Manual

Piston Pump
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USER’S MANUAL
Date of issue :
HIGH-PRESSURE LIQUID GAS PISTON PUMP
COMMISSIONING AND MAINTENANCE INSTRUCTIONS
Type:
A-MRP 40/55-T
Comm. No.:
Order No.:
Customer:
These instructions are provided to facilitate pump commissioning and prevent any
mishandling. Please read these instructions before carrying out any operation on the pump
and follow our recommendations to save you time and unnecessary repair cost.
We advise you to keep a stock of spares as indicated in this manual. For ordering parts,
please use our product descriptions and indicate the machine No. to prevent any error. The
serial No. is engraved on the name plate of each equipment unit.
Please submit orders to:
Sales and service departments
Manufacturer
Cryostar-USA
2670 Lehigh Street
Whitehall, PA 18052
Telephone: (610) 231-0210
Fax:
(610) 231-1522
Cryostar-USA
9211 S. Greenleaf Ave.
Santa Fe Springs , CA 90670
Telephone : (562) 903-1290
fax :
(562) 903-4511
Piston Pump
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USER’S MANUAL
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BUSINESS CENTERS
CRYOSTAR - FRANCE S.A.S.
Zone Industrielle
B.P. 48
F - 68220 HESINGUE / France
Telephone:
Telefax:
Web:
CRYOSTAR UK
Unit 1
Kea Park Close
Hellaby
GB – S66 8LB ROTHERHAM
South Yorkshire
Tel: +44 1709 702 777
Fax: +44 1709 702 771
+33 (0)3 89 70 27 27
+33 (0)3 89 70 27 77
www.cryostar.com
CRYOSTAR SINGAPORE
203 Henderson Road
Blk B# 10-09
Henderson Industrial Park
SGP – 0315 SINGAPORE
Tel: +65 276 7441
Fax: +65 276 7442
CRYOSTAR CHINA
393 Dongxin Road
Hangzhou, CHINA
310004
Tel: +86 571 8536 8331
Fax: +86 571 8536 8409
USER’S LIABILITY
This equipment will fulfil the functions stated in this manual and in reference documents if it is installed, put in
service and maintained according to instructions. It must be over-hauled periodically. Any defective equipment
shall not be used. All broken, missing, worn, deformed or contaminated parts must be immediately replaced.
Should any repair or replacement operation be required, CRYOSTAR - FRANCE at HESINGUE recommends
you call upon its Customer Service. The Customer shall keep a stock of spare parts to be ordered according
to the instructions stated at the end of this manual.
The machine, including each one of its components parts, should not be modified without prior written
approval of CRYOSTAR - FRANCE. The user and/or the purchaser will be solely liable for any operation
defect resulting from misuse, inadequate maintenance, possible damage, use of replacement parts other than
original CRYOSTAR make parts, inappropriate modifications or repairs carried out by any person other than
the Manufacturer.
Caution
It is essential to read these instructions before unpacking and commissioning this equipment. In addition, the
machine must be used and maintained by qualified people.
Note
These technical documents are Cryostar property. Any copying or communication to third party or illegal use
is prohibited.
Piston Pump
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USER’S MANUAL
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CONTENTS
1.
GENERAL INFORMATION ......................................................................................... 5
1.1.
2.
TECHNICAL DATA ..................................................................................................... 6
2.1.
2.2.
2.3.
2.4.
2.5.
3.
DESCRIPTION OF EQUIPMENT ................................................................................................................. 5
PUMP CHARACTERISTICS ....................................................................................................................... 6
SERVICE FEATURES............................................................................................................................... 6
MOTOR DATA ........................................................................................................................................ 6
ACOUSTIC PRESSURE ............................................................................................................................ 7
TEST .................................................................................................................................................... 7
SAFETY....................................................................................................................... 8
3.1. DANGER ............................................................................................................................................... 8
3.2. LOCKING PROCEDURE ......................................................................................................................... 10
3.2.1. Locking of process gas energy.................................................................................................... 10
3.2.2. Locking of barrier and purging gas energy.................................................................................. 10
3.2.3. Electrical locking .......................................................................................................................... 10
3.3. SAFETY SHEET - SUMMARY ................................................................................................................. 11
4.
PUMP STORAGE BEFORE INSTALLATION ........................................................... 13
4.1.
4.2.
4.3.
4.4.
5.
FINAL INSPECTION AT CRYOSTAR FRANCE SA ................................................................................ 13
DEGREASING, GREASE AND OIL FOR OXYGEN SERVICE .......................................................................... 13
RECEIVING INSPECTION ....................................................................................................................... 13
PUMP STORAGE .................................................................................................................................. 13
EQUIPMENT.............................................................................................................. 14
5.1. HANDLING........................................................................................................................................... 14
5.2. ASSEMBLY .......................................................................................................................................... 14
5.2.1. Guard........................................................................................................................................... 14
5.3. INSTALLATION DIAGRAM ....................................................................................................................... 14
5.4. TANK .................................................................................................................................................. 15
5.5. PIPES ................................................................................................................................................. 15
5.5.1. Suction pipe ................................................................................................................................. 15
5.5.2. Summary: suction pipe design .................................................................................................... 16
5.5.3. Degasification pipes .................................................................................................................... 17
5.5.4. Nitrogen flushing.......................................................................................................................... 17
5.5.5. Option: Temperature sensor........................................................................................................ 17
5.5.6. Discharge pipe............................................................................................................................. 18
5.6. VALVES AND CONNECTIONS ................................................................................................................. 19
5.7. TEMPERATURE SENSORS - OPTIONS .................................................................................................... 20
5.8. SUMMARY TABLE OF ADJUSTMENT THRESHOLDS ................................................................................... 20
5.8.1. Temperature sensor. ................................................................................................................... 20
6.
LUBRICATION .......................................................................................................... 20
6.1.
6.2.
6.3.
6.4.
6.5.
7.
LUBRICATED BEARINGS ....................................................................................................................... 20
LUBRICATED BEARINGS ....................................................................................................................... 21
OIL – PROPERTIES ............................................................................................................................ 21
MOTOR BEARINGS ...............................................................................ERROR! BOOKMARK NOT DEFINED.
TYPICAL CHARACTERISTICS ................................................................................................................. 23
COMMISSIONING ..................................................................................................... 24
Piston Pump
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7.1.
7.2.
7.3.
7.4.
8.
TROUBLESHOOTING............................................................................................... 28
8.1.
9.
INSPECTION BEFORE COMMISSIONING .................................................................................................. 24
ROTATION DIRECTION .......................................................................................................................... 24
STARTING OF PUMP ............................................................................................................................. 25
PUMP STOP ........................................................................................................................................ 27
FAULTS/CORRECTIVE ACTIONS ............................................................................................................ 28
EQUIPMENT OVERHAUL INSTRUCTIONS ............................................................. 29
9.1. GENERAL............................................................................................................................................ 29
9.1.1. Assembly/Removing: Table of tightening torques and forces ..................................................... 30
9.2. VACUUM INSULATION CHAMBER ........................................................................................................... 31
9.2.1. Belt alignment and tightening (new belts) ................................................................................... 32
9.3. MAINTENANCE .................................................................................................................................... 33
9.3.1. Motor............................................................................................................................................ 33
9.3.2. Pump/Linking assembly............................................................................................................... 34
10. COLD HEAD REMOVAL ........................................................................................... 36
10.1. COLD HEAD/LINKING ASSEMBLY REMOVAL ............................................................................................ 36
10.2. SUCTION HEAD REMOVAL ..................................................................................................................... 37
10.3. DISCHARGE VALVE REMOVAL ............................................................................................................... 37
10.3. 38
10.4. REMOVAL OF TIGHTENING SLIDE ........................................................................................................... 38
10.5. REMOVAL OF PISTON, HP-LP JOINTS AND GUIDE BUSH.......................................................................... 38
10.6. REMOVAL OF COLD HEAD SUCTION VALVE ............................................................................................. 39
10.7. REMOVAL OF SUCTION VALVE (COLD HEAD) .......................................................................................... 39
10.8. REMOVAL OF SUCTION VALVE (COLD HEAD) .......................................................................................... 40
10.9. REMOVAL OF JOINT CARTRIDGE (CASING OF LINKAGE ASSEMBLY) .......................................................... 40
10.10. REMOVAL OF BEARING UNIT ................................................................................................................. 41
10.11. REMOVAL OF OIL PUMP ........................................................................................................................ 43
11. MOUNTING OF COLD HEAD ................................................................................... 44
11.1. MOUNTING OF SUCTION VALVE ............................................................................................................. 44
11.2. MOUNTING OF SUCTION VALVE ON CYLINDER ........................................................................................ 45
11.3. ASSEMBLY OF SPRINGS AND SEGMENTS HP ON PISTON ......................................................................... 45
11.4. MOUNTING OF LP JOINTS ASSEMBLY .................................................................................................... 46
11.5. MOUNTING OF TIGHTENING SLIDE ......................................................................................................... 46
11.6. MOUNTING OF SUCTION HEAD .............................................................................................................. 47
11.7. MOUNTING OF DISCHARGE VALVE .................................................................................................... 47
11.8. MOUNTING OF OIL PUMP ...................................................................................................................... 48
11.9. MOUNTING OF BEARING ASSEMBLY....................................................................................................... 48
11.10. MOUNTING OF BEARING ASSEMBLY IN THE CASING ................................................................................ 50
11.11. MOUNTING OF JOINT CARTRIDGE .......................................................................................................... 50
11.12. COUPLING OF COLD HEAD WITH LINKAGE .............................................................................................. 51
12. LIST OF DRAWINGS AND REPLACEMENT PARTS .............................................. 53
13. REPAIR SERVICE - REPLACEMENT PARTS ......................................................... 54
13.1. INFORMATION TO BE SUBMITTED BY THE CUSTOMER .............................................................................. 54
13.2. APPENDIX WITH REPLACEMENT PARTS LIST ........................................................................................... 54
14. APPENDIX................................................................................................................. 55
14.1. NPSH ................................................................................................................................................ 55
14.2. INSTRUMENTATION .............................................................................................................................. 57
Piston Pump
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USER’S MANUAL
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1.
GENERAL INFORMATION
1.1.
Description of equipment
It is a single-cylinder, single-action piston pump.
This pump is supplied standing on foot with drive belt or other.
The piston is attached to a crosshead by coupling. The latter is pulled by a rod
driven by a cam.
Maintenance is facilitated as the various components (cold head, linkage
assembly) are easily removable.
Motor rotation direction has no effect. The pump can run in both directions.
This manual covers the description of the pump, but contains also complete
information on pump equipment, startup and maintenance.
The function of this equipment is to raise pressure in bottle filling units for
example, with tank, gas scrubber, heater.
Option:
A frequency controller can be fitted to set unit flow and pressure to the desired
requirements.
According to equipment supply limit, the unit will be provided with anti-pulsation capacity,
suction hose, discharge hose, gas backflow hose, suction filter, safety valves, stop valves,
degasification taps, non-return valves, pressure gauges, and differential pressure controller…
If the unit is supplied with an electrical heater, refer also to heater instructions.
Piston Pump
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2.
TECHNICAL DATA
2.1.
2.2.
2.3.
Pump characteristics
Serial No.
Type
Piston diameter (mm)/Stroke (mm)
Rotation speed
Year
A-MRP 40/55-T
40/55 mm
250 min-1
2005
Service features
Fluid
Fluid temperature
Flowrate
Maximum suction pressure
Discharge pressure
NPSP min.
Effective power
LOX/LIN/LAR
-196°C
5.8 gpm / 22 l/min
max. 15 barg
6000 psi/410 barg
0.8 to 1.5 m
40 HP
Motor data
Cryostar Ref.
Type
Frequency
Phase
Protection
Insulation/Heating Class
Voltage
Power
Speed
Motor connection
730154090-1/029
04018EP3H324T WEG
60 Hz
3
IP 55
F/B
460 V
40 HP
1800 min -1
Delta
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2.4.
Acoustic pressure
Average value
2.5.
˜ 85 dB A
Test
Fluid
Test Speed
Nitrogen
Refer to test protocol
Note:
The operating features were measured on test stand.
The test makes it possible to check the pressure under cryogenic operating
conditions.
Note If required, test protocols, material certificates or test pressure certificates are included
in the Quality Manual in accordance with contractual requirements.
Piston Pump
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3.
SAFETY
3.1.
Danger
Please conform strictly to safety requirements in force on site. Provide
safety fence around the equipment to limit access of non-authorised
personnel.
Any servicing on the equipment under operation is strictly prohibited
Any standard maintenance operation must be carried out in accordance
with the recommendations of this manual
Any operation to be carried out following an incident must be performed
in accordance with the recommendations of the manual
NON COMPLIANCE OF SERVICE PERSONNEL WITH SECURITY
INSTRUCTIONS MAY RESULT IN VERY SERIOUS INJURIES OR DEATH
Before carrying out any operation, make sure that the pump is in
condition suitable for operation (see starting procedure) and that no one
is staying in the machine starting area.
This equipment is operating under electrical voltage.
Any electrical component must comply with Low Voltage EB-60204-1 and
EMC electromagnetic compatibility Directives.
In case of power failure, take all necessary measures to prevent
unwanted restarting
The motor shall comply with Low Voltage EN-60204-1 and EMC Directives.
Minimum motor protection degree must be IP 55.
The machine must be provided with a control device making it possible to stop
it in safe conditions. Machine stop command must take precedence over start
commands.
The control device and cabinet must comply with 60204-1 Standards.
The minimum protection degree must be IP22 in closed room and IP55 in
outside conditions.
The machine must be provided with an emergency stopping device in
conformity with EN418 Standard requirements, quite visible and quickly
accessed.
After emergency stop, any automatic restarting must be prevented.
Piston Pump
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The machine and the motor must be fixed on a frame sufficiently stable to
prevent any risk of unwanted inversion or displacement. The frame shall be
equipped with an earth connection and anchoring bolts as needed.
Ensure compatibility of system’s design between gas and materials (oxygen
compatibility).
The materials shall be selected according to their compatibility with the
pumped fluids.
Depending on liquid gas used, risks of poisoning risks, fire or explosion may
exist. Refer to motor manual.
Risk of explosion
All components must be cleaned and degreased for oxygen service.
After cleaning and degreasing, components and parts will be packed
hermetically and protected from any contact with fatty materials not
compatible with liquid or gas oxygen. Please contact Cryostar.
Hermetic packing and protections will be removed only at the precise time of
equipment installation.
Risk of explosion when oxygen is present.
Remove with caution any residue of grease-remover.
For obvious technical reasons related to white frost formation, full insulation of
all parts of pump is not feasible.
Risk of burn
Throughout the entire cooling process and operation, all hand contact
with the machine is strictly prohibited.
Our products must be handled using a slinging system. Please refer to
the corresponding chapter on Installation.
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3.2.
Locking procedure
(Maintenance)
Our equipment must be installed within a lockable unit providing all
required features of equipment cut-off, separation, locking, purging and
pressure checking.
All external utility supplies to our product provided by the customer
(power, barrier gas, compressed air, purging N2, etc.) must be locked using
lockable disconnecting switches (manual valves with lock, lockable electrical
disconnect switch…). Valves of gas lines shall be selected so as to make
INTENTIONAL locking and unlocking feasible by the user with valve locking.
3.2.1. Locking of process gas energy
The components and equipment units ensuring process gas energy insulation
and locking depend on internal locking procedures of users and on features of
their networks. Therefore, CRYOSTAR can not drawing for the installation of
certain equipment on the machine supplied.
3.2.2. Locking of barrier and purging gas energy
The user must make sure that barrier or purging gas pipes are insulated and
locked before any operation on our products.
3.2.3. Electrical locking
Before any operation on parts or equipment normally under voltage, personnel
must lock them when at stop.
- Cut off and separate equipment from its power source by opening the switch
- Lock the switch in separation position using a lock or any other equivalent
device. The disconnecting switch must be set to the open position.
- Before starting any servicing, check that no residual voltage accumulated
remains.
(Note: all orange colour electrical circuits of CRYOSTAR supplied electrical
equipment remain under voltage permanently).
Only qualified personnel must carry out the needed electrical
operations. Electrical connections are to be performed by authorised
personnel in conformance with local regulation and protection rules in
force.
The
certificate can be not validated unless all requirements stated in this
chapter were complied with.
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3.3.
Safety Sheet - Summary
WARNING
All operations must be carried out by
appropriately trained personnel
AVERTISSEMENT
Toutes les interventions doivent être
effectuées par un personnel habilité
ACHTUNG
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Gases and liquid under high pressure
Gaz et liquides sous High Pressure
LIFTING
Vertical lifting : prevent uncontrolled
rotation
LEVAGE
Levage vertical : Empêcher toute
rotation non contrôlée
Flüssigkeiten und Gase unter hohem
Druck
HEBEN
Senkrechtes Heben : unkontrolliertes
Drehen vermeiden
PRE-INSTALLATION CHECKS
CONTRÔLES AVANT
INSTALLATION
Toute pompe doit être contrôlée dès
réception
UEBERPRUEFUNGEN VOR DER
INSTALLATION
Jede Pumpe sollte unverzüglich nach
Ankunft untersucht werden
Check nameplate details
Vérifier les informations sur la plaque
signalétique
Typenschilddetails prüfen
Check stored equipment every 6
months
Vérifier le matériel entreposé tous les
6 mois
Gelagertes Material alle 6 Monate
kontrollieren
No loose fasteners
Pas de fixations desserrées
Keine losen Befestigungen
MECHANICAL INSTALLATION
Refer to instructions
INSTALLATION MECANIQUE
Se reporter au manuel d’instructions
MECHANISCHE INSTALLATION
Siehe Betriebsanleitung
ELECTRICAL INSTALLATION
All operations must be carried out by
appropriately trained personnel
INSTALLATION ELECTRIQUE
Toutes les interventions doivent être
effectuées par un personnel habilité
ELEKTRISCHE INSTALLATION
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Earthed
Mise à la terre
geerdet
Check rotation, untorqued
Vérifier la rotation à vide
Maschine in Leerlauf prüfen
Connections are tight ?
Les connexions sont-elles serrées ?
Sind die Anschlüsse fest angezogen ?
Covers must be fitted
Les capots de protection des boîtes à
borne doivent être en place
Abdeckungen der Klemmenkasten
müssen angebracht sein
Fused and insulated correctly
Protégé par coupe circuit et isolé
correctement
Korrekt abgesichert und isoliert
Every control box with a heating band
must be ‘’on ‘
Jeder Elektro-Schrank mit Heizband
Toute armoire électrique équipée
d’une résistance chauffante doit rester muss unter Spannung sein
sous tension
Respect tightness of the control box
while cabling
Respecter l’étanchéité de l’armoire
électrique lors du câblage
Beim Anschlussen des ElektroSchrank Dichtheit beachten
Shut front protection covers after use
Veiller à fermer les capots de
protection en façade après utilisation
CONNEXIONS
Vérifier le schéma de câblage
Nach dem Gebrauch vordere
Abdeckungen zumachen
ANSCHLUESSE
Anschlüsse nach Anschlussdrawing
überprüfen
Check driven equipment is free
Vérifier que la machine entraînée soit
libre
Prüfen, ob angetriebene Maschine frei
beweglich ist
Correct terminal arrangement
Vérifier le repérage des bornes
Auf einwandfreien elektrischen
Anschluss achten
Every pump should be checked
immediately upon discharge
CONNECTIONS
Check connection diagram
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PROBLEMS
Refer to instructions manual
PROBLEMES
Se reporter au manuel d’instructions
PROBLEME
Siehe Betriebsanleitungen
Pressure drop
Perte de charge
Druckverlust
Heat inleak
Pénétration de chaleur
Wärmeeinfall
Gas formation
Poche de gaz
Gasbildung
Additional forces
Contraintes mécaniques
supplémentaires
Zusätzliche Krafteinwirkung
Pump or seal failure
MAINTENANCE
Isolate
Risques de détérioration de la pompe
et des joints
ENTRETIEN
isoler
Schadensgefahr für die Pumpe und
Dichtungen
WARTUNG
trennen
Refer to supplier for details of
greasing etc...
Pour les détails de lubrification etc..
consulter le fournisseur
Schmierung usw. siehe
Herstellungsangaben
SPARES
Refer to supplier
PIECES DE RECHANGE
Consulter le fournisseur
ERSATZTEILE
An Hersteller wenden
Quote equipment number, stock
number, designation
Indiquer le numéro de la machine, le
numéro de drawing de la pièce, la
désignation
Maschinennummer,
Zeichnungsnummer, Benennung
angeben
HAZARDOUS AREAS
All operations must be carried out by
appropriately trained personnel
ZONES DANGEREUSES
Toutes les interventions doivent être
effectuées par un personnel habilité
GEFAHRENBEREICHE
Alle Arbeiten müssen von
entsprechend geschultem Personal
ausgeführt werden
Refer to:
construction standard EN 294
Se reporter à:
norme de construction EN 294
Bitte nachschlagen in :
Baunorme EN 294
STORAGE
Storage in a dry environment
the right way round
STOCKAGE
Stockage en lieu sec
à l’endroit
LAGERUNG
Lagerung in trockenem Raum
Richtig stellen
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4.
PUMP STORAGE BEFORE INSTALLATION
4.1.
Final inspection at CRYOSTAR FRANCE SA
Each pump is submitted to a final test with liquid nitrogen before dispatch from
our factory. All our equipment is supplied in perfect operating condition.
4.2.
Degreasing, grease and oil for oxygen service
Pumps carrying the mark "Dégraissé par du trichloréthylène pour la marche
avec de l’oxygène liquide” (Degreased with trichlorethylene for operation with
liquid oxygen) can be operated with oxygen. These pumps are provided with
an oxygen compatible lubricant. Pumps supplied with mineral oil are marked
"Pas pour Oxygène" (Not for oxygen).
4.3.
Receiving inspection
The customer must inspect the pump on receiving. Any equipment missing
part or damage must be immediately reported to the carrier or to Cryostar.
Please refer to the Conditions of sale according to Incoterms, Edition 1990.
4.4.
Pump storage
Store pump in a dry and clean place, free of oil, dust and sand.
Caution: Protective caps of all pump openings must not be removed to
prevent any foreign body from penetrating inside cold head unit. They will be
removed only at the time of pump connection.
Warning:
Check the stored equipment and spare parts regularly, at least once every six
months. This inspection is not required for equipment supplied in maritime
packing. Correct immediately any undesirable condition noted (moisture, dust,
rust, etc). Machines intended for operation in oxygen service, and stored for a
period of over six months, must be removed and controlled before
commissioning. No trace of moisture, dust or rust shall appear before
commissioning with oxygen. Inspection schedules stated above are our
recommendation. They can be modified according to safety requirements in
force at the user. Serious accidents may result if service personnel do
not conform to safety instructions.
For storage periods over a year, we recommend packing the equipment in
special maritime packing.
NOTE If the equipment is supplied in a maritime packing, it can be stored for two years
unpacked under open shelter. (Refer to the SEI Requirements, packing type 4.c).
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5.
EQUIPMENT
5.1.
Handling
It is mandatory that all equipment unit of weight over 55kg be handled using
slinging means. Refer to the slinging diagram No.702 111523.
5.2.
Assembly
The skid must be installed on a plane surface according to the floor space
drawing. This surface must resist the load indicated.
The skid shall be fixed by anchoring screws whose quantity and size are
indicated on the drawing. Joint skid as required to limit vibrations as much as
possible. Ensure overall assembly stability.
5.2.1. Guard
At the time of installation, provide enough clearance around the skid to allow
maintenance on site and access to all major parts of the pump.
Make sure that the installation allows opening the guard above the pump.
5.3.
Installation diagram
The installation diagram attached and the operation instructions herein apply
under normal operation conditions. It provides general indications about the
major features of the various operation applications. The installation diagram
indicates only essential instrumentation and piping for a liquid gas pump
commissioning. The diagram must be supplemented according to the various
modes of use.
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5.4.
Tank
A pressure tank ensures best results. The pressure variation makes it possible
to reach pump NPSH (refer to the Appendix). It is advisable to install the
machine as close to a tank as possible.
The suction pipe must be short and run from the bottom of the tank. The
use of a plunger tube or a siphon is not authorized, because it would prevent
the evacuation of gases that would be formed.
Such a pipe diameter will be larger or equal to the diameter of the suction
opening to prevent NPSH fall during operation.
5.5.
Pipes
Pipes must be designed to prevent any mechanical stress on the pump, when
stopped or in service. In particular, length variations due to temperature
differences must be taken into account. For this reason, the installation of
hose devices, and as needed, of an expansion joint is desirable in order to
prevent any transmission of vibrations to the pump or excessive stresses on
flanges.
5.5.1. Suction pipe
The coupling of the suction pipe between the tank outlet and the pump suction
opening must be the shortest possible.
THERMOSYPHON T VERSION
The suction pipe between tank outlet and the pump has a constant slope of 5°
upwards. The gas return line between the pump and the bottom of the tank
has a constant slope of 10° upwards. This loop design supports a fast gas
return. It is essential to strictly conform to the angles and slopes
recommended for piping in order to guarantee an effective good circulation of
the liquid.
See diagram below.
STANDARD K VERSION
The suction pipe between the outlet of the tank and the pump has a constant
slope of 10° downwards while the line gas return of the pump towards the top
of tank has a constant slope of 10° upwards so that the gas that would be
formed can return to the tank by one of these pipes.
The gas return line is related to the gas phase of the tank to ensure optimal
equipment operation.
See diagram below.
The diameter of piping shall be selected according to the flow rate so that fluid
speed does not exceed 1 m/s. Lower speeds reduce pressure losses, but has
the disadvantage of increasing heat penetration (decreasing available NPSH)
as well as losses due to vaporization during cooling.
• A lower speed of 0.5 m/s increases heat penetration.
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• A speed over 1.5 m/s results in a significant pressure fall.
For this reason, it is necessary to provide appropriate insulation. However,
this insulation shall allow free movement of hose devices.
The insulation valve and the filter, which must be cooled, shall not be too
bulky because of losses due to vaporization.
All pumps are equipped with a suction filter to prevent foreign bodies from
penetrating in the equipment and remove any risk of fire or explosion.
The filter must have a smoothness of approximately 150 microns and a
minimum surface of twice the suction pipe section.
All taps must be located as close possible of piping in order to minimize
vaporization.
Caution:
When installing a tap, make sure that no impurity
penetrates piping.
All closed loops are to be equipped with safety valves to limit pressure due to
vaporization.
Note
We recommend installing only one liquid feeder by pump. The installation of
several pumps on the same line may result in a preferential flow, turbulences,
inadequate liquid supply or a penetration of excessive heat.
5.5.2. Summary: suction pipe design
Suction pipe installation
•
•
•
•
Pipe as short and straight as possible
Correct insulation, no mechanical stress on pump
Same diameter as that of pump suction (same as for accessories)
Accessories limited as much as possible
Mandatory accessories
•
•
•
•
•
Isolating valve
Safety valve
Hose device
Filter (for oxygen service)
Non-return valve at pump discharge
Recommendations
•
•
•
•
•
Isolating valve on each bypass
Pressure gauge
Piping of gradual diameter variations
Slanting bypass
Installation of a filter regardless of the type of fluid piped
Piston Pump
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• Insulation
Caution:
All piping that may be closed must be provided with safety systems to
prevent any possible overpressure due to liquid pressurization.
Possible installation errors
Significant valve or pipe diameter differences
Tightened elbows, T-shaped bypasses
Pipe not insulated and too long
By-pass valve too distant and bypass pipe not
insulated
High point of pipe
Bent hose device
Missing filter or safety valve
Effects
Load loss
Load loss
Load loss and penetration of heat
Gas formation (cavitation)
Gas pocket stopping flow
Additional mechanical stresses
Risks of pump and joints deterioration
Note: Loss of load, penetration of heat = reduction of available NPSH.
5.5.3. Degasification pipes
The degasification pipe shall have the same section as the degasification
coupling of the pump. The pipe linking the pump and the tank must be
ascending with no siphon. It must be suitably supported so that it will not
produce any stress on the pump.
5.5.4. Nitrogen flushing
Nitrogen flushing of the linkage assembly lubricated by oil bath is not
mandatory, but can be used to limit the water content likely to reduce bearings
lifetime.
In a wet or cold environment, it is strongly recommended to start flushing
fifteen minutes before cooling and stop it fifteen minutes after pump use has
ended, i.e. after the end of liquid nitrogen supply.
In addition, when the equipment is not used for an extended period (over two
days), it is recommended to flush the pump daily for one hour to remove
moisture.
Gas output and pressure are stated in the ‘Set Point List'.
5.5.5. Option: Temperature sensor
Two temperature sensors provided on the linkage assembly casing are used
to measure the oil temperature and that of crosshead.
Value indicated the ‘Set Point List’.
Piston Pump
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5.5.6. Discharge pipe
The discharge pipe must have the same section as that of pump discharge
coupling or larger for lines longer than 3m. An anti-pulsation capacity must
also be included in the pipe and located immediately behind pump discharge
coupling. For pumps with several cylinders, piping shall converge immediately
after the cylinders, then enter the anti-pulsation capacity. To facilitate the
starting of the pump, it is recommended to install in the discharge pipe a drain
cock, a stop valve, a non return valve, a safety valve, a pressure gauge and a
pressure controller. The safety valve will have to be installed between the
pump and any other device which closing or accidental obstruction would stop
circulation in the pipe such as for example, a valve or a nonreturn valve.
Piston Pump
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STANDARD INSTALLATION
CONNECTION PRINCIPLE FOR A-SDPD / A-GDPD / A-LDPD
THERMOSYPHON INSTALLATION
CONNECTION PRINCIPLE FOR A-SDPD / A-GDPD / A-LDPD
5.6.
Valves and connections
All valves, connections, filters, pressure gauges, etc must comply with safety
regulations, including those of official monitoring bodies.
Connections to be carried out by the customer must conform to the floor
space drawing.
CRYOSTAR FRANCE SA declines all liability for damages due to piping
system faulty design.
Piston Pump
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5.7.
Temperature sensors - Options
Limits of supply: Refer to ‘Set Point List’.
During operation when the pump is running, a temperature check must be
carried out in two points, at pump outlet and vaporizer outlet. In both cases, if
the operating temperature is not reached, the pump must be stopped.
5.8.
Summary table of adjustment thresholds
5.8.1. Temperature sensor.
All adjustment thresholds of options installed are specified in the ‘Set Point
List'
6.
LUBRICATION
Caution:
For oxygen service use of grease or mineral oil is strictly prohibited
because of explosion risks.
6.1.
Lubricated bearings
The following lubrication products shall be used:
For oxygen service
For * argon service,
* Nitrogen or other
* gas
Bearings with balls
or needles
Krytox 283 AC
* To prevent any confusion and any risk, CRYOSTAR uses always the same
grease Krytox 283 AC.
CRYOSTAR recommends using KRYTOX 283 AC for all types of liquids.
During the mounting of the linkage assembly and cold head, lubricate all
threads with the same grease.
Page 1
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CHARACTERISTICS
KRYTOX 283 AC
UNIT
AVERAGE
VALUE
ST
270
Basic oil viscosity at 38°C
Evaporation pressure of basic oil
at 38°C
at 260°C
Basic oil volatility (Loss of weight in 6 hours
and a half at 204°C
Penetrability after 60 impacts from10 to
25°C
Mechanical stability after
2 hours of friction
100,000 impacts
Evaporation, Weight loss of 22 hours
at 204°C
at 260°C
Stability with oxygen O2 after 600 hours at
99°C
Shock resistance under liquefied oxygen
Density at 25°C
Oil separation, Weight loss after 30 hours
at 99°C
at 204°C
Resistance to water
Weight loss at 80°C
Characteristics of friction (during 1 hour at
204°C, 1200 rpm)
Average diameter of the cap
Load (Kg)
0
10
20
30
40
Torr
Torr
8x10 -8
2x10 -8
%
mm
1
%
%
bar
1
6
0
g/cm3
Yes
1.97
%
%
3
13
%
-
MIN
MAX
ASTM D445
Knudsen
265
295
290
300
330
320
ASTM
D972Mod.
ASTM D217
ASTM D1831
ASTM D217
FTMS 791B,
350.1
ASTM D942
ASTM D2512
FTMS 791B,
321.2
mm
0
0.3
0.5
0.7
0.9
Waste oil and grease
Waste oil and grease may contain impurities that are health hazards. They
must be handled with precaution, and the contact with the skin shall be
prevented as much as possible. Recovery and disposal must be carried out
according to regulations in force.
6.2.
Lubricated bearings
For oxygen service
For use with other
gases
6.3.
Oil – Properties
Bearings with balls or
needles
Bearings with balls or
needles
Oil Fomblin Lox 120
Oil Shell Tellus
Piston Pump
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Fomblin LOX 120
Type
Method
Cryostar Ref.
ASTM D 97
Flow point
ASTM D 445
Kinematic viscosity
ASTM D 972
Volatility
(% Mass loss/22 hours at 120°C)
BAM test (1)
Ignition temperature
(The corresponding oxygen
pressure is 110 kg/cm2)
ASTM D 891/A
Density
ASTM D 1331
Surface tension
ASTM D 1747
Refraction index
MAN PF 29/24 (2)
Average molecular weight
730001184
- 41°C
120 ST
7
365°C
1.89 g/cm3
21 dynes/cm
1.296 N 20
2400
(1) Bundesanstalt für Materialprüfung
(2) Bundesanstalt für Materialprüfung
Type
Cryostar Ref.
Density at 15°C
Viscosity at 40°C
Viscosity at 100°C
Viscosity index
Flow point
Flash point
Aniline point
Shell Tellus 32
Method
NF T 60 101
NF T 60 100
NF T 60 100
NF T 60 136
NF T 60 105
NF T 60 118
NF M 07 021
783000980
877 kg/m3
32 ST
5.6 ST
98
-30°C
218°C
- 41°C
Piston Pump
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6.4.
Typical characteristics
CHARACTERISTICS
ESSO BEACON 325
UNIT
Appearance
Type of soap
Consistency (Grade NLGD)
Type of basic oil
Viscosity of oil at 40°C
Drop point
Bearings corrosion performance
Test NF T 60-135
Resistance to washing out with water at 40°C
Losses
Performance on bearings at high temperature
Test FTMS 791 b-331-2 at 120°C
Evaporation losses
Test ASTM D 972 (22 H at 121°C), losses
mm2 / s
°C
AVERAGE VALUE
White
Lithium
2
Synthetic ester
11.8
180
0
% mass
1
H
> 1000
% mass
0.5
ASONIC GHY 72
CHARACTERISTICS
UNIT
Basic oil, thickener
°C
Range temperature of use
Colour
Drop point DIN ISO 2176
°C
Worked penetration at 25°C
DIN ISO 2137
0.1 mm
(NLGI)
Consistency class
DIN 51818
300 S -1
Apparent dynamic viscosity at 25°C
mPas
And shearing gradient
mm.min -1
Factor of rotation n. dm
mbar
Flow pressure at –40°C
DIN 51805
Low temperature torque test according
to IP 186
Start torque Nmm/temp.
°C
Bearing torque Nmm/temp.
°C
Resistance to water DIN 51807 (partia1) Assessment
3 H/90°C
Anti-corrosion behaviour
DIN 51 802
(Emcor Test), 1 week, dist. water
Test FAG-FE9 DIN 51821 (part 2)
Rotation speed: 6000 min -1 , Fa = 1500 N
L50 value
at 180°C
H
SKF-ROF Test Rotation speed:
10000 min -1 F = 100 N, Fr = 50 N, L50
Value at 170°C
H
Basic oil viscosity DIN 51561
at 40°C
mm2 / s
at 100°C
mm2 / s
AVERAGE VALUE
Ester oil, synthetic hydrocarbon
-40 to 180°C
beige
> 250
250 - 280
2/3
About 4000
About 600000
< 1400
About 100/-40
About 80/-40
0 - 90
Degree of corrosion
0/1
> 100
1700
70
9.4
Piston Pump
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7.
COMMISSIONING
7.1.
Inspection before commissioning
Check all pipes, couplings, attaching bolts and electrical connections to
prepare equipment for commissioning:
0. Check that all caps are removed before connecting the pump.
1. Check that the pump is well connected.
2. Check that the motor is well connected to the appropriate voltage.
3. Check that hosepipes are dry.
4. Check that the suction pipe has no siphon.
5. Check the upward slant of return gas lines towards tank.
6. If a pressure controller is installed, check the release pressure (adjust if
necessary).
7. If a control cabinet is installed, check or adjust safety parameters.
8. Check high-pressure couplings tightening.
9. Check connections of temperature sensors and collars or heating tapes if
necessary.
CAUTION:
BEFORE STARTING COMMISSIONING, IT IS MANDATORY TO PURGE
ALL SUCTION PIPES, DISCHARGE PIPES AND PUMP WITH DRY GAS
TO PREVENT PENETRATION Of HUMIDITY AND FORMATION OF ICE
WHEN PUMP IS COOLED
Check the operation of high-pressure system and gas scrubber and heater, as
applicable.
7.2.
Rotation direction
The direction of rotation has no effect since the pump may run in both
directions. It can be reversed periodically (every 500 hrs) as this increases
pump lifetime.
Piston Pump
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7.3.
Starting of pump
Note: If system is manual operation, continue reading.
If the system is equipped with an automatic control panel. Please see insert,
between pages 26 & 27.
Protective clothing, gloves, glasses, etc in accordance with site safety
requirements.
Never put the hand in contact with the machine during operation
Note: If the pump is equipped with nitrogen flushing, it is mandatory to carry
out permanent flushing.
Conventional equipment, POSITION K:
Start pump suction, open the suction valve GRADUALLY, and the gas return
valve and DISCHARGE valve as applicable. The fluid runs in the pump by the
suction pipe, by driving out gas in the tank by the gas return line.
After cooling of about 15 minutes, the pump will be started with the valves
open.
Thermosyphon equipment, POSITION T:
To cool the pump, open the suction valve GRADUALLY and the discharge
valve located on the gas return line enters the pump and the tank. The liquid
runs out in the pump by the suction pipe. A circulation occurs through
thermosyphon effect and the heated fluid flows back to the liquid phase of the
tank. After cooling of about 5 minutes*, the pump is started with the valves
open.
•
The cooling time period is provided as an indication. Refer to Chapter. "Electrical
starting".
Note: For high pressure (Pasp. > 7 barg), the opening of the suction valve must be
gradual to prevent sudden liquid pressure on the various joint systems.
Piston Pump
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Important Note: If the system is equipped with an automatic or manual
degasification valve at outlet pump, open this valve for 10 to 20 seconds when
starting the pump.
After starting, note that:
a) The discharge pipe is covered with white frost
b) Slight clicks indicate that valves are operating
c) The pressure gauge of the discharge pipe indicates a pressure increase.
If the pressure rise did not occur, the pump must be stopped and cooling must
be resumed. If after cooling, the suction is still missing or if a pressure fall
occurs, increase the pressure in the tank (NPSH).
(Reminder: Check that the white frost does not reach the driving devices. If that occurs, carry
out a hot nitrogen flushing.)
After successful commissioning, close partially the gas return valve, so as only
the gas from the suction head will escape. This will prevent useless
vaporization from occurring in the gas return line.
Caution:
Pressures may exceed 1500 bars on a piston pump if the DISCHARGE
tap is turned off.
It is mandatory to fit a safety valve in the DISCHARGE pipe
If the pump produces unusual noise or if the pressure is out of the
normal range, stop the pump and identify the reasons of such unusual
conditions.
Piston Pump
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7.4.
Pump stop
Follow below steps to stop the pump:
Type K equipment
1. Press the button "Pump stop"
2. Close the suction valve (tank)
3. Open fully the gas return valve (tank)
4. If the equipment is equipped with a High-pressure discharge valve, close
this valve
5. Open the High Pressure degasification valve
6. After de-icing, close the degasification valve
Type T equipment
1. Press "Pump stop" button
2. Close the suction valve
3. If the equipment is equipped with a High Pressure valve, close this valve.
4. Open fully tank gas return
DANGER
Degassing pump discharge pipe is mandatory!
If no degassing is carried out on the discharge pipe, the liquid remaining
after pump stop is transformed into gas, which may produce a strong
pressure and damage the discharge valve and the bush seals.
Piston Pump
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8.
TROUBLESHOOTING
8.1.
Faults/Corrective actions
Fault
Probable cause
Corrective action
Suction is defective,
pressure falls
Inadequate pump
cooling or suction
pressure
(Insufficient NPSH)
Degasification pipe
closed
Continue cooling or increase the
suction pressure, increase the
pressure of the tank
Impurity in the pump
Flush inside with a dry gas or
remove and clean
Increase speed to reach the
nominal value (if possible) check
the belts
Overhaul the cold head
(Clean the filter, check and
replace valves…)
Operation is too slow
Wear of parts
(Clogged Filter, suction
or discharge valves
blocked …)
Gas in the liquid
Leak in low pressure Used packings, piston
packings
seals, O-ring
Unusual noise or
Overload
excessive
temperature of
linkage assembly
Worn or damaged parts
(Bearings)
Suction pressure is too
low, cavitation
Vibrations
Pump anchoring is not
correct
Overheat casing of
Faulty operation of oil
linkage assembly
pump.
Open the degasification pipe
running towards the tank
Control piping
Change worn parts (packings…)
or cold head
Reduce the discharge pressure
Stop the pump, repair or replace
worn parts
Increase the suction pressure
Fix firmly the pump onto the skid
Check oil flow in the pipe by the
opening of filling cap
Piston Pump
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9.
EQUIPMENT OVERHAUL INSTRUCTIONS
9.1.
General
Although the pump construction is simple, we advise against its general
overhaul carried out at user’s premises because of high precision parts
assembly with very tight tolerances.
Upon your request, we will submit you an estimate for any repair work or
replacement part supply.
CAUTION:
Before servicing, make sure that the pump is switched off and is no
longer cold. If necessary, lock all equipment and conform to all safety
procedures.
CAUTION:
During each servicing operation, make sure that no impurity gets in the
pump or the piping.
CAUTION:
When assembling parts, it is recommended to lubricate joined parts
with the same oxygen compatible grease to prevent seizing.
Piston Pump
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9.1.1. Assembly/Removing: Table of tightening torques and forces
After manual pre-tightening, final tightening is carried out with a torque wrench
to the working value (75% of elastic limit) or to the value indicated on the
drawing.
Torques and forces for stainless steel H type bolts of class A1, A2, A4
Strength class of bolts: 70
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Max torques (Nm)
5.9
14.5
30
50
79
121
174
244
182
234
328
445
Working
5
12
25
42
66
101
145
203
152
195
273
371
Max force (kN)
6.85
12.6
20
29.1
40
55
69
88.6
61.5
70.9
90
109.4
Working
6
11
17
24
33
46
58
74
51
59
75
91
Working
7
16
33
56
88
134
193
271
Max force (kN)
9.13
16.7
26.6
38.8
53.3
73.3
92
118.1
Working
8
14
22
32
44
61
77
98
Strength class of bolts: 80
M6
M8
M10
M12
M14
M16
M18
M20
Max torques (Nm)
8
19.3
39.4
67
106
161
232
325
Piston Pump
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Torques (Nm) for hexagon socket screw with low or milled stainless steel
head, Class A2, A4
Type of
screw
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
DIN 6912
Chc
70
Max
5
12
24
40
66
110
Working
4
10
20
33
55
92
170
142
DIN 7991
Fhc
70
Max.
5
7
21
30
66
Working
4
6
18
25
0
55
DIN 7991
FHc
70
Max
5
8
20
33
50
55
Working
4
7
17
28
42
46
120
100
75
63
235
196
200
167
Torques (Nm) for hexagon socket screw with low or milled stainless steel
head
Type of
screw
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
9.2.
DIN 6912
Chc
8.8
Strength
class
Max
9
20
40
65
110
180
Working
8
17
33
54
92
150
280
233
DIN 7984
Fhc
8.8
Strength
class
Max
8
12
35
50
110
Working
7
10
29
42
0
92
DIN 7991
FHc
10.9
Strength
class
Max
9
15
40
65
100
110
Working
8
13
33
54
83
92
200
167
150
125
390
325
400
333
Vacuum insulation chamber
The cold head is a vacuum insulated system keeping heat ingress to the
minimum.
The vacuum must be maintained at 10-3 torr.
Not applicable to PPC pumps.
Piston Pump
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9.2.1. Belt alignment and tightening (new belts)
It is important that pulley alignment be suitable to prevent excessive wearing
of the belts. Check alignment by placing a rule on the sides of the pulleys.
(After checking alignment)
A new drive mechanism must be tightened to take up the slack resulting from
belt breaking in.
After 50 operating hours, check tightening again.
Correct tightening of new V-belts is reached when the force required to tighten
them corresponds to the higher values P of table below.
Type of belt
SPZ
SPA
SPB
SPC
DEFLECTION FORCE F OF 16 MM FOR 1M CENTRE-TOCENTRE
Small pulley
Newton (N)
KilogramDiameter
force (kgf)
(mm)
56 - 95
13 to 20
1.3 to 2.0
100 - 140
20 to 25
2.0 to 2.5
80 - 132
25 to 35
2.5 to 3.6
140 - 200
35 to 45
3.6 to 4.6
112 - 224
45 to 65
4.6 to 6.6
236 - 315
65 to 85
6.6 to 8.7
224 - 355
85 to 115
8.7 to 11.7
375 - 560
115 to 150
11.7 to 15.3
80% of belt lengthening occurs on the first 15 operating hours.
Measure centre-to-centre. At centre-to-centre middle point and at 90° angle to
the belt, measure the deflection force of each belt by means of a pressure
dynamometer or similar equipment. The arrow F should be equal to 16 mm
per centre-to-centre meter.
2. Belt tightening can be adjusted by varying motor screwing on the rails.
Increase belts tightening if the force P is smaller than the stated minimal
values in the table. Similarly bet tightening should be lowered if P is too high.
685
F
Piston Pump
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9.3.
Maintenance
On each use
Carry out a visual inspection. Check that all pipes, electrical connections,
fastening bolts are ready.
9.3.1. Motor
(See drawing "Motor bearings")
Please refer to the folio “Technical data” to identify the type of motor used.
- Small motor bearings are equipped with life-lubricated bearings.
We recommend replacing them every 4000 hours.
- 180+ size motor bearings must be lubricated as follows:
• Every 4000 operating hours or every year
Motor bearings are to be lubricated when the pum is running
• Every 8000 operating hours or every 2 years
Bearing removal, cleaning and replacement is advised.
Caution: Motors of size 180 and + are supplied with low point drain holes
blocked by removable cap. Plugs must be removed.
Caution: If the storage period of motors exceeds 2 years, motor bearings
should be replaced on small motors (motors without lubricators). For larger
motors, bearings will be re-lubricated.
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9.3.2. Pump/Linking assembly
MAINTENANCE
OPERATIONS
Clean bearings, lubricate if
necessary
Check the suction filter
Clean the filter
Remove the cold head
Replace cuffs
Replace segments as needed
Cold head visual inspection:
remove protection caps and
check parts inside the pump
a) If no moisture is present,
flush the pump with dry
nitrogen during a few hours
b) If moisture is present,
remove the cold head. Dry
and clean all parts for
oxygen service before
reassembly. Cryostar
recommends calling upon
Cryostar qualified
technicians.
Change the guide bush
Belleville washers in the cold
head
Return to Cryostar:
Complete overhaul of cold
head and linkage assembly
Create vacuum in the cylinder
Check the discharge and suction
valves (breaking in)
Replace the pressure valve
Change the rotation direction
Check and tighten belts as
needed
Tighten the coupling
Cold head/Linking assembly
Check the instrumentation
(Safety valves…)
MAINTENANCE SCHEDULE
(OPERATION HOURS)
9 months
to 1 year
storage
X
50
500
X
X
1000
1500
2000
X
2500
3000
4500
Once
a
year
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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GREASE OPTION
9 months
to 1 year
storage
50
Lubricate bearings on the
linkage assembly (with
lubricators)
Refer to the linkage assembly
plate
Bearing with knee joint
FILLSAFE 3 g
Needle bearing FILLSAFE 5 g
Roller bearing FILLSAFE 3 g
Change bearings on the linkage
assembly (with lubricators)
OIL BATH OPTION
Change the guide bushes of
crosshead
Change the bearings on the
linkage assembly (oil bath)
Replace Fomblin oil
Replace Shell Tellus oil
Inspection of oil level
(Position of rod, downwards
shaft key)
Check operation of oil pump
500
1000
1500
2000
2500
3000
X
X
X
X
X
X
4500
Once
a
year
X
4500
Once
a
year
X
9 months
to 1 year
storage
50
500
1000
1500
2000
2500
3000
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Piston Pump
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10.
COLD HEAD REMOVAL
10.1. Cold head/Linking assembly removal
IMPORTANT NOTE:
Cut off power supply before carrying out any servicing on the
machine.
¾ Disconnect suction, degasification and discharge pipes.
Remove tightening collars and protection sheet.
¾ Turn the machine by hand until the coupling screws are as close as possible
to the joint cartridge (opening on casing).
¾ Unscrew both screws, remove them with washers, deflector in two parts and
peel shims.
¾ Unscrew the six nuts of cold head fixing pins and remove them with the
valves.
¾ Remove the cold head of linkage assembly casing.
Screws/Washer
Peel shim
Cross head
Piston
Coupling
Deflector
Piston Pump
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USER’S MANUAL
Date of issue :
10.2.
Suction head removal
¾
¾
¾
¾
Unscrew the six screws and remove them with the valves.
Remove the enire suction head of the cold head.
Using circlips pliers, remove circlips and filter from housing
Remove spiral joint from its housing.
Screw/washer
Spiral joint
Circlips
Suction head
cover
Filter
10.3. Discharge valve removal
Discharge
valve
Joint washer A
Discharge
coupling
Joint washer A
Bottom nut
Piston Pump
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USER’S MANUAL
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10.4. Removal of tightening slide
¾ Unscrew piston coupling.
¾ Unscrew and remove both counter nuts and both nuts.
¾ Remove slide unit of cold head cylinder.
¾ Remove guide bush, soak the assembly in liquid nitrogen.
¾ Remove scraping joint, extract circlips from their housing and soak
assembly in liquid nitrogen.
Slide
Nuts + counternuts
Guide bush
Joint
Circlip
10.5. Removal of piston, HP-LP joints and guide bush
¾
¾
¾
¾
Screw coupling back on the piston without tightening.
Remove gently the complete unit piston and joints of cylinder.
Remove the joints high pressure as well as the springs of segment.
Remove guide bush.
Guide bush
Adjustment
shims + peel
shims
HP joints +
segment
springs
BP joints assembly
Joint
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Piston Pump
USER’S MANUAL
Date of issue :
10.6. Removal of cold head suction valve
Prior to removing the suction valve, perform the following
operations:
¾ Tighten the tool (assembly support No. 740 128345) in a vice.
¾ Place cylinder in a vertical position (flange downwards) on the tool, use
two screws M16 to fix it.
¾ Loosen the valve nut.
¾ Unscrew both screws M16 to turn over the cylinder and make the
suction valve and valve joint slide.
Suction valve
Valve nut
Skirt
Cylinder
Valve joint
10.7. Removal of suction valve (cold head)
Spring
Valve body
Valve nut
Brake pad
Guide nut
Valve
Ring
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Piston Pump
USER’S MANUAL
Date of issue :
10.8.
Removal of suction valve (cold head)
¾ Unfold the strip of the lock plate, unscrew the nut and separate the
valve from the guide nut and spring.
¾ Extract the bush with a drift to replace it.
Spring
Valve body
Nut
Lock plate
Guide nut
Valve
Ring
10.9. Removal of joint cartridge (casing of linkage assembly)
After uncoupling the pump, follow the following steps (see Paragraph 1)
¾ Unscrew and remove counter screw, then the screw located in the
casing.
¾ Remove the cartridge body using two screwdrivers. Place the tip of
each screwdriver in the groove (see groove on diagram) and using the
screwdriver as a lever push up the cartridge.
¾ After removing the body, extract joint A and B
¾ Remove the O-ring C.
Joint A
Joint B
Cartridge body
Screw
Conter screw
Joint C
Groove
Piston Pump
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USER’S MANUAL
Date of issue :
10.10. Removal of bearing unit
Prior to removing the bearing unit, please proceed as follows:
¾ Drain the oil of casing by the drain plug located at the bottom of casing.
¾ Unscrew and remove the six screws and valves of linkage assembly
cap.
¾ Remove the linkage assembly cap.
¾ Unscrew the six screws of both covers on casing sides.
¾ Unfasten clips of oil feeder pipe and place it in an appropriate position
to complete the removal operation.
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
Unscrew the four fastening screws of two bearing housings.
Extract the bearing unit from the linkage assembly casing.
Remove bearing 1 with external bush of bearing B.
Remove rod/ crosshead unit with external bush of bearing C.
Remove the guide split segments.
Remove the key with its pin.
Remove bearing 2 by removing both D2 circlips.
Remove circlips B1, C1 and D1 and spacers B1, C1 and D1.
Remove internal bushes of bearings B, C and D using extractors.
Remove from shaft the remaining valves, spacers and circlips.
Remove bearing 1, B2 circlips and external bush of bearing B.
Remove rod, valves and C2 circlips and the external bush of bearing C.
Extract circlips A and rod/crosshead axis.
Extract the rod from the head of crosshead and remove the valves DU,
spacers and bearing A.
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Piston Pump
USER’S MANUAL
Date of issue :
Head of crosshead
Bearing B
Guide
segments
Spacer A
Circlips B2
Spacer B1
Circlips B1
Bearing1
Spacer 1
Bearing A
Circplis 1
Circlips A
Spacer C1
Rod./crosshead axis
Circlips C1
Washers DU
Rod
Bearing C
Screw/Washer
Washers /
circlips C2
Bearing 2
Spacer D1
Pin/key
Circlips D1
Bearing D
Shaft
Circlips
Piston Pump
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USER’S MANUAL
Date of issue :
10.11. Removal of oil pump
¾ Remove the coupling oil feed pipe.
¾ Unscrew and remove screws/washers 1, then remove the oil pump unit
with peel shims (Make sure to store them in a safe place for future
use).
¾ Unscrew and remove screws/washers 2 and cover, piston and spring.
¾ Unscrew and remove the coupling, washer and valve.
Screws/washers 2
Cover
Screws/washers 1
Washer
Peeel shims
Spring
Valve
Connection
Piston Pump
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USER’S MANUAL
Date of issue :
11.
MOUNTING OF COLD HEAD
11.1. Mounting of suction valve
¾ Install the bush DU.
¾ Mount the valve then the spring, the guide nut, the support plate and
the nut.
¾ Screw and tighten the nut. (See checklist No. 706128150)
¾ Fold back the lock plate on the nut and on guide nut.
Spring
Valve body
Nut
Lock plate
Guide nut
Valve
Soupape
Ring
Piston Pump
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USER’S MANUAL
Date of issue :
11.2. Mounting of suction valve on cylinder
¾ Tighten the tool (mounting support No.740128345) in a vice.
¾ Put the cylinder on the tool in a vertical position (flange downwards)
using two screws M16 to fix it.
¾ Mount the valve with its joint.
¾ Screw the valve nut using a wrench with the required torque (see
tightening torque on the cold head section drawing).
¾ Unscrew the two screws M16 to turn over the cylinder.
Suction valve
Valve nut
Lining
Cylinder
Valve seal
11.3. Assembly of springs and segments HP on piston
¾ Mount the five springs of segment then the five joints HP, making sure
that slots are staggered.
¾ Mount guide bush on the piston.
¾ Position the cylinder vertically (supporting face on suction side).
¾ Use the tool (assembly socket no. 740 128343) to mount the unit
piston/joints HP/ guide bush in the cylinder.
¾ Remove the mounting socket by turning over the cylinder.
Piston Pump
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USER’S MANUAL
Date of issue :
Mounting socket
5 segments HP
Piston
Guide
bush
5 segment
springs
11.4. Mounting of LP joints assembly
¾ See the checklist No. 706128150.
11.5. Mounting of tightening slide
¾ Soak guide bush and scraping joint in liquid nitrogen and mount them in
the slide
¾ Fit the circlips.
¾ Mount the slide unit on the cylinder (see mounting procedure No.
706128150).
Slide
Scrap joint
Circlips
Guide bush
Piston Pump
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USER’S MANUAL
Date of issue :
11.6. Mounting of suction head
¾ Mount the filter, then circlips using circlip pliers.
¾ Mount the spiral joint, then the suction head assembly on the cylinder.
¾ Assemble the six screws/washers and tighten them to the
recommended torque (see drawing of suction head)
Spiral joint
Screws/washers
Circlips
Filter
Cover
11.7. Mounting of DISCHARGE valve
¾ Mount valve B joint, the pressure valve, then screw the discharge
coupling.
¾ Mount valve A joint, then screw the bottom nut on the cylinder.
Discharge
valve
Joint A washer
Discharge
coupling
Joint A washer
Bottom nut
Piston Pump
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USER’S MANUAL
Date of issue :
11.8. Mounting of oil pump
¾ Mount the valve and washer then screw coupling fully.
¾ Mount the spring, piston, cover and the two screws/washers
assemblies.
¾ For mounting the pump oil assembly, refer to the checklist No. 706
128150-01 for calculating the thickness of the peel shims.
Screw/washers 2
Cover
Screw/washers 1
Washer
Peel shims
Spring
Valve
Coupling
11.9. Mounting of bearing assembly
¾ Mount spacers A with bearing A in the rod.
¾ Place the rod/spacers A/bearing A with valves OF on the crosshead
using the mounting tool "support" No.753 028770.
¾ Mount circlips A.
¾ Mount bearing C, washers/circlips C2 in the rod.
¾ Mount the external bush of bearing B and B2 circlips in bearing 1.
¾ Mount bearing D on the shaft, then mount bearing 2 and D2 circlips.
¾ Mount D1 spacer and D1 circlips on the shaft.
¾ Mount spacer C, circlips C on the shaft.
¾ Mount the complete rod unit on the shaft, then C1 spacer and C1
circlips.
¾ Mount circlips B, spacer B as well as the inside bush of bearing B, then
B1 spacer and B1 circlips.
¾ Mount bearing 1 on the inside bush of bearing B.
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Piston Pump
USER’S MANUAL
Date of issue :
Crosshead cap
Bearing B
Guide
segments
Spacer A
Circlips B2
Spacer B1
Circlips B1
Bearing
Spacer 1
Bearing A
Circplis 1
Circlips A
Spacer C1
Rod/crosshead shaft
Circlips C1
Washers DU
Rod
Bearing C
Screw/washer
Washers /
circlips C2
Bearing 2
Spacer D1
Pin/key
Circlips D1
Bearing D
Shaft
Circlips
Piston Pump
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USER’S MANUAL
Date of issue :
11.10. Mounting of bearing assembly in the casing
Caution:
Check that the oil pump is well in place (peel shim adjusted, checklist
No. 706 128150-01) before mounting the bearing assembly.
¾
¾
¾
¾
¾
¾
¾
¾
¾
¾
Mount the oil feeder pipe on the coupling of oil pump.
Mount both segments of guide on the crosshead.
Oil slightly the two guide bushes to facilitate the mounting.
Mount the complete assembly in the linkage assembly casing.
Mount the screws/washers on each bearing, and tighten to the
recommended torque
Clip the oil feeder pipe.
Put Goretex on the linkage cover, on the linkage casing and on both
covers on each side of linkage casing. Make sure to seal the assembly.
Install the linkage cover, and fix it with six screws/washers.
Put the two covers on each side of casing and fix them with the six
screws/washers.
Fill the linkage casing with oil (1.71 liters) by the filling plug located
above the cover.
Caution:
For an oxygen pump, it is mandatory to fill up with FOMBLIN oil.
11.11. Mounting of joint cartridge
¾
¾
¾
¾
¾
Mount joints A and B (soften it in hot water prior to mounting).
Put the O-ring C.
Put the joint cartridge assembly in the casing.
Place the screw in the casing and tighten it in abutment.
Screw the counter screw until it comes against the screw.
Caution:
When mounting the joint cartridge,
make sure that the oil drain hole is directed downwards
See checklist No. 706 128150-01
Piston Pump
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USER’S MANUAL
Date of issue :
Joint A
Joint B
Cartridge body
Screw
Conter screw
Joint C
Groove
11.12. Coupling of cold head with linkage
Caution:
Cold heads supplied as replacement parts are degreased for
oxygen service. During mounting, make sure no impurity gets
into the pump, piping and couplings.
Before mounting the cold head on the linkage assembly, follow these steps:
¾ Bring the crosshead cap of linkage assembly to the high dead centre.
¾ Measure distance X between the chuck face of casing and the end of
crosshead.
¾ Mount the coupling on the piston.
¾ Put the piston in abutment against the suction valve.
¾ Measure the distance Y between the chuck face of cylinder and the
chuck face of coupling.
¾ The clearance J between the head of piston and the suction valve must
be within 0.8 and 1.3mm (see checklist No.706128150).
¾ Determine thickness Z of peel shim: Z=x-y-1.1
Piston Pump
Page 1
USER’S MANUAL
Date of issue :
Croshead
Y
X
Coupling
¾ Mount the cold head on the linkage assembly and fix it with the six
nuts and washers to the recommended torque.
¾ Bring the crosshead to the low dead centre (the closest to the joint
cartridge).
¾ Bring the coupling close to the crosshead, put the screws/washers
in place and the peel shim of suitable thickness (see previous
paragraph) and screw slightly.
¾ Place the two half-deflectors and tighten both screws.
Important Note
Confirm the correct adjustment of piston slack by checking the
free rotation of linkage assembly by hand.
Peel shim
Deflector
Screws and washers
Piston
Crosshead
Coupling
Piston Pump
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USER’S MANUAL
Date of issue :
12.
LIST OF DRAWINGS AND REPLACEMENT PARTS
DRAWING TITLE
DRAWING NO.
Test curve
Slinging diagram
Pump assembly (skid)
Dimensional drawing
Pump dimensional drawing
Cold head, section
Suction valve
Suction head
Crank drive assy
w/o coupling
Performance curve
Crank drive checklist
Cold end checklist
Acceptance protocol
708111523
760154357-01
760154338
702129925
760129850
760127364
760129921
760131071
700130745-01
706128150-01
706128150
REPLACEMENT PART
LIST NUMBER
760154357-01
760129850
760127364
760129921
760131071
Piston Pump
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USER’S MANUAL
Date of issue :
13.
REPAIR SERVICE - REPLACEMENT PARTS
13.1. Information to be submitted by the customer
These instructions include a list of spare parts. The reference mark numbers
on overall drawing are identical to the reference marks of replacement parts
list. The latter includes also each part description and stock No. It is highly
recommended to keep in stock the parts indicated in the heading ' A', to speed
up delivery.
For ordering all replacement parts, please submit the following information:
1.
2.
3.
4.
Number of Cryostar commission
Machine number
Part description
Stock number or part drawing number
If a more important repair or a complete overhaul is required, we recommend
you return the pump to the factory. You may also choose to call upon a
service technician.
13.2. Appendix with replacement parts list
P U
A B
Ref. No.
™
™
™
™
XXXXXXX
X
IMPORTANT:
Date
Comments
Position on the overall drawing. Pos. 800 and more: Replacement parts supplied
with machine
Quantity of parts per assembly
Wear parts to keep in stock for replacement on each removal.
Replacement parts for start-up
Parts recommended for 2 years of service
Stock No.
Prices may be changed without notice and are net in
Euros, ex-works, including packing, customs duties
and other taxes not included.
Administrative charges for any order under €76.00 are
€46.00
30/11/2001
Only original CRYOSTAR parts must be used as replacement part.
CRYOSTAR declines all liability if this rule is not complied with.
MADE IN FRANCE
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Piston Pump
USER’S MANUAL
Date of issue :
14.
APPENDIX
14.1. NPSH
NPSH = "Net positive Suction Head" = difference between the static
pressure (Ps) and the instantaneous pressure (Pt) of liquid free of any
gas in the suction coupling of pump.
A specific NPSH is required to make a cryogenic pump start and discharge.
The NPSH in the pump suction coupling makes it possible to prevent the local vaporization of
the liquid and can be also expressed by a relative under-refrigeration ( ΔT). The instantaneous
pressure of the vapour (Pt) is only a function of the temperature (TS) of the liquid in the suction
coupling of the pump.
Vapourization line
Liquid state (f)
Liquid state (f)
Gaseous state (g)
Measurement device
Saturation curve
Gaseous state (g)
State diagram
Measuring arrangement: measurement device
Vapour presses diagram: saturation curve
Press enthalpy chart: state diagram
Vapour state: gaseous state
Liquid: liquid state
Saturated liquid: line of vaporization
State of the liquid in suction nozzle: state of liquid at suction
The required NPSH (= NPSHr) must be available on starting and operation of the pump.
The NPSH available (= NPSHa) on suction coupling of pump can be reached or improved in
the following way:
- Increase of height of supply
- Relative under-refrigeration of liquid
- Increase of tank pressure, the latter will be higher than the instantaneous
pressure of the vapour
- Effective insulation of piping
- Reduction load losses in the piping
The required NPSH must be guaranteed on starting and during operation.
Piston Pump
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USER’S MANUAL
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The NPSH required for suction can be reached and improved thanks to:
- A larger dislevelment on suction
- A super cooling of fluid
- A rise of tank pressure
- A better insulation of piping
- A reduction of load losses in the piping
Piston Pump
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USER’S MANUAL
Date of issue :
14.2. Instrumentation
CRYOSTAR Ref.
DESCRIPTION
Motor
Valve HP
Valve BP²
SUPPLIER DOCUMENTATION
Note
Safety valves must be calibrated once a year
WEG MOTORS AND DRIVES
FLOW SAFE, Set pressure 410 barg
REGO, Set pressure 17 barg