar shaft pumps The pump without packing can be lifted and transported by ropes witch are laid around casing parts (shaft seal housings). See sketch 3.1-2.

Sketch 3.1-1

Sketch 3.1-2

Fastening spots for units In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these spots by shackling the rope. See sketch 3.1-3. Units up to a certain weight can also be lifted by ropes which are laid around certain parts of the pump such as pump branches, bearing frames, motor housings etc. See sketch 3.1-4. If required use traverse

Sketch 3.1-3

If required use traverse

Sketch 3.1-4

Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened parts during assembly and disassembly

M000/e3-0-00-000 Page 1

3.2

Preservation and storage

A. General remarks This information will enable you to store your pump effectively and safely. Should further information be desired, or should particular problems arise which are not covered sufficiently please contact your nearest Sulzer representative. The following storage instructions apply only to the pump and may not be appropriate to furnished auxiliary equipment. Follow manufacturer’s instructions for all other components of the pump system. The preservation measures required for storage depend on the despatch preservation applied. The pump unit can be stored in a dry warehouse without maintenance measures up to the time given by the dispatch preservation.

B. Preservation for despatch Standard packing When the pumps are shipped, smooth outside faces are sprayed with “Tectyl 506” and pump internals with “Mobilarma 524” (or equal product). Attention: this is not suitable as long-term preservation; 6 months are max. allowed time for storing.

Seaworthy packing The pump is despatched with PE-foil welding and with added moisture absorber. Sea-worthy packed pumps can be stored up to one year without any special maintenance if the packing is not damaged.

Special packing On special request the pump can be packed in aluminium foil (with moisture absorber). In this case the preservation time amounts to 2 years without special maintenance. If the seaworthy or other special package is removed, only the standard preservation is ATTENTION effective, i.e. if no further measures are taken, the max. storage period will be 6 months.

C. Intermediate storage Pumps which are not installed and commissioned immediately after delivery can be stored for the period determined by the dispatch preservation. ATTENTION To avoid the forming of condensate and consequently corrosion (especially in the gap areas), bearing damage and contamination, a dry room, possibly with constant temperature as well as a clean, shock- free storage space has to be selected. ATTENTION

In each case unfavourable climatic circumstances will have a negative influence on period of proper preservation.

In case the units are not or no longer enclosed in a special packing the following has to be observed: ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand, etc.) the connection flanges of the pumps have to be plugged airtight.

D. Longterm storage - preservation 1. General The pumps should always be stored in her functional position, that means that horizontal pumps should be stored horizontal and vertical pumps should be stored in vertical position. Align and support the pump as required. ATTENTION

In case of long term storage a number of precautions must be observed to prevent pump damage. It is recommended to enter all storage inspections and preservation measures in an log.

0000/e3-0-00-000

Long term storage may be required for: 1. New pumps witch are not commissioned. The pump can be stored as described in Intermediate storage. After the dispatch preservation time measures have to be taken to protect the equipment against corrosion damage. 2. Stand by pumps or pumps affected by a longer shut down of the plant. The long term storage procedure depend on the material used in pump construction (cast iron, steel, stainless steel, special alloys), medium delivered and environmental conditions (freeze damage) see following table. Material of construction Cast iron Steel Stainless steel Special alloys

Medium delivered Neutral Hydrocarbon, ... B B B B

Water, ... A A

Aggressive Seawater, ... Acids, ... B A B A

A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium and after draining (and drying) be protected with a preservative. For this purpose the disassembly of the hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure described below in section 2. to 4. B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure for the bearing housing as described in the sections below. Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturers.

2. Protection of not painted outer parts of the pump Pump outer parts: e.g.

- raised faces of flanges - pump shaft - coupling - connections for small conduits etc. We would urgently advise against using normal lubricating oil as a rust preventative. For the preservation of bright pump parts, the mineral-oil industry has developed special rust preventatives which at first are liquid and are applied manually, by means of brushes, spray nozzles or aerographs. After the evaporation of the solvent, a wax-type cover will remain. This protective film can be removed by means of solvents or alkaline cleansing agents (see section V.). We recommend rust preventatives - Tectyl 506 from VALVOLINE - Rust Ban 397 from ESSO Other rust preventatives of the same quality may however be used as well. The average time of protection is 1-3 years. Rust preventatives are rust-preventing agents which however do not remove rust. For this reason, it is a prerequisite for the application of rust preventatives that the parts to be protected are clean and rustfree. The surface of the parts has to be cleaned carefully before the respective rust preventative is applied.

3. Protection of the interior of the pump If the hydraulic pump part (casing parts, impeller, wear rings…) are made of non-corrosive stainless or special alloy, no protective measures (instead of flushing, case A) are required. Note: Bearing housing and bearings have always to be protected. Pump interior parts: e.g. - pump casings - stuffing box chambers - bearing housing, bearings, ... 2 For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm /s should be used.

0000/e3-0-00-000

We recommend the rust preventatives ATTENTION The rust preventative for the pump interior have to be selected according to the gasket or seal materials used. Gasket or seal material: Perbunan (NBR), Viton (FPM), Teflon (PTFE):

Rust preventative - Mobilarma 524 from MOBIL - MZ 110 from ESSO - Ensis motor oil 30 from SHELL

Ethylene-propylene (EPDM):

- Klüber Syntheso D 220

4. Proceeding in case of longterm preservation General Protect the pump and attachments with a vinyl-coated nylon tarpaulin. Lash tarp evenly to provide drainage that does not form pools. Maintain sufficient air circulation with minimum 10 cm clearance between tarp and pump parts. Protect pump from blowing sand or dirt. Shaft seal Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. The use of any preventative is not recommended. Soft packing If the pump is supplied with a stuffing box packing installed, the packing has to be removed and replaced by a special packing which is to remain in the stuffing box chamber during the preservation time, only. ATTENTION

Preservation packing material recommended: Synth. fibres, with PTFE impregnation (e.g. Chetra 1711 GS or Hecker 1820). The packing chamber is filled completely with the separate packing rings. Pump casing At first the raised faces of the pump flanges have to be cleaned thoroughly and preserved with one of the rust preventatives mentioned under I. On smooth flanges and those with annular tee-slots, flat gaskets should be placed; in case of slotted flanges, 2 gaskets should be placed in the slot, and all the sockets have to be closed tightly by means of metal covers. The connections for the cooling water/circulation lines etc. should also be closed by means of normal steel plugs, using Molykote. Then fill (or spray) pump casing with rust preventative (see 3.). While filling in this agent, turn pump shaft manually several times (observe sense of rotation). Generally speaking in practical handling the casing interior of bigger pumps usually is only sprayed, in this case the preservation has to be repeated every 6 months. Bearing housing If present: Drain lubrication oil thoroughly. Remove filler plug on the top of bearing housing and fill bearing housing with rust preventative (see II.) up to the correct oil level. During filling rotate the pump shaft by hand in the proper direction. If present: Fill also constant level oiler bottle with rust preventative.

E. Maintenance of the longterm stored pumps Visual inspection The exterior of the stored pump unit should be conducted every 30 days and inspected for surface damage, dirt or animals in the pump area. If required initialise appropriate measures.

Maintain rust prevention coatings If any rust is observed, measures should be taken to remove rust and protect against it.

Turn pump rotor manually To avoid corrosion damage at bearings, drain the preservation oil every 3 month and refill if on the top of the bearing housing. The pump rotor should manually be turned simultaneously, so that the preservation oil will be distributed over the running surfaces of the bearings. Turn pump rotor at least 5 revolutions in the proper direction of rotation.

0000/e3-0-00-000

Filled pump parts At the parts which are filled with rust preventative (pump casing / bearing housing) the condensate should be drained every 6 months; rust preventative should be added, if required. According to manufacturers indications, the rust preventative has to be drained and refilled every 12 month. If the rust preventative 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, we recommend to establish maintenance sheets. ATTENTION

If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than after 6 months.

F. De-preservation procedure Surface protected parts In most cases the protection film must not be removed. If required remove rust preventative by the following cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be used. Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety precautions specified by the manufacturers. Note: Do not use nitro thinners!

Pump casing Drain pump casing thoroughly, it may be required to lift the pump to fully drain the pump casing (see job specific drawings). If required flush pump casing, turn pump rotor by hand in the proper direction of rotation. For absolutely cleaning (pumping of clean product) the disassembly of the hydraulic part of the pump becomes necessary in most cases.

Shaft seal Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer seals are subject to material specific and time-based alteration (aging) witch might reduce the efficiency of the seal, therefore we recommend after a storage time for more than 3 years to change the seal rings. Packing: Before commissioning, make sure that the preservation packing is removed and replaced by packing rings of the quality provided for operation.

Bearing housing Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the preservation oil thoroughly. Flush bearing housing with lubrication oil and allow to drain. Mount constant level oiler (if removed) and refill bearing housing with lubricating oil as given in the pump operating manual. Dispose of rust preventive oil according to statutory regulations. Do not put into waste water by any means.

G. Additional Information When the pump is removed from storage special care have to be taken. Clean pump and equipment surfaces (piping, coupling, driver,…) and inspect:

Minimum checks

Additional recommended checks

Inspect for completeness Inspect bearings (if any sign of contamination be detected, replace brg.) Check all pressure case (plugged) openings and Inspect shaft seal and change all elastomer connections for tightness seal rings Check for any sign of cracks or damage Check pump rotation, check for correct gap Install additionally suction strainer between stationary and rotating parts … Check coupling alignment Check all fasteners for tightness Check service data (are the pump suitable) ATTENTION If the pump has been stored for more than 3 years we recommend to open and inspect at least bearings and shaft seal before start-up. If the pump has been stored for more than 5 years we recommend to disassemble the pump and change all gaskets and seal rings. 0000/e3-0-00-000

4. DESCRIPTION

Sketch 4.1-1 Typical view

4.1 General Pumps of the SULZER series MC are horizontal, radially split, multi-stage, high pressure ring section pumps designed for boiler feed and other high pressure applications. 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 class, at a max. ambient o 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 Group Category Temperature class

4330/e4-1-00-000 page 1

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

4.2 Description of the pump Casing The casing is radially split and consists of suction casing, stage casings (ring section casings) as required and discharge casing. The elements are sealed by O-rings and held together by external tie bolts. 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 packed glands or mechanical seals. See 7.2 or description of the seal manufacturer for further information. The shaft seal 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 splash oil lubricated bearings. The bearing at the coupling end absorbs radial forces, while the opposite bearing determines the axial position of the rotor. The lube oil quantity is given under 1.4.2 and 7.3 . ATTENTION

Depending on the service conditions the bearing housings may require water cooling to maintain acceptable bearing temperature. In this case the cooling water quantity is given

under 1.4.3. Antifriction bearings Roller bearings are used as bearings for the massive pump shaft in the bearing bracket on the drive side, whereas paired taper roller 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

4330/e4-1-00-000 page 2

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 c

605.01

a

b 603.01

F A

axial thrust Sketch 4.4-1 Balance drum working principle

The balance device consists of a balance drum (603.01) rotating with the shaft and a balance drum 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 pressure + frictional resistance in the balance pipe) creates an axial force "F" on the balance drum. This axial force is opposite in direction to the pump axial thrust. The magnitude of the force "F" 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. A perfect balance is only achieved if there is no 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.

4330/e4-1-00-000 page 3

5. INSTALLATION 5.1 Installation of the pump unit A. General (refer to Job specific drawing(s), Installation plan …) 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 metal closures at least 5mm thick, with elastomer gaskets, 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

65% Fine sand

grain size

1 - 5 mm

(0.04 – 0.2 in.)

of the foundation bolts

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)

40% Fine sand

grain size

1 - 5 mm

(0.04 – 0.2 in.)

of the baseplate

60% Coarse sand

grain size

5 - 15 mm

(0.2 – 0.6 in.)

100 - 140 liters (7 - 10 gallons) of water Table 5.1.1 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.

4330/e5-1-00-001 page 1

Tools and Equipment Required The following tools will be required temporarily for the installation work: -

2 Dial gauges

-

1 Spirit (machinist’s) level

-

1 Set of standard hand tools

-

Suitable lifting devices for installation and repair work.

-

Suitable lighting

B. Mechanical completion and installation sequence check list REF. PAR.

EVENT

5.1 A-G

Instructions for site installation

5.1 C

Installation of pump and driver

5.1 D

Levelling, check leveling of baseplate

5.1 E

Grout in foundation bolts

5.1 G / 5.1 D 5.2 A-H

Let the concret set Snug-Up (tighten) foundation bolts and recheck levelling Mount driver (If field mounted) Align driver to pump

5.2 D

Check for soft feet, pump and driver

5.1 F

Grout baseplate

5.1 G

Final tighten of foundation bolts after grout cures

5.3 A-H

Install main piping

5.3. C

Check stress free pipe connection

5.3 F

Clean the pipework

5.4 A-H / 8. A-B 5.5 A-B 5.2 A-I

Mount ancillary equipment Install Minimum flow device (if present) Fill and vent the pump system Final alignment (mount coupling guard)

Table 5.1.2 Check off when satisfactorily completed

C. 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. Note: With separate baseplates for pump and driver first erect the pump, then align the driver. Precondition - The location place must be sufficiently rigid to prevent pump vibration. The specific base design will depend on location and external piping forces requirements. Location place / surface check - Check mounting surfaces. All location place surfaces used for mounting the pump unit must be clean. Remove rust, dirt or other extraneous material. - 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.

4330/e5-1-00-001 page 2

Installation - Attach wire rope slings to the pump unit (see 3. Transport and lifting) and lift the pump unit carefully. 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.

D. Levelling Use mechanical installation report TC 0000/5-1-00-000. - 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). ATTENTION Check levelling in the direction of the pump axis and also at right angles along the 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

adjusting screw

foundation bolt disc

baseplate sheet metal

shim

shim

concrete shaft

Sketch 5.1-1 Levelling the unit

foundation

Sketch 5.1-2 Grouting foundation bolts

E. Grout in the foundation bolts - Before grouting wet the foundation holes. Fill foundation holes with concrete. See sketch 5.1-2. - After setting tighten the foundation bolts (see table 5.1.3) 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 operation or the alignment of the coupling will not possible. - Before grouting the baseplate align the coupling as described under 5.2 (alignment report). ATTENTION

4330/e5-1-00-001 page 3

F. 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.

grout hole

baseplate

chamfer strip

-

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 temperature of the foundation should not fall below 10 oC o (50 F). The optimum temperature for the setting process is o o o 20 C +/-10 C (65 +/-15 F).

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 5.1.3) and check coupling alignment (alignment report).

G. Tightening torques for foundation bolts Thread size (OD in.) Tightening torque Nm (lbf.ft)

Table 5.1.3

4330/e5-1-00-001 page 4

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)

Title:

Test Certificate

Mechanical Installation

Plant / Location:......................................................................................................................................... Aggregate Specification:........................................................................................................................... Pump type:......................................................

Driver:..............................................................

Serial-No.:.......................................................

Type / No.:.......................................................

Measures

Confirmations

1. Foundation construction Main dimensions and connections checked 2. Level baseplate

Yes

No

Date:

Sign:

Date:

Sign:

longitudial

crosswise

Levelling

X

Direction

longitudial

crosswise

Measured:

.................

................

Prescribed:

0 ... 0.5 mm over 1 meter

Dimension X

Min:

Max:

Foundation bolts grouted

Yes

No

Date:

Sign:

Foundation bolts tightened after setting

Yes

No

Date:

Sign:

Check distance between baseplate and foundation 3. Foundation bolts

4. Grouting baseplate Levelling checked Baseplate completely filled with grout

Direction

longitudial

crosswise

Measured:

.................

................

Yes

No

Date:

Sign:

Coupling alignment checked

Yes

No

Date:

Sign:

Pump foot and driver tightened

Yes

No

Date:

Sign:

Stress control of main piping performed

Yes

No

Date:

Sign:

Piping cleaned and connected (main and auxiliary)

Yes

No

Date:

Sign:

Electrical connections (main and auxiliary)

Yes

No

Date:

Sign:

Lubrication check (pump, driver, ...)

Yes

No

Date:

Sign:

Driver test run, rotation check (pump uncoupled)

Yes

No

Date:

Sign:

5. Piping connection

6. Auxiliary checks and connections

TEST DECLARATION

7. System checks System cleaned

Yes

No

Rework:

System filled and vented

Yes

No

Yes

Pressure tested

Yes Date:

4330/e5-1-00-001 page 5

Accepted: No

Yes

No

TC 0000 / 5-1-00-000

No Sign:

Page … of …

5.2. Alignment of coupling A. General 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. Driver “No Load” run 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. ATTENTION

ATTENTION

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

ATTENTION

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

ATTENTION

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

ATTENTION

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

Scope 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 reference machine (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 reference machine (pump) is level and positioned correctly. 3. Work outwards from the reference machine, and position the next machine A 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 B is included in the drive train, use machine A as the reference machine to position and align B to A. In the same way, position and align C to B, etc. B

A

Reference Machine

A

B

D

C

B

A

Reference Machine

Sketch 5.2-1 Reference machine – next machine

4330/e5-1-00-001 page 6

B. Misalignment types There are three basic types of misalignments between the pump and driver shafts:

Sketch 5.2-2 Angular misalignment Shafts with axes that intersect at a point

Sketch 5.2-3 Parallel offset Shaft with axes parallel but offset

Sketch 5.2-4 Axial distance Shaft with axes parallel but wrong distance

C. Assembly 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.

D. Check for „soft machine feets” 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 .

E. Pump foot tightening torques 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. Thread size nominal diameter in. mm M 16 (0.6) M 20 (0.8) M 24 (0.95) M 27 (1.05) M 30 (1.18) M 33 (1.30) M 36 (1.42) M 42 (1.66) M 48 (1.88) M 56 (2.20) M 64 (2.51) Table 5.2.1

4330/e5-1-00-001 page 7

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

Non- drive end

Tightening torque acc. to table

Drive end

Tightening torque acc. to table

Sketch 5.2-5 Pump foot tightening torques

F. Compensation of thermal growth 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. The unit with the greater thermal growth must be set lower than the other unit, by the difference between their thermal growth. Pump thermal growth At pumps with feet bottom (not at axe level) and ATTENTION operating temperatures above 80 oC the thermal growth should be considered according following table. Pump size MC

H

> 80 40 – 180 160 0.10 50 – 220 185 0.11 80 – 260 240 0.14 100 – 300 275 0.17 150 – 360 325 0.20 200 – 400 360 0.22 X = Casing feet at axe level

Thermal growth H in mm o with operating temperature C > 100 > 130 > 150 > 170 0.13 0.18 0.22 0.25 0.15 0.21 0.25 0.29 X X 0.20 0.28 X X 0.23 0.32 X X X 0.27 X X X 0.30

Shaft

Thermal growth H

Shaft

Thermal growth X negligible

Sketch 5.2-6 Pump thermal growth

Driver thermal growth ATTENTION 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.

G. Axial shaft distance 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. Coupling Hub Spacing 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.

4330/e5-1-00-001 page 8

DBCFF or DBFF

DBSE

Sketch 5.2-7 Coupling hub spacing

H. Alignment General 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 TC 0000 / 5-2-00-000 have to filled in during each alignment check / procedure (see next pages). ATTENTION Each alignment check / control has to be done only with pump in cold condition and under 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 during pipework connection and re-checked after 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 ATTENTION pipe connection. Adjustment device 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. ATTENTION After alignment and tightening the machine fasteners loosen all adjustment screws. Adjustment devices

Adjustment screws Machine feet

Baseplate pedestals

Moving machine

Baseplate pedestal

View "X" Sketch 5.2-8 Adjustment device

X

Coupling alignment procedure 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.

4330/e5-1-00-001 page 9

Tolerances 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. Clock gauge alignment 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 o left, i.e. every 90 , while both shafts are simultaneously turned. Optical Alignment 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.

Sketch 5.2-9 Alignment of spacer couplings

Sketch 5.2-10 Optical Alignment

I. Coupling safety guard 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.

4330/e5-1-00-001 page 10

Test Certificate

Title:

Coupling alignment

Plant / Location:......................................................................................................................................... Aggregate Specification:........................................................................................................................... Pump type:..............................................................

Driver:..............................................................

Serial-No.:...............................................................

Type / No.:.......................................................

Alignment before pipework connection:

Remark:..............................................

Alignment after pipework connection:

...........................................................

Alignment before commissioning:

...........................................................

Alignment after commissioning (maintenance):

...........................................................

1. Axial distance check Coupling gap (mm) Specified gap: Pump Driver Spacer coupl.

Pump

Driver Non-spacer coupl.

Coupling type:....................................................

Tolerance: Actual gap: Spacer: ...............mm

Yes

No

2. Check of radial misalignment (see also 2.1) Radial misalignment (mm) Measuring p.

Left

Right

Top

Bottom

Measured: Pump

Prescribed:

Driver

0 ... 0.1 (0.05 preferable)

2.1. Check of correct axis displacement (only in case of defined displacement by different thermal growth between driver and driven machine) Axis displacement (mm) Displacement

Horizontal

Vertical

Measured: Pump

Prescribed: 0 ... 0.05 Driver is set ............... mm higher / lower Driver is set ............... mm to right / left

Driver

3. Check of axial misalignment (parallelism) Axial misalignment (mm) Measuring p.

Left

Right

Top

Bottom

Measured: Pump

Driver

Prescribed:

0 ... 0.05 (0.03 preferable) Test declaration

4. Bolt tightening check (after alignment) Pump foot checked:

Yes

Driver foot checked:

Yes

No

Anchor bolt checked:

Yes

No

Date:

4330/e5-1-00-001 page 11

No

Rework: Yes

Accepted: No

Yes

No

TC 0000 / 5-2-00-000 Sign:

Page … of …

5.3. Suction and discharge pipework A. 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.

B. 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

C. 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

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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 ATTENTION to the pump may result.

D. 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. ATTENTION Fittings having the same nominal bore of the pipework should be used. If the pump branches have a smaller nominal bore than the fittings suitable taper pieces should be installed.

E. 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 ATTENTION duty and standby pumps which may have common suction pipework since only one pump operates at any time.

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F. 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.

G. Suction strainer In order to prevent any of the above impurities entering the pump, we recommend 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. (0.008 in.) (0.015 in.) Monitor the pressure drop across the strainer by a differential pressure Sketch 5.3-5 Wire cloth gauge. If at any time, a reduction in pump suction pressure is observed, the strainer should be removed and cleaned. The differential pressure ≥0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5 ATTENTION bar (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.

H. Pressure test ATTENTION

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

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5.4. Ancillary equipment A. 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. All the auxiliary flushing piping and C&I cable tray can’t be treaded and climbed to prevent the destroyed and accident. The following instructions may be used as a guide insofar as they apply to the pump as delivered.

B. 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. If provided on baseplate the earthing lug must be connected.

C. Pressure measuring equipment - The start-up and monitoring of the operating point of the pump is made easier with pressure gauges. See also 6. and 6.7. 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).

D. 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). - If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid vaporization in the sealing range (see 1.4.5). - At heating the max. temperature of heat carrier has to be controlled (see 1.4.4). - 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. - 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. - 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.

E. Bearing monitoring (Vibration measurement) By means of impact impulse measurement (possible with antifriction bearings), by bearing housing vibration or by shaft vibration measurement. - Advancing bearing damage and other machine failure can be recognised and deteced by means of electronic sensor measurement. This electronic (computerized) vibration system can be used to continuously measure and monitor a variety of supervisory parameters for preventing unexpected machine failure. For further information refer to the manufacturer’s description. 4330/e5-1-00-001 page 15

F. 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.

G. 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.

H. 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. - 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. - 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. - 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. - 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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5.5. Minimum flow device Note: In accordance local-safety standards these instructions must form part of every operating manual. Safety instructions for pumps which operate in the partial load region. The following information may be disregarded, if the pump supplied never runs in the partial load region.

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General In the partial load region (when operating the pump near zero flow) almost the total pump power is imparted to the flow as thermal energy. If this flow is less than a certain minimum (see 1.4.1), heating will occur and continue until the liquid boils, causing severe damage to the balance device, impellers and casing wear rings leading to eventual breakdown of the pump. To avoid this there must always be a certain flow of liquid through the pump. ATTENTION

If the shut-off device in the delivery pipe is tightly throttled or closed during pump operation, the delivery fluid inside the pump will heat up after just a short time. This may cause the surface temperature on the pump casing to rise above the permissible temperature class. If necessary, provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with emergency switch-off). The following two situations arise for multi-stage pumps with hydraulic balance of the axial thrust: 1. The balance quantity is sufficient This means that in cases of relatively low driver power and favourable suction conditions the balance flow is sufficient as the leak-off to be piped away. If this condition applies to the pump supplied, it is noted expressly on the data sheet under 1.4.1 that the minimum flow is equal to the balance flow. The balance pipe must not be connected to the suction casing, but must lead to the suction tank. 2. The balance quantity is insufficient A device must be fitted in the discharge pipe immediately after the pump, which guarantees minimum flow even with closed discharge valve. The following devices have proved successful in use: a)

Automatic leak-off non-return valves operate such that as the flow decreases the minimum flow line automatically opens and an integral throttle element controls the minimum flow. The contrary happens on increasing the capacity. The minimum flow line is directly flanged to the automatic leak-off non-return valve and leads back to the suction tank.

b)

Constant by-pass. A by-pass line is fitted between the pump and the discharge valve, which also leads back to the suction tank. A throttle is built into the pipe which determines the flow rate. With this type it should be remembered that the by-pass quantity also flows with the discharge valve open, which reduces the efficiency of the pump. It must be considered carefully whether it is worth buying an automatic leak-off non-return valve.

Minimum flow line or by-pass The minimum flow line is not supplied by the pump manufacturer. It must be provided by the operator. The pipe must always lead from the pump to the suction tank. For shutdown and disconnection for maintenance, a shut-off valve must be fitted in the minimum flow line, but must be locked open before commissioning. If several pumps are installed to operate in parallel and the minimum flow pipework connects into a common header, it is necessary to install a non-return valve in each feed piping. ATTENTION

ATTENTION

Separate pipes must be laid for minimum flow pipe and balance pipe if both are required to be led back to the suction tank. minimum flow line

Never operate below pump ATTENTION minimum flow. Minimum flow operation causes in higher internal wear therefore operation at minimum flow should be maintained for no longer than 2 hours in any 24 hours of operation.

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Minimum flow valve

Suction tank

Sketch 5.4-1 Typical piping layout for minimum flow line

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. All fasteners should be checked and tightened to prevent leakage according to operation conditions before pump hydro testing or start running. 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 table recommended lubricants. c. Alignment 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 ATTENTION In case of hot (or cold) product: extreme caution must be exercised when filling a pump that is at ambient temperature. To prevent thermal shock the pump should slowly and controlled 3 filled up with small fill up rate 0.3 to 0.5 m /h (1.2 to 2 gpm) so that the pump case and internals can be warmed up (or cooled down) uniformly. 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 vent • If existing (see installation plan): Open vent (not (not valid for self-venting casing) 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) • Fill pump (suction pipe must have foot valve) • As far as existing: Close vent when pumped medium flows without bubbles • As far as existing: Close vent when pumped • Fully open shut-off valve in inlet line medium flows without bubbles 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). ATTENTION

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).

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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.

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 Start-up with pressurised system • Close shut-off valve in the discharge pipe (precondition is non-return valve in discharge (minimum flow must be guaranteed). pipe) • Start driver and bring the pump rotor • Start driver with open discharge valve and immediately to operating speed. bring the pump rotor immediately to • Open discharge valve slowly, until the operating speed differential pressure drops to the value given on the data sheet. Operation below min speed (1400rpm) e.g. by variable speed drive or turbine drive, cauATTENTION ses serious damage to the pump. The max allowed run up time to min speed is 10 senconds. Pump should produce pressure at discharge as soon as rated operating speed is reached. If ATTENTION not, shut down immediately and vent pump system. 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.

Starting of a Stand-by pump or starting a Parallel working pump

Head in (m)

Note: If a stand-by pump should replaces the function of another one (operating pump), both pumps have to run parallel for a short time. a. Proceed preliminary work for the stand-by or parallel working pump as given in section 6.1 General and 6.2 Commissioning. b. Start-up pump as given in 6.3, check discharge pressure. Operate both pumps parallel. c. Stand by pump After running in full operation the first operating pump can be shut down. Refer to 6.5 shut down. Parallel working pumps Both pumps remain in operation. Each (identical) pump deliver only half of capacity delivered, see pump curves below. Non-identical pumps can also operate in parallel but selection must be done very single pump curve two identical pumps carefully. working parallel

3

Capacity in (m /h)

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6.4 Inadmissible operating modes

z z z z z z z z z z z z z

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. exceeding of the max. admissible speed 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) exceeding or remaining of the medium viscosity exceeding of the max. admissible inlet pressure exceeding of the max. admissible temperature exceeding or remaining under the operating range of the pump running of the pump without proper venting of pump interior running of the pump without required safety devices ( safety valves, electrical overload protection etc.) 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). operation of the pump with closed or throttled shut-off device in the inlet line (dry running) operation of the pump for the delivery of fluids, for which the pump are not suitable (chemical, solids, gas content ...) operation of the pump with wrong sense of rotation 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) Remark: If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shutdown 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. a. Close discharge valve slowly and top 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. W e recommend to start-up the pump unit once every month and run for 30 minutes. Extended shut down b. 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. c. If existing, close quench piping. d. 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 e. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including external heat exchangers and pipings.

Emergency shut down of the pump a. In case of failure of the pump or any auxiliary system shut down the driver immediately. b. Before restarting the unit once again follow 6.6 Restart procedure

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. b. Proceed restart as given in section 6.3 Start-up and operation. 4000/e6-0-00-000 page 3

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”.

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 pressure (bar) x 10 200 generated head (m) =

3

density of liquid (kg/m ) Metric units

3

generated head (m) x density of liquid (kg/m ) generated pressure (bar) =

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.

Operating range

Maximum capacity

Minimum capacity

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

Head in (m)

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.)

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.

7. MAINTENANCE 7.1 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).

0000/e7-1-1-000 page 1

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) > W ear 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.

0000/e7-1-2-000 page 1

Inspection and check list

Pressure

Temperature

During Overhaul

➊

> Delivery pump (suction and discharge)

1.4.1 / 6.7

> Balance chamber

4.2 / 7.1

> Medium delivered

1.4.1

> Pump bearing / oil sump

7.3

➊

X

Yearly

(Pressure gauges, thermometers ammeters as far a existing and not monitored by automatic switches alarm/emergency out)

Monthly

Daily

Measuring devices

Weekly

Further recomm. see

6 monthly

The intervals between the necessary overhauls may vary extraordinary, as the differing operating conditions can have substantial influence on the service life of machine parts. Under normal operating conditions and with pumps which are not neglected in maintenance and care, the check and overhaul works are recommended in the following intervals.

➊ X

Further checks and inspections Oil level

> Oil sight glass / Constant level oiler

7.3

X

Leakage

> Shaft seal / Mechanical seal cover

7.2

➊

> Flange sealings (main connections)

-

X

> Lubricating oil from bearing housing

-

X

> Vibration measurement

7.1

➊

> Bearing shock impulse

5.4 / 7.1

➊

Vibration

Maintenance works Oil change

> Bearing housings

1.4.2 / 7.3

Coupling

> Check alignment

5.2

General overhaul / wear check

> Bearings, balance drum and liner, shaft seal, impellers, wear rings ...

8.

➊ ➊ ➋

➊ These parameters should be recorded in an operating log and used as a basis for maintenance works. ➋ Overhaul allows supervision of wear, early recognition of any sign of damage and replacement of defective parts in time. All signs of wear and spare parts used should be recorded in the operating log.

0000/e7-1-3-000 page 1

Title:

Report

Supervision check list

Plant / Location:......................................................................................................................................... Aggregate Specification:........................................................................................................................... Pump type:..............................................................

Driver:..............................................................

Serial-No.:...............................................................

Type / No.:.......................................................

normal

abnormal

Remark:...........................................................

Run

D

D

........................................................................

Noise

D

D

........................................................................

Start-up

Vibration

D

D

........................................................................ ........................................................................

Comments:................................................................................................................................................. ................................................................................................................................................................... ................................................................................................................................................................... TIME

Start up

Shut down

Gauges

Suction

Remark:

o

Temp. C Balance

D-side

ND-side

Oil level D-side

ND-side

R 0000 / 7-0-00-001 Date:

0000/e7-1-4-000 page 1

Pump Discharge

Bearings

Sign:

Page ... of ...

Title:

Report

Inspection check list

Plant / Location:....................................................................................................................................... Aggregate Specification:......................................................................................................................... Pump type:..............................................................

Driver:..............................................................

Serial-No.:...............................................................

Type / No.:.......................................................

1. Leakage

normal

abnormal

Remark:.....................................................

Pump suction

D

D

..................................................................

Pump discharge

D

D

..................................................................

Shaft seal

D

D

..................................................................

Remark:.....................................................

2. Gauges Pump suction

..............

bar

..................................................................

Pump discharge

..............

bar

..................................................................

Balance chamber

..............

3. Bearings

bar

..................................................................

normal

abnormal

Temperature

D

D

.................................. C D-side / ND-side

Oil level

D

D

................................... O.K. Yes / No

Oil refilled

D

D

................................... Refill QTY. liters

Oil leakage

D

D

................................... Yes / No

normal

abnormal

D

D

4. Vibration / Noise Bearing hous. D-side ND-side Pump casing Noise

o

Remark:..................................................... ..................................................................

D

D

..................................................................

D

D

.................................................................

D

D

................................................................. ..................................................................

Comments:............................................................................................................................................ .............................................................................................................................................................. .............................................................................................................................................................. Remark:

R 0000 / 7-0-00-002 Date:

0000/e7-1-5-000 page 1

Sign:

Page ... of ...

Title:

Report

Maintenance list

Plant / Location:....................................................................................................................................... Aggregate Specification:......................................................................................................................... Pump type:..............................................................

Driver:..............................................................

Serial-No.:...............................................................

Type / No.:.......................................................

Maintenance interval No.: .......

Operating hours: .........h

Number of starts: ........

Bearings: D Lubricating oil change

Lubricant type : .........................................

D Leakage checked

Quantity: ...................................................

Bearing monitoring:

Green

Yellow

Red

Drive side:

D

D

D

Non-drive side:

D

D

D

everything o.k.

attention

damage

by impact impulse measurement Comments:

......................................................................................................................

Mechanical part: D Coupling alignment checked (reported) D Bearings opened and checked D Mechanical seal checked D Balance device opened and checked D General overhaul with pump hydraulic part opened and checked D Rotor newly adjusted (axial / radial center position)

Parts changed: D Mechanical seal - Drive side / Non-drive side D Balance device D Bearings - drive side / non-drive side D Shaft D Wear rings D others: ..........................................

Comments:.............................................................................................................................................. ................................................................................................................................................................ ................................................................................................................................................................ Remark:

R 0000 / 7-0-00-003 Date:

0000/e7-1-6-000 page 1

Sign:

Page 1 of 1

7.2 Shaft seal Single-acting mechanical seal 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 considerably higher than operating temperature no impurities in the slide ring region

ATTENTION -

If auxiliary facilities like - flushing - blocking - 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 can be limited to the control of the auxiliary facilities, leakage and temperature at the mechanical seal cover. In the case of normal flushing by circulation the seal cover must not reach any higher temperature than the adjacent pump casing. In the case of cooling or heating the data mentioned in paragraph 1.4 have to be observed. A slight leakage of the mechanical seal is normal. It is impossible, however, to make special ATTENTION 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. In this case defective parts have to be replaced. Auxiliary seals (such as O-rings) have to be renewed during each assembly. Mechanical seal rings (stationary and rotating) have always to be replaced as a unit.

0000/e7-2-01-002

7.3 Bearing / Lubrication Anti-friction bearing with splash oil lubrication General Centrifugal pumps are often exposed to heavy stress caused by continuous operation and heavy forces (radial, axial). Therefore a proper oil quality is a prerequisite for a long bearing life and troublefree operation. The oil must not contain any foreign substances, acids or resins. Minimum requirements of suitable lubrication oils are given in DIN 51 511, API-SF/CC, MIL-L-46152 B. All lubricating oil suppliers are therefore in a position to classify their products accordingly and to propose a product which satisfies these standards. ATTENTION

Failure in terms of lubrication (e.g. through lack of maintenance, use of inappropriate lubricants/lubricant qualities, leakage, 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).

Oil viscosity Since, with anti-friction bearings, the self-heating of the bearing due to fulling plays an important role, and 2 since, on the other hand an oil viscosity of at least 12 mm /s at operating temperature of the bearing is required for a sufficient lubrication film, the oil viscosity has to be selected as follows: Multigrade Engine Oil SAE 15W-40 should be used. The max. allowable temperature values are given in the table below. In case of deviations contact the service. If the temperatures o after overhaul rises over the given values for continues operation (> 90 C in the oil sump), as a first measure check thrust bearing axial clearance (see 8.). ATTENTION

Change intervals and oil quantity In case of first commissioning or of an overhaul, change the oil after 10-15 hours of operation. If further pollution by foreign substances and water is low, change intervals of 6 months can be adhered to. Pump size

40 - 180

50 -220

80-260

100-300

Oil filling in liters drive side

0.1

0.15

0.2

Oil filling in liters non-drive side

0.15

0.2

0.25

150-360

In the case of automatic constant–level-oilers pay attention to refill the reservoir (oiler tank).

Max. allowable temperatures Measuring spot Mode

externally at bearing housing near bearing o

< 110 C

o

> 120 C

o

> 130 C

Continuous operation

< 100 C

Alarm at

> 110 C

Switch off aggregate

> 120 C

Check temperature at the measuring spots regularly.

4330/e7-3-01-001

at external bearing race

in the oil sump

o

< 90 C

o

o

> 100 C

o

> 110 C

o

o

Recommended lubricants 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 o centrifugal pumps which are suitable for an ambient temperature between -10 C and o +40 C. The lubricants have been listed in alphabetical order which does not say anything about their quality. Supplier

Multipurpose- Engine oil SAE 15W-40

4330/e7-3-01-001

AGIP

F1 SUPER MOTOR OIL, SINT 2000

ARAL

SUPER ELASTIC MOTOROIL 1540

BP

BP SB MOTOROIL, VISCO 2000

CASTROL

GTX 2, GTX 3, TXT SOFTEX CASTOLITE

DEA

REGIS MULTIGRADE, TORUS 15W40

ELF

PRESTIGRADE, SPORTI T, MULTIPERFOR. 3C

ESSO

ESSOLUBE MHC 1540, MHX 1540

MOBIL OIL

SUPER FORMULA, DELVAC SUPER 15W40

SHELL

HELIX STANDARD, ROTELLA MX 1540, RIMULA TX

TEXACO

HAVOLINE, URATEX MULTIGRADE 15W40

WINTERS-HALL

TFE 10W40, MAGNUM SL, MULTI RECORD 15W40

Oil level ATTENTION

Monitoring oil level in the constant level oiler bottle. The bottle should always until 2/3 be filled up. A sudden oil level drop can indicate a leak. Stop operation and inspect unit.

Oil replacement Warning: Lubeoil 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.

Filling-in of oil with constant level oiler (Type Adams) Remove oil filling plug at the top of the bearing housing. Fill oil through the bearing housing fill opening until the casing of the constant level oiler begins to fill up (swing back oiler bottle to check oiler case filling). Then fill the bottle with the same oil and swing it back to its working position. Repeat this procedure until a minimum of 2/3 of the bottle remains filled up. Screw in and tighten filling plug. Maintenance: Check the supply in the bottle at times and refill, if necessary.

Constant level oiler working principle When the oil level within the bearing housing drops, the opening to the supply bottle gets free. Oil flows from the supply bottle until the former oil level is reached and the opening to the supply bottle is covered by the oil level.

Oil bottle swinged back

Oil bottle in working position

refill here

Oil level

casing

gasket

ATTENTION

4330/e7-3-01-001

Make sure that the glass bottle is tightly closed, if necessary replace gasket. Turn bottle handtight into threaded cover.

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, Oring seals...) well beforehand to minimise the down time. W hen 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: This 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.

A. 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

4330/e7-5-01-002 Page 1

B. 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...).

-

Remove hexagon socket screws (914.03) from bearing cover (360.02). Clean and lubricate shaft, carefully push 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. Take off lockwasher (931.01) and distance disc (551...).

-

Arrest the shaft before drawing off the bearing bracket on non-drive side to avoid damage to the mechanical seals. 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. - Screw off hexagon nuts (920.02) of the bearing bracket fastening, mount puller (see sketch) and draw off bearing bracket together with antifriction bearings (320...). ATTENTION

-

Draw spacer sleeve (525.02) together with labyrinth seal (423...) off the shaft or remove it from bearing bracket bore. Dismantle antifriction bearings from bearing bracket. 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

Bearing bracket non-drive side

Bearing bracket drive side

shaft

C. 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. W ARNING: 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).

4330/e7-5-01-002 Page 2

-

-

Unscrew hexagon socket screws (914.01) fastening shaft seal housing (441...), loosen shaft seal housing and pull it off. Be careful: Remaining medium will flow out. Mount device and draw balance drum (603.01) and balance drum liner (605.01) together with the spacer sleeve (520.02) off the shaft. See sketch 8.1-3. Take off keys (940.04, 940.02).

Delivery cover (163.01)

Balance drum (603.01) Shaft

Balance drum liner (605.01)

D. Removal of bearing – drive side Sketch 8.1-3 Removal of balance drum and - To disassemble the bearing bracket drive balance drum liner 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. - Unscrew hexagon socket screws (914.02) from bearing cover (360.01). Clean and lubricate shaft, carefully push bearing cover together with labyrinth seal (423...) off the shaft. - Bend lockwasher tang out of bearing nut (920.15) and screw off bearing nut. Take off lockwasher (931.02) and spacer disc (551.01). - Unscrew hexagon nuts (920.02) of the bearing bracket fastening. Loosen and remove bearing bracket together with bearing. Press out antifriction bearing outer race with rolling elements. - Draw spacer sleeve (525.01) together with labyrinth seal (423...) off the shaft, the anti-friction bearing inner race will automatically be taken along as well. If required use suitable puller.

E. 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. W ARNING: 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).

4330/e7-5-01-002 Page 3

F. Dismantling of the hydraulic pump part Mark the stage casings, diffusers and impellers with the stage number during dismantling, as they must be refitted in the same place. - Remove nuts (920.01) from the tie bolts (905.01) and withdraw the tie bolts.

- Loosen and remove the delivery casing (107...) 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 delivery casing

- Slide the 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. - Slide next impeller (230...) off the shaft, remove key (940.01) - Dismantle stage by stage in the same way. Support shaft adequately to prevent bending. - W ithdraw carefully shaft with first stage impeller out of suction casing, slide impeller off the shaft and remove key. - Press diffusers (171...) out of the stage casings (108...) - If required (in case of wear, see 8.2): The wear rings (502...) in the suction casing / stage casings and the interstage bushes (541...) in the diffusers can be replaced.

G. 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. Handle the pump shaft with care and where ever possible store shaft by hanging vertically to maintain staightness. Inspect all pump parts for wear or damage, see 8.2.

4330/e7-5-01-002 Page 4

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.

A. 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.

B. Wear rings and clearances Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum (new) diametrical clearances are given in the table below. Replace impeller and 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, then 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

40-180

50-220

80-260

Material index

Min. clearance

0.3

0.35

cast iron or soft nitrided steel

(with new parts)

0.45

0.5

stainless steel

Max. clearance

0.6

0.7

cast iron or soft nitrided steel

(with worn parts)

0.9

1.0

stainless steel

* clearance in relation to diameter

C. 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. 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. Heat wear ring in an electric oven or hot oil bath to approx. o 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. 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.

4330/e7-5-01-002 Page 5

Sketch 8.2-2

Sketch 8.2-3

Sketch 8.2-4

D. 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.

E. 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 (max. permissible run-out 0.025 mm). If the run-out is outside the permissible value replace the shaft.

F. 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. W e recommend the use of new rotating and stationary seal rings. Assembly must be done very carefully and under conditions of extreme cleanliness. The ATTENTION seal 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.

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

H. 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

40-180

50-220

80-260

Material index

Max. permissible

0.3

0.4

cast iron or soft nitrided steel

clearance (worn parts)

0.5

0.5

stainless steel

* clearance in relation to diameter

4330/e7-5-01-002 Page 6

I. Rotor concentricity check (shaft with rotating parts) Concentricity should be checked with the shaft in unloaded and loaded condition. Assemble the complete rotor. Place a washer * between the last impeller and the balance drum during assembly. A sleeve * of the appropriate length is fitted instead of the axial bearings. See sketch 8.2-5 Do not fully tighten the nuts that locate the bearings. Support shaft at bearing area (use V-blocks or rollers). Check the concentricity in the unloaded condition. The measuring points are: diameter of impeller clearances, the impeller hubs, the shaft sleeves, the balance drums and the coupling shaft end. The permissible run-out is 0.05 mm. If the concentricity check in the unloaded condition is satisfactory, tighten the nuts to lock the rotating parts on the shaft. Repeat concentricity check at the same points. If the run-out now exceeds tolerance, 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 shoulders, impeller hubs, balance drums and sleeves, must 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.

Washer Sketch 8.2-5 Rotor concentricity check

4330/e7-5-01-002 Page 7

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.

A. 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.

B. Assembly of the hydraulic pump part (Refer to matchmarks during reassembly) Note with pump sizes: 40-180 from 9 stages; 50-220 from 10 stages and 80-260 from 8 stages: With pumps having a large number of stages, the pump casing must be adjusted to the deflection line of the shaft. In such cases the correction is obtained by obliquely turning one or more of the stage casings. The oblique stage casing carries the mark “OBEN" and the number of the stage in which it must be mounted (counting from the suction end). See sketch 8.3-1. oben

Sketch 8.3-1 If the pump is assembled horizontally, the stage casings should not be supported underneath before the tie bolts are tightened, so that the stage casings can be “suspended". - Clean shaft, impeller bores and coat the contact surfaces slightly with lubricant. - Insert key (940.01) for the first normal impeller, and push impeller (231...) onto shaft stop (210...) - Insert diffuser (171...) in the first stage casing (108...) and slide it into the centering element of the diffuser device - if necessary, knock with a rubber hammer. Place O-ring seal (412.01) for sealing against next stage casing. - Insert key (940.01) and push on next impeller (230...) from the non-drive side. - Fit another pre-assembled stage casing (with diffuser) - if necessary, knock with a rubber hammer. Place O-ring seal. - Assemble remaining stages in the same way. - Slide delivery casing (107...) with inserted last diffuser (177.01) and O-ring seal (412.12) on the spigot of the last stage casing (108...). - Drive side: Place O-ring seal (412.01) on the spigot of the diffuser device (170....) and mount suction casing (106...). ATTENTION Adjust and support pump suction and discharge casing feet on a smooth steel plate. -

Fit tie bolts (905.01), discs (550.01) and nuts (920.01). Clamp the whole hydraulic assembly together evenly and crosswise. See Table 8.5 for tightening torques.

C. 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 casing bore and allow the cylindrical dowel pin (561.02) preventing rotation to engage in the hole.. Insert key (940.04) into shaft and slide on sleeve (520.01).

4330/e8-0-01-001 page 8

D. Assembly of the shaft seal housings -

Drive side: Insert key (940.04) for shaft sleeve. Insert O-ring seal (412.02) in groove of the shaft seal housings (441...). Locate shaft seal housings on delivery casing (107...) and suction casing (106...) using hexagon socket screws (914.01). Note: Be sure venting bores of seal chambers are on top.

E. 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 "Assembly of shaft seal non-drive side" 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. Remark: Mount all parts required for the measurement without O-ring seals. -

-

Drive side: Push mechanical seal shaft sleeve (523.01) and spacer sleeve (525.01) onto shaft stop. Non-drive side: Push mechanical seal shaft sleeve (523.01) on the shaft. Assemble bearing brackets (330...) on both sides of the pump and fasten with nuts evenly and crosswise. Push rotor until stop in the direction of the non-drive side. On the non- drive side: Determine measurement „A" (see sketch 8.3-3) from the support shoulder of the thrust bearing in the bearing bracket bore to the front face of the shaft sleeve (523.01) with depth gauge. The spacer sleeve (525.02) must be longer than the measurement "A" by the value "B" given in the following table Pump size

40-180

Dimension

± 0.1

B=

5.3

50-220 6

± 0.1

80-260 6.5

± 0.1

Dimension in mm

New spacer sleeves are supplied with oversize, they must be machined to the calculated dimension. When repair work is done the nominal dimension can also be gained by applying supplementary discs.

Note: The spacer sleeve shoulders must be parallel to each other within 0.01 mm after machining.

Rotor pushed up to stop in direction of non-drive side

Shaft sleeve (523...)

A A+B Running position Remachine shoulder

Sketch 8.3-3 Measurement and adjustment of the axial position of rotor

4330/e8-0-01-001 page 9

- On the drive-side: Check the length dimension of the spacer sleeve (525.01) while the rotor is moved to the non-drive side. To do so measure with depth gauge from the circlip in the bearing bracket (stop anti-friction bearing outer race) to the front face of the spacer sleeve dimension “C”. The measuring result should correspond to the dimensions given in the following table. Pump size MC Dimension C =

40-180

50-220

80-260

Dimensions

3 ±1

3.5 ± 1

4 ±1

in mm

Remark: Because of the big tolerance the spacer sleeve on the drive side has very rarely to be remachined. - After measurement and if the “check of free running state of the rotor” is not required, remove bearing bracket on both sides again. Also remove spacer sleeve (525.01) on non-drive side and shaft sleeves on both sides.

F. Check of free running state of the rotor The check of free running is always required if the hydraulic pump part (stage casings) had been disassembled, otherwise continue with paragraph "Assembly of the shaft seals". - Non-drive side: Slide spacer sleeve (525...) onto shaft. Assemble thrust bearing as given in “Assembly of antifriction bearings”. - Drive side: Assemble radial bearing as given in “Assembly of antifriction bearings”. Due to manufacturing of the pump parts within given tolerances the rotor theoretically should ATTENTION 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. Causes and measures in case of touching of the rotor Tightening the screws in practice may however cause a different prestress in each screw by differing friction values in the thread and the nut support. Due to the differing prestress 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. W ith 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, the bending of the stage casing package needs correction by tightening the tie bolts with differing torques. As there is no proper way of predicting how the bending of the stage casing package will work out, the tie bolts to be tightened more strongly will have to be found by trying. ATTENTION

Note: The torques given in the table 8.4 may be exceeded in these cases by max. 50 %. If check of free-running rotor is satisfactory: Disassemble bearing housings, bearings and shaft sleeves again (see 8.1) and proceed with “Assembly of the shaft seals”.

G. Assembly of shaft seals Mount shaft seals on drive side and non-drive side. 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.

4330/e8-0-01-001 page 10

H. Assembly of bearing brackets Mount bearing brackets on drive side and non-drive side. - Lubricate spacer sleeve surface (525.02) 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 (525.02) in nominal dimension (together with labyrinth seal) into position on the shaft. - In case of shaft seal housing cooling: Place O-ring seal (412.02 or 412.03) on the spigot of the seal housing and O-ring seal (412.04) into the shaft seal housing groove. - Mount bearing bracket (330...) to do so push inboard labyrinth seal (423...) into bearing bracket bore. Note: Labyrinth seal stationary part with leakage groove or bore downwards. Lube threads and support surfaces of nuts (920.02) and tighten fasteners evenly and crosswise. See Table 8.5 for tightening torques.

I. Assembly of antifriction bearings -

Assemble thrust bearing – non-drive side: Build in outer race of inboard taper roller bearing (320...) with bearing intermediate ring (make sure that one bore of the bearing intermediate ring points downwards) into bearing bracket bore. W arm taper roller bearing inner races with rolling elements in an oil o bath to approx. 80-100 C and push it up to shaft stop. Fit outer race of outboard taper roller bearing. In case of renewed taper roller bearings: Use only paired bearings, never replace one ATTENTION bearing of a unit. The bearing design number is given in the pump parts list.

-

Screw on shaft nut (920.16 or 920.15 depending on model). Shaft nut (920.16): Screw on and tighten shaft nut (920.16). Secure shaft nut by tightening the adjusting screws. Shaft nut (920.15): Install spacer ring (551...), 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.

Insert O-ring (412.06) into the bearing bracket groove. Install bearing cover and tighten bearing cover fasteners (914.03) evenly and crosswise. See Table 8.5 for tightening torques. Note: During tightening the rotor reaches the final axial position.

Assemble radial bearing – drive side: Heat inner race of roller bearing (320.01) in an oil bath to approx. o 80 - 100 C and push up to shaft stop. Build in anti-friction bearing (320.01) outer race with rolling elements into bearing bracket bore. - Fit spacer disc (551...) and lockwasher (931...) onto shaft, screw on bearing nut (920...). Apply lubricant to the contact face of bearing nut and lockwasher. - Tighten bearing nut and bend the lockwasher tang into one of the bearing nut slots. ATTENTION Do not overtighten bearing nut. -

-

Insert O-ring seal (412.05) in bearing cover (360.01) and fit bearing cover with hexagon socket screws (914.02). See Table 8.5 for tightening torques.

4330/e8-0-01-001 page 11

J. Check and correct the thrust bearing axial clearance (end play) 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. ATTENTION

-

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 8.3-4. W ith 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 ① (not too strongly), ② loosen, read clock gauge, loosen ①, tighten ② and read nominal end play.

nominal dimension 0.04 to 0.06 mm

Sketch 8.3-4 -

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. ATTENTION

If the taper roller bearing temperature after overhaul rises >90 oC, as a first measure check bearing end play.

K. Final assembly -

Labyrinth seals: On both sides of the pump. Lubricate shaft surface and bearing cover bore. Push outboard labyrinth seal (423...) 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 inboard labyrinth seal. Shaft seal - Cartridge mechanical seal: If present tighten clamping device (shaft/shaft sleeve). Tighten nuts (920...) of the mechanical seal cover evenly and crosswise. Tightening torque see table 8.6. Loosen the assembly bars of the Cartridge mechanical seal at the seal cover, draw them out of the shaft sleeve groove and reattach them. - 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 (900.06).

4330/e8-0-01-001 page 12

Coupling: Mount the coupling half. See sketch 8.3-5. - Clean coupling bore and shaft extension, insert key that drives the coupling into shaft. A thin coating of oil on the shaft surface and hub bore is recommended, do not use molybdenum disulphide or similar products. - Remove heat-sensitive parts (e.g. rubber buffers and seal rings etc.) o and heat up the coupling half to approx. 80 C by means of uniform dry heat (e.g. oven or hot plate). Slide the coupling half onto the shaft and fit removed parts again after it has cooled down. Couplings with bores up to a diameter of 50 mm can also be fitted cold with an appropriate attachment.

coupling half

pump shaft

nut

bar

stud

Sketch 8.3-5 The bearings must by no means be subjected to any ATTENTION pressure or shock. 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. Rinse bearing housing with oil and fill with lubricating oil, see 7.3. 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.

4330/e8-0-01-001 page 13

8.4 Tools A. Disassembly equipment for the balance piston and thrust bearing housing Part No. 1

Pump size

Part

40-180

50-220

1 Flange

80-260

200 x 25 x 165

Drawing No.

2-104 084 159

Article No. (tool set complete)

104 998 809 362

2

4 Stud (bearing hous. removal)

M 10 x 165

M 12 x 200

3

2 Stud (balance piston removal)

M 10 x 440

M 12 x 620

4

4 Disc

A 10.5

A 13

5

4 Nut

M 10

M 12

6

1 Hexagon screw

7

1 Ball

12 mm diameter

Sketch 8.4-1 Thrust bearing housing removal 1

2

M 20 x 1,5 (140 or 180 length)

1 6

7

4 5 Sketch 8.4-2 Balance drum (drum liner) removal 1

3

1 6

7

4 5

B. Rotor concentricity check (see also 8.2) Qty. 1

Between balance drum and last stage impeller Disc Dimension in mm, inner dia. x outer dia. x thickness Pump size 40-180 50-220 80-260 Dimension

Qty. 1

S 50x62x3

S 65x85x3.5

S 70x90x3.5

Instead of thrust bearing Sleeve Dimension in mm, inner dia. x outer dia. x length Pump size 40-180 50-220 80-260 Dimension

4330/e8-0-01-001 page 14

40x52x46

60x75x62

55x68x58

Casing seal

8.5 Screw tightening torques Tightening torques (Nm) part no.: 905.01 Working pressure (bar) > 80 to 120 1030 1580 940 1450 2250 3110

Pump size < 80 710 1090 650 1000 1550 2100

O-ring

40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400

> 120 to 150 1260 1940 1160 1780 2770 3850

Tightening torques (Nm) for Pump size 40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400

bearing bracket fastening part no.: 920.02

bearing cover screws part no.: 914.02 / 03

105

20

30

205

Note: Tightening torques are only valid, if thread and support surface for nuts (respectively screw head supports) are lubricated.

Bolting sequence

A. 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.

➃

B. Thread lubes

➇

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.

➅

➀

➁

➄

➆ ➂

C. 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.

nuts 920.02

tie bolt 905.01

nuts 920.02

➃

➁

➀

➂

screws 914.02

screws 914.03

Note: Refer also to 5.2 for tightening torques for pump feets 4330/e8-0-01-001 page 15

➃

➀

➁

➂

➆ ➁

➃ ➅ ➀ ➇ ➄ ➂

ENCLOSURES Table of enclosures for operating instruction PUMP Performance data-diagram Performance curve Dimension drawings Installation plan Plant drawings P + I Diagram Device list Sectional drawing Centrifugal pump Parts list - pump SHAFT SEAL Shaft seal system Shaft seal drawing Instruction Barrier system Instruction ACCESSORIES Drive Coupling Driver Valves Minimum flow regulation