Special fe of other secti INSTALLATION, OPERATION ANOIMRINTENANCEMANUR (HPA/HPE (oy SCRE} UTC raCONTENTS I Safety see enn een cee ene es ssenensce cesses sae aee ces ses ans eavensceeecraceseeceel 1) Il. General information ++ +++ +++ +++ ser eee eee ere cee eee one eee eee eee eeeene eee 2) TIL Installation +++ +++ +++ s0+eseese eee eeeeee cee ens can can wee sor ens crvearesessesne( 4) V. Operation and maintenances+: +++ +++ +++ e+ eerste ene ene eee eeeaeeaeeeeenee( 13) VI. Shutting down: VIL. Disassemblys++ +++ +++ sesess eee teseesans ene ene estes eecaseneeasenseneeseneee(16) VIL. Assemblyss+s++vssessesessesarco senses senses aneaneaneaneeny env essaseasanee(1B) TK. Spare parts --+s++ssssssseesescsscsnssvssesnnssestsnse nen ces ssseevssnssnsee( 19) X. Troubleshooting - 2009.07Assuring that all the stafT involved in installation, operation, inspection and maintenance fs familiar with the accident prevention regulation. Instruction and training should be provided for those who are lacking the related knowledge. 1. This manual is not fully considering all the details of the design, the performance parameters of the pump, installation dimcasions and sealing piping system, ax-well as the possible changes in the installation, operation and maintenance process. If you want to know them specifically, please refer to our company's product sample or consult our technical center. 2.Only comply with the provisions in mechanical engincering and electrical engineering field, and operate strictly according to the installation, operation and maintenance procedure, can the ‘Pamap and ifs unit run smoothly and safely: If you don't keep this manual operation, out company will be not responsible for the pump and its unit. 3.1 the pump and the unit are transferred to other places, the operation condition must satisfy the conditions stipalated in the contract; if the actual operating conditions have one or many changes, you should consult our company, and can use the pump after written confirmation. Our company is not responsible forthe consequences eaused by changing working conditions without notice. 4, Machinery replacement and changes need to obtain the company’s approval, ry 29 use the sccessories made by our company, we doo’ assume the responsibility of the consequences caused bby using other company’s accessories. §. This manual contains some important instructions that must be implemented. in the commissioning operation, operation and maintenance periods. Therefore, study it prior to the installation and the commissioning operation, and put itchrocically clase to the pump or the unit, 1s well as ensure that all the suff can understand the manual contents 6.1 this manual cannot meet the requirements, please contact with us. 7. The copyright of this manual belongs to our company, technical content and drawings contained in the manual, whether the whole ora part, are not allowed to duplicate, extend oF use uunautorizedly with competition purpose,i2 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL + Ensure there are no missing fasteners * Beware of corroded or loose fasteners ‘Operation: + Do not operate below minimum rated flow, or with suction/discharge valves closed * Do not open vent or drain valves, or remove plugs while system is pressurized Maintenance Safety: + Always lock out power + Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plugs, or disconnecting piping + Use proper lifting and supporting equipment to prevent scrious injury + Observe proper decontamination procedures: + Know and follow company safety regulations ‘Observe all cautions and warnings highlighted in pump Installation, Operation and. Maintenance Instructions. ‘This pump has been designed for safe and reliable operation when properly used and maintained in accordance with instructions contained in this manual. ‘A pump is a pressure containing device with rotating parts that can be hazardous. Operators and maintenance personnel must realize this and follow safety measures. Our company shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions in this manual. Throughout this manual the words WARNING, CAUTION, and NOTE are used to indicate procedures or situations which require special operator attention: * WARNING ‘Waring is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warming is ignored. + CAUTION ‘Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warming is ignored. + NOTE ‘Operating procedure, condition, etc. which is essential to observe. Il.General introduction PUMP DESCRIPTION HPA/HPB series petrochemical process pump is designed according to APIG10(LO" edition), API 682 (2" edition) and VDMA24297, The pump is a centrifugal volute pump with single stage, end suction and cantilever design. The casing is sustained by centerline, and with axial suction and radial discharge. ‘Using front and rear wear ring and balance holes to keep hydraulic balance, Single face mechanical seal ‘or dual balanced cartridge seal can be used with cooling, flushing or scaling liquid system. Pipeline system is standardized by API, The maximum operating pressure of HPA is 5.0MPa, and the maximum operating pressure of HPB is 10 MPa. Suction and discharge flanges are designed by HG, DIN, and ANSI standards. It is suitable to convey clean liquid or liquid with small amount of particles, liquid in low or high temperature, liquid neutral or corrosive, and mainly applies to industries of oil refining, petrochemical, seawater desalination, coal processing. The major features of our products are flexible to use, safety and wide applications.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 3 STRUCTURAL DIAGRAM (Fig 1) 1.Casing 8.0il ring 15, Water cooling tube assessories 2.Impeller 9.Retainer 16, Wear ring of pump cover 3:Pump cover 10.Thrust bearing 17 Impeller wear ring 4,Cantridge seal 11. Back cover of bearing 18,Casing wear ring 5 Front dustproof plate 12.Support plate for coupling guard 19. Impeller nut 6, Front cover ofbearing 13. Retaining nut 7 Radial bearing 14.Shaft NAMEPLATE INFORMATION Every pump has.a nameplate that provides information about the pump. The nameplate is located on the pump frame, Special tags which provide additional information (mechanical seal data, etc.) and special tagging required by customers can be found in the pump data package. ‘The standard nameplate provides information about the pump’s size, rating, bearings, serial number, hydrostatic test pressure of pressure containment parts, maximum allowable working pressure at designated temperature and construction / customer's item number. Note the format of pump size:series No Suction Diameter (mm) X Discharge Diameter (mm) - Norninal Impeller Diameter (mm), for example, HPA 100-80-125.4 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL RECEIVING THE PUMP Inspect the pump as soon as it is received. if it is proved that there is no damage due to misleading, leakage or transportation, loading and unloading, and that the covers of the import and export are intact, as well as sure that there is no other thing entering into the pump, well then, it needn't be taken down and reinstalled, and can be installed directly, Before putting into operation, the pump and the unit in the storage period (the longest is six months) should be moisture-proof, shock-proof, and dust-proof. Pump should be stored in the place without weather influence and is paid attention to maintenance. In the storage period, the inlet and outlet of the pump casing as well as that of othcr pipclincs should be closed. Please contact with the company if the storage period exceeds six months. Pump and components are heavy. Failure to properly lift and support equipment could result in serious physical injury, or damage to pumps. Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pump using suitable slings under the outboard end of the bearing frame and under the suction flange, and It must be operated by qualified persons, Baseplate mounted units with or without drivers are moved with slings through the baseplate's lifting lugs. The front and back covers of the bearing is labyrinth seal. Don't lean to prevent leakage while transporting. IIL. Installation ‘The installation quality of the Pump and its unit has an iniportant influence on its stable operation and service life, so we must carefully install and adjust it 1. The pump should be installed near the water source as possible, to shorten the length of suction pipe, and lower the suction head. When many pumps are installed, you should consider facilitating the installation, operation, management and maintenance work, and must set certain work space and channels, generally the net distance between the pump end or pump side and the wall should not be less than 1.5m, and that between two pumps should be not less than 0.7 m.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 5 2, Pump foundation should have enough strength and size in order to better absorb the: vibration and firmly support the pump unit. The weight of the pump foundation should be 3 times of the total weight of the pump unit. The size of the pump is usually decided by that of the pump foundation, the distance between the baseplate edge and the foundation is generally (100-120) mm, the height of the foundation is generally 200mm, the reserved hole of the foot bolt is commonly 100mm 100mm, but the distance between any part on the bolt and wall of holes should not less than 15mm, the length of the bolt decides the depth of the hole, but shouldn't touch the hole base. The location and size of foundation bolts are shown on the outline assembly drawing provided with the pump data package. All equipment being installed must be properly grounded to prevent unexpected static electric discharge. 3. For the foundation of small pump (shaft diameter under 35), gencrally one grouting method that ‘embeds the foot bolt is adopted. Before grouting, the foat bolt should be hung on the basic frame strictly according to the base size, when grouting is going on, prevent the deflection of the foot bolts, lest they ‘can not match with the pump base holes. Fig.2 Fig.2 one grouting method 4, For the big and middle sized pumps, two times of grouting method that reserves holes is adopted, that is: when grouting the foundation, reserve the foot bolt hole firstly, after the unit and the bolts are in place, grout again in the reserved hole. Fig3 Mould Prepared hole Fig.3 two times of grouting method6 HPA/HPB SERIES PUMI INSTALLATION OPERATION AND MAINTENANCE MANUAL 5. The foundation plane on which the pump will be installed should be horizontal by the level instrument, then put the pump on the foundation, check the level degree by the level instrument, if it isn't horizontal, adjust it with iron shim till itis horizontal, The arrangement principle of the iron shim group is: place a group on both sides of the foot bolt, make the iron shims near the bolts possibly, but don't touch them. Then, pour the concrete on the foundation and the foot bolt hole through the grauting hole. Its level should meet the following requirements: ‘a, For pumps installed disintegrately, the allowable deviation of the longitude and transverse level is 0,1 mm/m, on the basis of the pump's machined surface, ‘b.For pumps installed entirety, make it horizontal according to the inlet and outlet flange face or other horizontal faces. The allowable deviation of the level degree is; the longitude direction 0.Imm/m, and transverse direction 0.2mim/m. Before beginning any alignment procedure, make sure driver power is locked out. Failure to lack out driver power will result in serious physical injury. 6. After the concrete is dry, check the foundation and the foot bolt hole, adjust the pump and the base plate according to the above requirements, then screw up the foot bolt. 7. The center alignment of the coupling needs handling carefully to guarantee the units' long-term reliable operation. Bad centered property of the coupling will cause noise, vibration, and speed up damages of bearings, coupling and shaft seal. ‘a. For pump with direct flexible coupling, 4 check the concentric degree of the pump pa shaft and the motor shaft, the deviation of displacement d should not exceed 0,1mm, the parallel degree 8 should nat exceed 0.2mm, if | | not, adjust it with spacer under the motor or F the pump, the amount of the spacer should not exceed 3, The clearance between two ings should be 2mm-4mm. (the value should be the minimum one for small pumps) Fig4 Fig 4 ee >. When clastic sleeve pin coupling and metal slice coupling are used, the deviation of the radial displacement should not exceed 0.05-0.08mm, the clearance between two couplings is 3-Smm. Screw up the foot bolts after the center line is adjusted. cc. After the pump reaches the operating temperature, pressure (if it is used for pressure system), the ‘coupling should be adjusted again, When the process temperature changes, the pipeline changes or pump uses are replaced, coupling must be readjusted. Proper alignment is the responsibility of the installer and user of theHPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 7 d, Troubleshooting Probable Cause Remedy |The base plate isnt adjusted level | Readjust the base plate ‘The center height of the unit varies Adjust with iron shim The foot bolt of the motor jumps | Loosen the bolts of the pump and the motor, and move the pump and motor ‘ill it is parallel. the base plate is not adjusted ‘Readjust it ‘The pump and the inlet pipeline are not __-_-Diismantle the inlet and outlet pipeli concentric, the outline pipeline is adjust the pump and the motor, then pressed or hoisted, reassemble according to the 9h tip. ‘8. The comnection of the pipeline and the pump should conform to the following requirements: ‘a, The suction and discharge pipeline should have their respective support, it is not permitted that the pump directly bears the weight of pipeline. When the expansion tube is used in the pipeline, its supporting ‘way must ensure that the pipeline pressure cannot pass on to the pump. Don't install joints and tums near the inlet flange. ‘b, flush all the pipeline parts, the valve and the bypass before connecting the pipeline and the pump. ‘That the pipeline is compulsively connected to the pump flange is strictly Prohibited, which will bring dangerous stress to the unit, and thus cause deviation and difficulties to the motor and the pump. ‘The pipeline stress goes against the operation of the pump, finally causes the unit damage. c. The matched flanges should be parallel and concentric in the free condition, the deviation should conform to the requirement in the following diagram: Speed(r/min) Parallelism of the flange face ‘Radial displacement <1500 <030 Al bolts can enter smoothly 1500-6000 <015 <0.50 d. In a free state, the distance between two matched flanges is the minimum distance in which the ‘gasket can be put into smoothly (thickness of the gasket = 0.8mm) ¢. When the piping and pump are eventually connected, radial displacement should be monitored by dial indicator on the coupling, it should not exceed 0.1mm when the speed is less than or equal to 6000 t/min, otherwise the pipeline should be adjusted. f. After the final connection of the pipe and pump, if necessary, the centered deviation between two shafts of the coupling should be retested or adjusted. 9. For a long time's small flow, unsteady load of pump will increase, which may cause damage of bearing, ‘break of shaft and impeller as well as wear of pump cover, impeller and scaling ring. A by-pass pipeline should be installed near the outlet of pump, and is connected to the place far away from the inlet or directly to the supply resource, so the axial and radial load of pump will decrease.8 HPA/HPB SERIES PUMI INSTALLATION OPERATION AND MAINTENANGE MANUAL 10. The configuration of the cooling water pipe should comply with the design requirements, the low position is the water inlet, and the high one is the water outlet. The inlet and outlet can be connected by rubber tube, the outlet directly gocs into the sewer, and can not be connected with other equipments in series, to prevent it from influencing next device because of seal leakage. Fig 5 nt ‘Wror int Armes *o "o Akmoss Ral conn [Concentric Eccentric = [adjustable tube. ‘adjustable tubs Suction inlet below ‘Suction inlet below Fig. 5 LI. When transmitting liquid containing medium or solid particles, the filter should be installed in the inlet, it should be taper structure, and its net arca is 3 times as large as the sectional area of the inlet pipeline. The filter should make sure that particles entering the pump is not larger than 1.6mm, and also it should be installed on short tube for easy clean, rN On NPSHA must always exceed NPSHR as shown on our company performance curves received with order. Never be throttled on suction side. 12, When the pump is suctioning, a base valve or filling jar should be installed on the inlet pipeline, and the screw or valve is installed on the outlet pipeline to fill liquid before start. Pipeline should be slightly tilted upwards along pump inlet direction to prevent air bubble, the installing height of the pump should meet the following requirements: Fig 6, Fig?HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 9 Hg=(Pe-Pv)10"/ g-he -[NPSH] Hg----the geometric instanlling height of pump (m) Pe-—liquid level pressure-—-local atmospheric pressure (MPa) p =---density of the transmitted medium (kg/m") g—gravitational acceleration (m/s") hic----loss of suction device (m) Py-—saturated vapor pessure of transmitted medium under transmitted temperature (MPa) (NPSH] NPSHa----NPSHr of the pump (1.3-1,4)(m) ‘Example: A HPA 80-50-200 pump is used in KunMing China, when the design point Q=50 m'sh H=50m, the NPSHr is 2m. the medium is clean water, the temperature is 90°C, the installing height is 2. (Given: the atmospheric pressure in KunMing Chinais 0.08937(MPa), the staturated vapor pressure of ‘90°C Water is 0.07011(MPa), the density is 965.3 (Kg/ m’), loss of the suction drag is 0.5m) ‘Now: [NPSH]=2 1.3-62.6m Answer: Hg={Pe-Pv)10"/ p g-he-[NPSH] Hg=(0.08937-0.07011) 10 /965,3 9,8-0.5-2.6=-1.06(m) ‘The minus means back flow installation, that is: the installing height of the pump should be at least 1,06m below the liquid, if not, it will cause cavitation, and the pump can not work. ‘On the same condition, the temperature of the clean water is lowed to 25°C, so the installing height is 2. (Given: the staturated vapor pressure of 25 water is 0,00317(MPa), the density is 997 (kg/m’)] Hg=(0.08937-0.00317) x 10'/997 * 9.8-0,5-2.6=5.7(m) ‘That means the installing height of the pump can be at most 5.7m above the liquid. 13. When the jar near the pump inlet is placed reversely, a shutoff valve should be installed on The pipeline, whose distance to the pump inlct is at least 2 times of pipeline diameter, so it is convenient toclose the inlet pipeline while check and maintenance. The pipeline should be parallel or gradually slopes downward, any part of the pipeline should be higher than the pump inlet to prevent cavitation. Inict of pipeline should be immersed in decp liquid to prevent swirl or air. Without proper pressure or flow pattern near the inlet, the pump cannot yield the greatest ability. Fig 810 HPA/HPB SERIES PUMI INSTALLATION OPERATION AND MAINTENANCE MANUAL 14. The diameter of inlet pipeline Right and valve of pump should be larger than that of the pump inlet. Eocentric The adjusiable tube reducer should be installed and slops owniward downward, its base is parallc! with pump inlet. Fig 9 Fig. 9 Giving positive pressure ‘to the upper suction inlet 15. The outlet pipeline can be deployed according to the allowable speed of media, near the pump outlet,there should be a straight pipe whose diameter is at least 4 times of that of pump outlet, the diameter of outlet valve is equal to that of pump outlet. In most cases, shutoff valve and check valve should be installed on the outlet pipeline, and the check valve isinstalled between the pump and shutoff valve, The shutoff valve is used to open or adjust flow, check and maintain the pump. After stop, the check valve protects the pump and the mechanical seal from damage. Pressure gauge should be installed between the outlet and the valve, 16. If the inlet pipeline is in the vacuum condition, and there is air in the liquid, it is suggested that an exhaust pipeline be installed between pump inlet and water supply pond, and the outlet of exhaust pipeline should be above the highest water level. In the process of operation, the exhaust pipeline can prevent air concentration, and simplify start of pump. Fig 10 17, Final piping check After connecting the piping to pump: Rotate shaft several times by hand to be sure that there is no binding and all parts are free. ‘Check alignment, per alignment criteria outlined previously, to determine if pipe strain has affected alignment, If pipe strain exists, correct piping. ‘The mechanical seal must have an appropriate seal fush system. Failure to do'so will result in excess heat generation and seal failure.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL u Cooling system such as those for bearing lubrication,mechanical scal system, etc, where provided, must be operation properly to prevent excess heat generation, sparks and premature failure Sealing system that are not self purging or self venting, require manual venting prior to operation. Failure to do so will result in excess heat generation and seal failure, Auxiliary piping may be required for bearing cooling, seal chamber cover cooling, mechanical seal flush or other special features supplied with the pump. ‘Consult pump data sheet for specific auxiliary piping recommendations. Ifbearing cooling and/or seal chamber cover cooling is required, follow guidelines listed below. 1. Flows of 4 Vmin will generally satisfy cooling requirements for cach component. If both bearing and seal chamber cover cooling are provided, a minimum flow of $ Vmin will be necessary. 2. Cooling water pressure should not exceed 7.0 kg/em’. Serious damage may result if pump is run in the wrong ro' Lock out driver power to prevent accidental start-up and physical injury. 1, Make sure that all the process pipes are correctly connected, there is mo leakage, the rotating direction of the motor conforms to. design requirement, and clean up sundries in the inlet and outlet pipeline, 2. Check the lubricating oil, and keep the oil clear, the surface of the oil must be at the normal place ‘(between two oil levels). Operation without correct lubricating will cause bearing malfunction and lead to jam the pump. 3. Rotate the coupling by hand, it should be fell easy to rotate, if there are stridulation and rolling voice, try to solve it. Open driver power, jog the motor to determine direction of rotation, which must ‘correspond to arrow on the pump frame.12 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL US TATe Never operate a pump without coupling guard properly installed. 4, Lock out power to driver, Refer to Appendix for coupling guard installation instructions. NOTE Bearing must be lubricated properly to prevent excess heat generation,sparks and premature failure. A NOTE Assure that oil rings has been properly seated in grooves in shaft . ry Bataind Operation of the unit without proper lubrication will cause bearing failure and pump seizure. 5. When the pump inlet is placed reversely, first open the inlet valve slowly, open the outlet valve ‘enough so as to transmit 25% of rated flow, open the air vent (if has) and fill liquid into the pump, until the air is all out, then close it, 6. When the pump is suctioning, fill pump with external liquid resource by use of base valve or filling Jar, the extemal liquid resource can be discharge pipeline that has been started with pressure, or other supply sources. Close the outlet valve, open the air vent on the outlet and inlet pipeline, open the Vacuum Liquid Oil level Wrong Right Air mass External supply pipeline until all the air is out. close the air vent, then the external supply pipeline. ‘When handling hazardous and/or toxic fluids, proper personal protective equipment is required. If pump is being drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable regulations. WN Butane Rotate reverscly is prohibited, test of the rotation direction of the motor must go head under the condition of full liquid in the pump or the smooth movement of the cooling water, rotating without water is also not allowed. Both of them will cause severe damage to the pump. ‘There should be liquid in the pump chamber before start, operation without liquid is prohibited, so as not to damage the mechanical scal. 7. Start the motor, open the outlet valve gradually, (for pump whose capacity is larger than $00m'/h, and head is lower than 15m, as well as with a high speed, open the inlet and outlet valves firstly) and adjust it to the required working condition. The outlet pressure decides the required working condition.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 13 ‘The outlet pressure=the total head on the pump nameplate +10 specific gravity of the medium— the inlet pressure,(10m head ~0,|MPa) Example: the total head on the nameplate is 50m, specific gravity of the medium is 1.4, the inlet pressure is 0.0SMPa, so the outlet pressure read from the pressure gauge is 50+ 10X 1.4—0.5=0.65MPa, a. All equipments and controllers must have been installed and operated normally. b. To prevent premature pump failure at initial start-up due to dirt or debris in the pipe system, ‘ensure the pump can be run continuously at full speed and flow for 2 to 3 hours .then shift into ‘working condition after conformation c. Variable speed drivers should be brought to the rated speed as quickly as possible. 4. Pumpage temperatures in excess of 93°C will require warm-up of pump prior to operation. ‘Circulate a small amount of pumpage through the pump until the casing temperature is within36°C of ‘the pumpage temperature and evenly heated. warm-up rate should not execed 1.4°C per minute. ¢. Check the pressure meter immediately after starting the motor. If the discharge pressure cannot ‘be reached in a short time, shut down the motor and start again after refilling the pump. f. Check the vibrating level of the pump, the temperature of bearing and the noisy condition. Stop ‘and check the pump if it exceeds the requirement. g. After the first stop, the coupling should be readjusted, and alll the joints should be reinforced. V. Operation and maintenance Any advanced and precise mechanical equipment cannot go without correct uses and daily maintenance. Proper use and elaborative maintenance is a key for the long service life of the pump, so we hope you follow the below: ROUTINE MAINTENANCE * Bearing lubrication + Seal monitoring * Vibration analysis + Discharge pressure monitoring * Temperature monitoring ROUTINE INSPECTIONS * Check for unusual noise, vibration and bearing temperature, + Inspect pump and piping for leaks. * Check seal chamber for leakage. 3 MONTHS INSPECTIONS * Check foundation and hold-down bolts for tightness, * If pump has been left idle, check mechanical seal,“ HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL Repair or replace if required. * Oil should be changed at least every 3 months (2000 hours) or more often if there are any adverse atmospheric conditions or other conditions which might contaminate or break down the oil. Oil should + Check shaft alignment and realign if required. ANNUAL INSPECTIONS: + Check pump capacity, pressure and power. If pump performance does not satisfy your process requirements, and process requirements have not changed, pump should be disassembled, inspected, and ‘wor parts should be replaced. Otherwise, a system inspection should be done. Inspection intervals should be shortened appropriately if the pumpage is abrasive and / or corrosive, or if the environment is classified as potentially explosive 1. Operate strictly according to the range on the nameplate, the motor power should not exceed the ‘output power on the nameplate, the state that the density of the transmitted medium exceeds the purchasing value or the capacity exceeds the rated one shall cause the motor overload. The temperature tise condition of the pump and motor should often be checked at initial start-up. The allowable temperature of the bearing is as follows : ‘C ‘Checking point Surface of the bearing The outside circle Oil temperature housing nearthe bearing | ofthe bearing in the box Normal <80 <90 <0 Should’be paid attention | 81-90 91-100 | 71-80 Should be shut up 91-100 101-110 81-90 2. Check the change of the oil level of the oil chamber in the frame at least once in a week, add oil in time. To keep the clean of the oil and good lubricating, renew the oil termly according to the using condition. Oil should be changed after the first operation of 200 hours, Afterwards, renew the oil every 2000 hours or 3 months, change it after one year's stop, and the brand of the lubricating oil is mechanical oil 464. Other lubricating oil can be used according to the working temperature of bearing, (shown in the chart) ‘the working temperature of bearing’C ‘the brand of the lubricating off <30 | 328 50-65 468 65-72 | 68 >n 1008HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 15 Every lubricating oil has its applicable range of temperature, and it should keep certain viscocity under the working temperature of bearing, 3. Check the using and the centering conditions of the parts of the coupling every 1000 hours’ operation. Elastic components should be replaced when they have been worn about 1/4 of the normal thickness. If they are seriously worn, the centering and the clearance of coupling should be checked. Operating the pump without providing liquid for mechanical seal is strictly prohibited. Mechanical seal without liquid, even several seconds, will cause its damage. 4, The service life and sealing performance of the mechanical scal relate to many factors, such as the cleanliness and lubricating performance of the transmitted medium. The service life and sealing performance differ due to the different operating conditions. 5. For pumps transmitting corrosive and worn medium, termly check the corrosive and worn condition of easily damaged parts. Replace them in time if they are seriously damaged. The first inspection should be after 3 months’ operation, later inspection should go ahead according to the operating condition. installed near the outlet of the pump, to make the capacity of pump reach the specified using range. rN Doi Pump shouldn't operate for a long time when the capacity is 1/3 of the designed capacity. Under that condition, due to the potential gasification of the medium, it will probably cause explosion, ‘eventually lead to failure of pump and physical damage. If it must go oa continuous operation, a by- ‘pass should be installed near the outlet of the purnp, to make the capacity of pump reach the specified ‘using range. A NOTE ‘When the outlet valve closed, the work time of the pump should not exceed 3 minutes. Long time work under this condition will cause the increase of the vibration, and influence the bearing and the mechanical seal. Moreover, gasification duc to the rising temperature of the liquid will lead to damage of pump parts. A TON Don't adjust the valve of the suction pipe for fear that the cavitation happens. 6. You should notice the pressure meter and vacuum meter, the pointer of the meter should be steady when works normally. If the numerical reading of the vacuum meter raise suddenly, it may be that the suction pipe is jammed or the water line goes down; if the numerical reading of the pressure meter goes down suddenly, it may be that there are gas getting into the pump or the motor speed slows down; if the numerical reading of the pressure meter raiscs suddenly, it may be that the outlet pipe is jammed. 7. Always check the fastening pieces, reinforce them if they are loose. 8. The dust and dunghill om the pump case is unfavourable for heat dissipation. Clean the pump termly.16 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL Don’t flush pump with high pressure water, which may flow into the bearing through labyrinth seal or ait vent cover. VI. Shutting down 1. Close the outlet valve before shutting down (30s at most), don't do this if there is a check valve. Cut the electric power off, and shut down the motor, Shut down the inlet valve and the auxiliary pipeline, and the cooling pipeline need to be shut down after the pump is cooled. 2. If there is freezing danger, the pump, the cooling jacket and the pipeline need to be fully emptied, When handling hazardous and/or toxic fluids, proper personal protective equipment is required. If pump is being drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable regulations. 3. Don't close all pipelines of seal/flushing and cooling, if pump keep running (temperature/pressure) after pump has been shutting down. 4. If there is the possibility of sucking in air (there is vacvum-pumping system or public pipeline), the shaft scal should be kept in the scaling state. 5. Check whether pump base and pipeline support are sloping or sinking. 6. Check the parts of the pump, make sure that they have been screwed up. 7. Check the concentric degree of the pump shaft and the motor shaft 8. Check the power plug, make sure that it isn't loose. ‘9. When the system needs to be shut up for a long time, pump should be cleaned thoroughly, get rid. of the remaining corrosive liquid to prevent cristalization. VI. Disassembly Pump components are heavy. Proper methods of lifting and securing must be employed to avoid physical injury and/or equipment damage, Preparation for disassembly 1. Shut off all valves controlling flow to and from pump. 2. Drain liquid from piping; flush pump if necessary. 3. Disconnect all auxiliary piping, tubing and equipment that will interfere with removal of assembly. 4.Remove oil drain plug at bottom of bearing frame and drain oil. Dispose of oil in accordance with applicable regulations.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL uv 5. Remove nuts, and then coupling guard adjustment section (where provided). Remove coupling guard. 6. Remove intermediate shaft of coupling. Removal of back pull-out assembly 1.Loosen and remove casing stud nuts. 2. Separate back pull-out assembly from casing by tightening jacking bolis provided. Tighten jacking bolts evenly using alternating pattern, 3. Remove back pull-out assembly using lifting sling through bearing frame or other suitable means. 4, Remove and discard casing gasket (Replace this with new gasket during reassembly). 5. Secure to prevent movement during transport. Transport back pull-out assembly to a clean work ‘area for further disassembly. ‘6. Support and secure back pull-out assembly firmly to workbench. Removal of impeller 1 .Loosen and remove impeller nut. ‘2. Pull impeller from shaft. 3. Remove impeller key. Removal of coupling 1. Remove the coupling. ‘2. Remove support plate for coupling guard. Removal of pump cover 1. Loosen and remove casing cover stud nuts. 2. Rig lifting sling to casing cover and to ovethead lifting device. Take light strain on sling, 3. Loosen and remove casing cover/bearing frame bolts. 4. Separate casing cover from bearing frame by tapping on cover flange with a hardwood block or a soft face hammer. ‘S. Loosen and remove bearing frame/seal chamber cover O-rings. 6. Loosen set screws and remave set-mounted mechanical seal from shaft . ‘7. Remove and discard mechanical seal O-ring or casing cover gasket. Disassembly of standard ring oil lubricated power end 1. Loosen and remove the front and back dustproof plate. 2. Loosen and remove bearing cover /bearing frame screws, Remove support plate for coupling guard. 3. Pry bearing cover out of bearing frame, 4.remove O-rings of front and back bearing cover. 5. remove water-cooled bellows accessories out of bearing frame. 6. Withdraw (vertical direction) shaft/bcaring assembly carefully from the bearing end sleeve of bearing frame. Take care not to damage oil rings. 7. Bend locking tang of bearing lockwasher from notch in bearing locknut. 8. Loosen and remove thrust bearing locknut and lockwasher, ‘9. remove duplex thrust bearing from shaft, 10. Remove oil rings from shaft and oil ring retainers. LI, Remove radial (inboard) bearing from shaft. (note: Save bearing for inspection) 12. Remove radial (outboard) bearing from bearing frame. 13. press back sleeve of bearing out of bearing frame, 14. Remove O-rings of back bearing sleeve. Final disassembly Remove other remaining plugs and fittings.18 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL Vil. Assembly Assembly of standard ring oillubricated power end Nn Rr Make sure that all parts.and threads are clean and that all directions under Inspections have been followed. 1. Install radial (inboard) bearing on shaft. 2. Install oil rings and retainers on shaft. 43. Install thrust bearings on shaft. ( note: duplex bearings mounted back-to-back) . 4, Place bearing lockwasher on shaft Place tang of lockwasher in keyway of shaft. 5. Thread bearing locknut onto shaft and tightened set bolts. 6. Bend bearing lockwasher and lock bearing nuts. 77. install back bearing ring and O-ring. and be eare for the position for installation of gap, It should be toward down as at top (6 o'clock) position. 8, Install front radial bearing on bearing frame, 9. Install bearing end cover and be care for the position for installation of gap, It should be toward down as at top (6 o'clock) position. 10. Carefully guide shaf/bearing assembly into bearing frame until thrust bearing is seated against shoulder of frame. Ensure oil rings do not bind or become damaged. LI. Observe oil rings through inspection connections in bearing frame . If oil rings are not properly seated in grooves in shaft .Reposition oil rings as necessary to seat in grooves. 12. Check shaft for free turning. If rubbing or binding is detected, determine cause and correct. 13, Install bearing end cover and be care for the position for installation of gap, It should be toward down as at top (6 o'clock) position. 14, Check shaft for runout, Total travel should fall in the range of 0.025mm-0,125mm. Ifnot, adjust it. 15. Check shaft impeller fit runout, If total indicator reading is greater than 0.05mm, determine cause and correct. 16. Check shaft seal fit runout, If total indicator reading is greater than 0.05mm, determine cause and correct. 17. Check bearing frame face runout, If total indicator reading is greater than 0.1mm, determine cause and correct. 18. Check bearing frame lock runout, If total indicator reading is greater than 0.1mm, determine cause and correct. 19, Install and tighten the front and back dust disk and water-cooled bellows accessories. 20. Install and tighten any plugs and/or fittings removed during disassembly. Installation of pump cover and cartridge seal 1. Install sct-mounted type mechanical seal on casing cover. (refer to sct-mounted type mechanical seal instruction) 2. Lift casing cover/mechanical seal fit and position to align with shaft. 3. Install casing cover/mechanical seal fit on bearing frame, by guiding cover carefully over shaft and ‘ensuring that cover pilots into bearing frame lock.HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL 19 4. Install casing cover/bearing frame bolts and tighten using alternating pattern. 5. Check casing cover face runout, If total indicator reading is greater than 0.13mm, determine cause and correct. 6. Check casing cover lock runout, If total indicator reading is greater than 0,13mm, determine cause and correct. 7. Check casing cove wear ring runout, If total indicator reading is greater than 0.5mm, determine cause and correct. ‘8. Check impeller and wear sleeve runout, If total indicator reading is greater than 0.13mm, determine ‘cause and correct. Installation of impeller 1 Install impeller key in keyway of shaft. Key should be at top (12 o'clock) position for installation of impeller. ‘2. Install impeller on shaft. 3. Install impeller nut and tighten evenly. 4. Check for free turing. If rubbing or excessive drag is detected, determine cause and correct. Installation of coupling hub ‘Install key and pump half coupling hub on shaft. Installation of back pull-out assembly in easing 1. Install new casing gasket on gasket surface of casing . 2. Replace back pull-out assembly in casing using lifting sling through bearing frame or other suitable means. 3. Slide back pull-out assembly into proper position in casing by loosening jacking bolts evenly. Ensure that casing gasket is not damaged. 4. Install casing stud nuts. 5. Inspect gap between seal chamber cover and casing and adjust casing stud nuts as necessary to ‘make gap uniform. 6. Tighten casing stud nuts uniformly using altemating pattern, until casing cover is in metal-to-metal contact with the casing. 7. Check for free tuning. If rubbing or excessive drag is detected, determine cause and correct. Coupling guard and additional assembly Install coupling guard, ensure that the groove in the guard is located around the support plate, and tighten tug to level. if coupling guard is not longer than coupling, it is necessary to install an adjustment section. align the hole of adjustment section to the long trough-shaped hole of coupling guard and fastened with bolts. Replace the coupling and auxiliary piping, the tubing and equipment that were removed during preparation for disassembly. IX. Spare parts If ordering spare parts is needed, please call+86 571 89905607 or contact our sales representative, When ordering, provide the exfactory number, model, dimensions, series number and item number.X. Troubleshooting HPA/HPB SERIES PUMPS INSTALLATION OPERA TENANCE MANUAL Problem The bearing istoohot Probable Cause ‘Too much or too litle lubricating oil . The lubricating oil deteriorated. The shaft is eccentric. Vibration. The bearing is insalled unsuitably, there isa malfunction, Overload when| The outlet valve hasn't been closed when start ina The picking isto tight Malfunction ofthe motor or circuit Nowaterout | There is gas inthe pomp or suction pipe The inlet or outlet valve is closed The head is higher than the max head of the pomp ‘The suction pipe leaks gas Rotation direction of irupellesis reverse There are foreign matters in the impeller The suction height isto high The diameter of suction pipe i too short, or thepipe is jammed, The speed is wrong The pamp don't | There is gas entering Low water level, low submerged dopth Worn or broken impeller The sealing ring wears too much ‘There are foreign matters inthe impeller The inlet or outlet valve isnt opened completely ‘The pipeline clogged Properties of medium dent conform to requirements of pump ‘The bead is higher than the max bead of the pump Rotation direction of impeller is reverse Let out the dirty olf, dose new oil after cleaning the frame. Reinstall or adjust. Check the balanced degree of the rotor, or ‘operate st a small flow, Check, repair and replace it ‘Close the outlet vatve and restart. Loasea it ‘Check nd repair Infuse water to discharge the gxs Open it ‘Change a pump with higher head ‘Stop the leakage on the inlet side Commect it Dismantle and clean it ‘Lower the beight and increase the suction pressure Increase the diameter of suction pipe, or remove the blockage ‘Make the speed conform to the designed requirement ‘Check suction pipe and pamp seal Prolong the suction pipe, and deepen the submerged depth Replace a new one Replace it Dismanile and clean it (Open it completely Get id of it ‘Change the pump ‘Change a pump with higher head Correct itHPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL Problem: load Probable Cause Bxces othe shaft is distorted The relative density of the media becomes dense. Resistance ofthe equipment decreases, pomp operas at big flow. Fraction happens between the | rotating parts. ‘The packing sea is 0 tight, the shaft sleeve wears Power of prime motor is low | Wrong installation of static and dynamic rings of mechanical cal Head of equipment daesat conform to | head of pump Pump vibrates | The pump and the motor are not centered ortasnose | ‘The impelteris broken, or is jammed | and out of balance. ‘The inlet pipeline is too narrow, the inlet valve is not fully opened, or the flow is ‘too small Air goes in ‘The pump and the motor are mot centered, | Adjustthe ouilet v | Repair the fra Remedy Readjust and repair them ‘Change the operating procedure, replace the ‘pump or the motor. ccreasc the flow, parts, Loosen it properly, replace the shaft sleeve, Replace it | Dismantle and reinstall or replace mechanical seal | Try to lower the resistance or height of discharge system Readjust them Replace a new one Replace a new one Fasten the foundation, and screw up the feet bolts Replace the impeller and get rid of the blockage | ‘inerease the diameter of inlet pipe, open the inlet valve, | Ptetion happens botwoon the rotating parta |The seal face is uneven | Damaged © ring or wrong installation | Damaged mechanical seal parts | Serious vibration | Damaged bearing ‘The impeller nut is loos "Tle pressure forthe secondary impeller | sling pnp is too high The outlet valve of secondary impeller seal purnp open partly | Worn packing or packing shaft sleeve in packing seal purap ‘ar adjust the outlet valve Change suctioning water level, improve the suction pipe, Replace the scal, and reinstall it Replace and reinstall it Find out reasons and replace the damaged ones Find oat reasons and deal with it Replace the bearing Screw it on Decrease it ‘Open it fully, make the pump operste at about the rated bead | Replace tho packing and packing shaft sloove22 HPA/HPB SERIES PUMPS INSTALLATION OPERATION AND MAINTENANCE MANUAL ‘Thank you for buying our pumps and parts. For more information, Call our sales representative or visit our website at www.alkalipump.com.