SVEDALA Ltd

SVEDALA
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SVEDALA Ltd .
Pumps & Process
OPERATION, INSTALLATION &
MAINTENANCE INSTRUCTIONS
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PD-14103204
SVEDALA Ltd.
Pumps& Process
SVEDALA Ltd., Pumps & Process
INST
ALLATlON.OPERATING
&.MAINTENANCE
INSTRUCTIONS
ORIONHEAVYDUlY ABRASION
RESISTANT
PUMPS,
PD-14103204.
1
-\.,..I
,
Page 1 of 40
Issued
8 FcbnJarY
1996
CONTENTS
1
1.1
12
CONTENTS
List of Illustrations
List of Tables
1
2
2
2
SERVICING AND REPAIR INFORMATION
4
3
3.1
32
SAFETY PRECAUTIONS
WarningsandCautions
Training
5
5
5
4
FOREWORD
6
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
DESCRIPTIONAND SPECIFICATION
Introduction
Base
CasingandBack Liner
BearingFrame
RotatingandBearingAssemblies
ShaftSealingArrangements
PumpDrive Arrangements
5.7.1 Belt Drives
5.72
Direct Drives
.7
6
6.1
62
6.3
6.4
6.5
6.6
6.7
INSTALLATION AND COMMISSIONING
Mannerof Shipment
InspectionUpon Receipt
Tools and SpecialEquipment
Storage
FoundationDetails
Lifting Instructions
Installation
6.7.1 Pump
6.7.2 Belt Driven Pumps
6.7.3 Direct Driven Pumps
PumpDischargePositions
ConnectingPipework
Long Term Field Storageof CentrifugalPumps
6.10.1 General
6.102 MediumTerm Storage
6.10.3 ProlongedStorage- Up to 2 Years
6.10.4 Storagein Excessof Two Years
to
to
to
10
to
to
10
1.1
1..1
11
"/
6.8
6.9
6.10
v
Ref.No.PD-14103204/M
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7
7
7
8
8
8
8
9
1..1
1.3
f3
14
14
1.4
14
15
7
7.1
7.2
7.3
7.4
OPERATING INSTRUCTIONS
Pre-StartChecks
Starting
RunningChecks
Stopping
16
16
16
16
17
8
8.1
MAINTENANCE, ADJUSTMENT AND INSPECTION
Introduction
8.1.1
Routine Maintenance
8.1.2
Maintenance Recommendations
18
18
18
18
SVEDALA Ltd., Pumps & Process
INSTAl.LATlON,OPERA
TlNG4. MAINTENANCE
INSTRUCT1<»iS
Page2 of 40
ORIONHEAVYDUTYABRASION
RESISTANT
PUMPS.
PD-14
103204.
Issued
8 Febni8Y1996
8.2.1 ImpellerAxial ClearanceAdjustments
8.2.2 Back(ShaftSide)Clearance
8.2.3 Front (SuctionSide)Clearance
82.4
Inspectionof WearingParts
8.2.5 Disassemblyfor Inspection,Front Pull-OutMethod
82.6
Disassemblyfor Inspection,Back Pull-OutMethod
8.2.7 Inspection
8.2.8 Assembly
MaintenanceProcedures- GlandSealing
8.3.1 RunningChecks
8.3.2 Stopping
8.3.3 RoutineAdjustments
8.3.4 ReplacingPacking
8.3.5 Maintenanceof the CentrifugalSeal(Removal)
8.3.6 Maintenanceof the CentrifugalSeal(Disassembly)
8.3.7 Maintenanceof the CentrifugalSeal(Inspection)
8.3.8 Maintenanceof the CentrifugalSeal(Assembly)
8.3.9 Maintenanceof the CentrifugalSeal(Replacement)
MaintenanceProcedures ShaftandBearingCartridge
8.4.1 Removal
8.4.2 Disassembly
8.4.3 Inspection
8.4.4 Assembly
8.4.5 Replacement
18
19
19
19
20
20
20
21
21
21
22
23
24
24
24
2S
25
25
2S
26
26
26
26
27
27
29
SPAREPARTS
Introduction
Replacement
SparesOrders
9.2.1 OrderingSpares
Recommended
MechanicalSparePartsList
30
30
30
30
30
APPENDICES
Maintenance Schedule
Pump Construction
32
33
3S
36
37
38
8.1.3
8.2
8.3
8.4
9
9.1
9.2
9.3
10
10.1
10.2
10.3
10.4
10.5
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1.1
Ref.No.PD-141032O4/M
Lubrication
-
Maintenance Procedures Pump End
-
Torque Settings
Table of Approximate Component Weights
Parts Identification Listing
ListornlustratioDs
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Figure I FlangeForces
Figure 2 - Typical Cenbifugal Seal (Polyurethane lined Expeller Ring)
Figure 3 - Arrangement of Packing Rings
Figure 4 Cartridge Support & Bearing Clearance Detail
13
23
25
28
Table I - MinimumDistances
Between
ShaftEnds(DBSE)
Table 2 - Recommended
LubricationIntervalfor Bearings
(hours)@ 70°C
l2
19
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SVEDALA Ltd., Pumps &. Process
INSTALLAllON.
OPERA11NG
&.MAINTENANCE
INSTRUcnONS
ORION HEAVY DUTY ABRASION RESISTANT PUMPS, PD-14103204.
-
Table 3 Bearing Clearances
Table 4
Table 5
-Recommended
- Torque Values
-
Mechanical
SparesList
Table 6 Major Item Weights(Approximate)
I
Ref:No.PD-141032O4/M
Page3 of40
Issued8 February 1996
29
31
36
37
SVEDALA Ltd., Pumps & Process
Ref.No.PD-141032O4/M
INSTALLATlON,OPERA
TlNG&.MAINTENANCE
INSTRUcnONS
ORIONHEAVYDUTYABRASION
RESISTANT
PUMPS,
PD-14103204.
.-.)
2
Page4 of 40
Issued
8 February
1996
SERVICING- AND -REPAIR INFORMATION
~
For any inquiry regarding the servicing and repair of ORION pumps please contact:
SVEDALA Ltd.
Pumps& Process
SiteServicesDepartment
Unit 7, ParkerCentre
MansfieldRoad
DERBY DE24 4AW
UK
Tel No: 01332380089
FaxNo: 01332291054
Pleaseprovide the following information:
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(1)
(2)
(3)
(4)
(5)
Model and size of pump.
Serial Number.
Build Number.
Approximate Date of Purchase.
Details of inquiry, apparent fault(s) etc.
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HEALm ANDSAFETY~~~TEMENT_-
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Do TAKE nME TO ENSURE THAT YOUR SAFETY AND OTHERS IS NOT PUT AT RISK. FAILURE TO OBSERVE
CERTAIN ELEMENTARY SAFETY PRECAUTIONS MAY RESULT IN PERSONAL INJURY OR DAMAGE TO TInS PUMP
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EQUIPMENT. THE SAFETY INFORMATION ON PAGE 5 IS INTENDED TO ENCOURAGE A SAFETY CONSCIOUS
APPROACH TO OPER.4.TING.4.NDCARRYING OUT MAINTENANCE.
SVEDALA Ltd., Pumps &. Process
Ref.No.PD-141032O4/M
INSTALLATION,
OPERATING
&.MAINTENANCE
INSTRlJCT1(»fS
ORION HEAVYDUTY ABRASIONRESISTANTPUMPS.PD-14103204.
PageoSof 40
Issued8 February1996
'-'"
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3
SAFETYPRECAUTIONS
3.1
Warnings and Cautions
J
.
For the purposeof defmition in this manual,a WARNING givesinformationwhich if ignoredcould leadto
serious injury of personnel.A CAUTION givesinfomationwhich if ignoredcould leadto seriousdamageto
the pwnp or associated
equipment.
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,.
,
rovide a WARNING noticeareboxedandhi Ii
rovide a CAUTIONARY noticeareboxed
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3.2
Training
It is strongly recommendedthat all customers' production and maintenancepersonnel and site visitors are made
fully aware of potential dangers of this equipment If any doubt exists, please contact SVEDALA Ltd. for
advice.
FOR YOUR OWN PERSONAL SAFETY READ AND TAKE NOTE OF THE FOLLOWING:
These are in the areas of the impeller and drive motor shaft, direct
drive coupling or drive belts. Under normal operating conditions
these areas MUST be enclosed by safety covers or guards. Pump
intake and discharge ports, when open, are also hazardous areas.
NEVER insert your hand into either of these ports without first
ensuring that the pump drive has been isolated.
HAZARDOUS AREAS
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LIn"ING THE PU~IP
.
OPERATING THE PUMP
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6
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Make sure that ALL slings, shackles, etc. are of adequate load
carrying capacity for the pump being lifted.
ORION Pimps may be provided with lifting eyes designed for lifting
individual components. However, these should NOT be used when
lifting the pump unit or a pump set. Individual pumps should
AL WAYS be lifted by using slings passed through the bearing
frame. When lifting bedplate mounted pump units, the lift should
AL WAYS be taken directly through the bedplate.
Ensure that ALL
securely fitted.
safety covers and guards are in position and
DO NOT wear loose clothing when working in close prox.imity to
rotating parts.
NEVER allow water or slurry to rise above the top of the pump base.
MAINTAINING THE PUMP
-
SWITCH OFF and ISOLATE d1e elecbical supply to the pump
motor and allow rotating parts to come to rest before carrying out any
maintenanceor adjustment.
SVEDALA Ltd., Pumps & Process
INSTALLATION.
OPERATING
&.MAINTENANCE
INSTRucnoNS
ORIONHEAVYDt.JrYABRASION
RESISTANT
PUMPS,
PD-1410J204.
Ref.No.PD-1410J2O4/M
Page6 of 40
Issued
a Febn8Y1996
'-'
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4
FORE,WORD
This manualcontainsgeneralinformationon the installation,commissioning.operationand maintenanceof
ORION Heavy Duty Abmion Resistant Pumps, which form part of tile current range ofSVEDALA equipment.
Generally,ORION horizontalhard metal pwnps haved1esamebasic features. However,as eachpwnp is
supplied to suit a particularduty requirement,build options will differ, particularly in the choiceof bearing
set-up,glandarrangements
and impellers.
This manual is divided into the following sections:
1
2
3
4
S
6
7
8
9
10
CONTENTS
SERVICINGAND REPAIR INFORMATION
SAFETY PRECAUTIONS
FOREWORD
DESCRIPTIONAND SPECIFICATION
INSTALLATION AND COMMISSIONING
OPERATING INSTRUCTIONS
MAINTENANCE, ADJUSTMENT AND INSPECTION
SPAREPARTS
APPENDICES
Infonnation containedin this manualis correct at the date of publication. As improvementsare continually
beingmade,SVEDALA Ltd. reservethe right to makealterationswithout giving prior notice.
The contents of this manual are copyright C and must not be reproducedwithout prior pennissionof
SVEDALA Ltd.
'ORION' is a trademarkofSVEDALA Ltd.
I
SVEDALA Ltd., Pumps & Process
INSTALLA1l0N,
OPERAl1NG
&.MAINTENANCE
INSTRUcnONS
n
ORIONHEAVYDUTYABRASION
RESISTANT
PUMPS.
PD-1
4103204.
~f. No.PD-141032O4/M
Page7 of 40
Issued
8 February
1996
J
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5
DESCRIPTION AND SPECIFICATION
5.1
Introduction
D
The ORION rangeof heavy duty, hard metal pumps have been designed for a wide variety of abrasive pumping
duties. While they may be used in many different industries, dtey are all designed for constant use in dte hardest
of conditions. ORION pumps can be supplied for use widt abrasive slurries (slurry pumps), for pumping larger
solids (gravel pumps), or other specialized applications. These high-efficiency pumps are of a simple design,
providing easeof maintenanceand replacement of wearing parts.
J
The pwnps are of the single-stage,centrifugal type with the shaft-mounted impeller supported in a greasesealed
bearing cartridge and operating within a purpose-designed pump casing. Various gland sealing arrangements
are available to suit a wide range of applications.
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The rotating element can be withdrawn from the back of the casing without disturbing the casing and pipework.
This "back pu\1-out" method simplifies inspection and site maintenance. Alternatively, the pumping parts can
be removed from the front after removing the pipework.
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The backand front impellerrunningclearancescan be adjusted,to ensuremaximumefficiency is maintained,
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The bearingsand labyrinth sealassembliesare greasepackedon assembly.Greasenipples are providedfor
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during maintenanceand shut-down periods.
periodic lubrication.
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5.2
Base
The baseis a welded steel fabrication providing the necessarysupport for the pump casing, bearing and rotating
assemblies.
Slots in the base vertical plate provide locations for casing bolts. The top and bottom dead centre holes in the
vertical plate are for the casing clamp bolts.
.
.
5.3
Casing and Back Liner
~
The casing and back liner are high quality, high-chrome iron castings. Larger size pump casings are ribbed and
incorporate a number of lifting lugs. The intake and discharge branches are titted with a joint seal and split
flanges to provide a leak-proof and secure pipework connection. The casing is clamped directly to the vertical
baseplate by special bolts and nuts at top and bottom dead-centre locations. This method of attachment allows
the casing to be positioned with the discharge in a number of positions. Shims between the casing and bearing
frame are used to adjust the front running clearance between the impeller and the casing.
J
The back liner, which forms the rear face of the casing, is attached to the bearing frame by tee bolts and
hexagon-headed nuts. For ease of assembly, the bolts are retained in the slots by means of a rubber strap.
O-rings are used to seal the back liner and casing.
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5.4
Bearing Frame
-
The bearing frameprovidesa rigid supportfor me completerotatingand bearingassemblies.Bossescastin
me frameareusedto mountme drive motor overhead,if required.
-
The innerflangeof the ftameprovidesa spigotfor the expellerring or stuffing box. For easeof assembly,the
casing bolts locate in slots aroundthe frame's front flange. Threadedholes are provided in the flange for
withdrawalscrews.
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SVEDALA Ltd., Pumps &; Process
INSTALLA-nON,OPERATING
&:.MAINTENANCEINSTR~
ORIONHEAVYDUTYABRASION
RESISTANT
PUMPS,
PD-14103204.
Ref.No.PD-141032O4/M
Page8 of 40
Issued
8 February
1996
Openings in each side of the body give accessto the gland and water flushing connection if fitted. Lubrication
points are extended through the gland guards. Other openings in the top or side of the frame body give access
to the bearing cartridge tension screws, saddle screws and impeller adjustment screw.
5.5
Rotating and Bearing Assemblies
The rotating assembly consists of a steel shaft with the impeller screwed onto one end. The other end of the
shaft is keyed to accept a coupling or belt drive alTangemenl
Heavy-duty, tapered roller bearings are used in various configurations as follows:
DoUBLE WET END
- Two bearingarrangement.
- Threebearingarrangement,two locatedat the glandendof theassembly.
DoUBLE DRY END
-
STANDARD
J
Three bearing arrangement,two located at the drive end of the assembly.
A labyrinth, fitted with piston rings, seals the bearings against dirt and other foreign matter. Grease nipples are
fitted to allow periodic bearing lubrication. Grease is purged mrough the bearing to remove any contamination.
The complete rotating and bearing assembly is secured in the bearing frame by a housing clamp, saddle block,
and adjusting screw. On larger size pumps, two housing clamps and two saddle blocks with adjusting screws
are used to adjust the shaft assembly axially.
5.6
Shaft SealingArrangements
There are a number of shaft seal options to suit a particular duty. Theseare:
Water Flush Glands
Standard Centrifugal Seal Glands
Two-Ring Centrifugal Seal Glands
Mechanical Seals
5.7
S.7.1
PumpDrive Arrangements
Belt Drives
Therearethreebelt drive arrangementsusedon ORION pumps:
Overhead Mounted
The motor and motor plate are mounted above dte pwnp directly
off the bearing frame. A baseplate is not required.
Motor
Reverse Overhead
Mounted Motor
Side Mounted Motor
(right or left hand)
.
The pump and motor are mounted in line on a fabricated bedplate.
The pump and motor are mounted on a fabricated bedplate at the
samelevel. The motor is sccW'edon slide rails.
All belt arrangementshave provision for adjusting die belt tension and are fully guarded.
SVEDALA Ltd.. Pumps"
Process
INSTAllATION,OPERATING
&.MAINTENANCE
INSTRUrnONS
ORIONHEAVYDlJIY ABRASION
RESISTANT
PUMPS,
PO-I4103204.
5.7.2
Ref.No.PO-I41032O4/M
Page9 of40
Issued
8 February
1996
Direct Drives
The motor drives the pump through a flexible coupling. The coupling can accommodatereasonable
misalignmentbetweenthe pumpandthe drive motor, andcanalsocushionreasonableshockloads.
The coupling partsdo not moverelativeto eachother,therefore,only a periodic visual inspectionis required.
!WARNING
J
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SVEDALA Ltd., Pumps &; Proeess
t
INST
ALLA110N.OPERATING
.t. MAINTENANCE
INSTRUcnONS
ORION HEAVYDUTY ABRASIONRESISTANTPUMPS,PD-14103204.
-"
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6
I
6.1
]
Ref.No.PD-141032O4/M
Page 10 of 40
IssuedI February1996
INSTALLA nON AND COMMISSIONING
Manner of Shipment
A pump is eitherdispatchedas an individual unit (bareshaftpump)or mountedcompletewith drive unit on a
bedplate(pump-set).In eithercase,anyexposedmachinedpartsarecoatedwith a suitablerust inhibitor.
Each pump is suppliedcompletewith intakeand dischargejoints and seals,drive key, and with the bearing
cartridge charged with grease.
,]
The packing or boxing will always be more than adequatefor the method of shipment and subsequentstorage.
:]
6.2
Inspection Upon Receipt
On receiptof me pwnp, check that the items listed on the consigmnent list have been supplied and have not been
damaged in b"ansit. Ensure that the intake and discharge apertures are clear and that the impeller runs freely
when the shaft is turned by hand.
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If the pump has been disassembled for shipment, a consignment list will contain complete information on the
identification of parts. Where parts are boxed, each box is numbered and the corresponding number is noted
on the consignment list.
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If damage has occurred or any items are missing, a report should be filed with the carrier making the delivery.
A written report should be submitted to SVEDALA Ltd. detailing the damage and/or missing items. This
should be done as soon as possible.
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6.3
J
Tools and SpecialEquipment
A standard fitter's tool kit, together with suitably-sized hexagon key wrenches and a torque wrench, should be
sufficient to install and maintain the pump. A dial test indicator is also required to set bearing clearance.
Special tools are sometimes advisable for larger sizes of pump for assembly or maintenance.
.
6.4
Storage
When storing pumps, care should be taken to protect the pump for grit. dirt and any damage as this may affect
the life of the unit Generally, pmnps should be stored under cover in a dry, secure environment If stored
outside, the equipment must be protected by some form of protective wead1erproof covering. A rust inhibitor
should be applied to all moving parts. During extended storage periods, moving parts should be rotated
occasionally to prevent any permanent set in the bearings. Refer to section 6.10 for long-term storage
instructions.
.
6.5
Foundation Details
Ideally, the pwnp and its drive shouldbe mountedon a commonbedplatewhich is fixed to a level foundation
of adequatestrength. All bedplatessuppliedby SVEDALA Ltd. incorporateholding down bolt holes. It is
recommendedthat the pwnp is installedso that maintenance
and adjustmentscan be easily carriedout. It is
essentialthatthe pumpis not subjectedto flooding.
6.6
Lifting Instructions
ORION pumpsmay be providedwith eyebolt holesor lugsfor lifting individual components.However, these
shouldnot be usedto lift the pwnp or the pwnp-setasa whole.