Sulzer Pump Operating Manual
Sulzer Pump Operating Manual
Sulzer Pump Operating Manual
MC
BA/e 4330 W
Content
1. GENERAL REMARKS
1.1
1.2
1.3
1.4
2. SAFETY
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Transport / Lifting
Preservation and storage
4. DESCRIPTION
5. INSTALLATION
5.1
5.2
5.3
5.4
5.5
6. OPERATION
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
General
Commissioning
Pump start-up and operation
Inadmissible operating modes
Shut-down
Restart procedure
Service control
Operating faults
7. MAINTENANCE
7.1
7.2
7.3
Pump general
Shaft seal
Bearing / Lubrication
8. OVERHAUL
8.1
8.2
8.3
8.4
8.5
ENCLOSURES
Table of enclosures for operating manual
4000/e0-1-00-000
1. GENERAL REMARKS
1.1 About this manual
The operating manual contains important information on how to operate the pump safely, properly and most
efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to
increase the reliability and life of the pump.
1.2 Guarantee
Guarantee is assumed according to the contractual agreements.
The normal Sulzer warranty covers manufacturing or material defect, it does not cover the damage caused
by improper storage conditions, incorrect installation, operation and using against designated use.
During the period of guarantee, repairs or modifications only can be made by our service personnel or with
our agreement.
1.3 Type of operating manual (Acc. to DIN 8418 and VDMA 24 292)
Documents no.:
see cover sheet
Service address:
see cover sheet
Issue:
20
We reserve all rights in this manual and in the information contained. Reproduction, use or disclosure to
third parties without our approval is strictly forbidden.
Revision history
3
2
1
0
20--25
First issue
E. T.
Revision
Date
Description
Sign
Remark
In the case of further questions, of spare part orders and other correspondence please mention always the
SULZER Serial No. and pump type. Both can be gathered from the rating plate of the pump.
0000/e1-0-00-000
01
02
04
05
Medium delivered
06
Capacity
m /h
07
Minimum capacity
m /h
08
Differential head
m FS
09
NPSH - R
10
Differential pressure
bar
11
bar
12
bar
13
14
Specif. grav. at PT
kg/m
15
Pump input
kW
16
Speed
1/min.
17
1.4.2 Lubrication
18
3
3
19
Oil temperature
20
Liter
21
1.4.3 Cooling
22
Cooling water
m /h
23
Pressure normal/max.
bar
24
25
1.4.4 Heating
26
27
Pressure normal/max.
bar
28
29
30
31
Quantity min.
m /h
32
Pressure
bar
33
34
35
36
Quantity min.
m /h
37
Pressure
bar
38
1.4.7 Quench
39
Quench medium
40
Quantity min.
m /h
41
Pressure
bar
42
43
bar
44
0000/d1-4-02-000
C
4
03
2. SAFETY
This operating manual contains basic information, which has to be observed on the installation,
commissioning, operation and maintenance. Therefore this operating manual has to be available
constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or
assembly/disassembly of the pump.
Not only have the general safety instructions to be observed, which are given under this main point
"Safety", but also the special safety instructions given below in the operating manual.
0000/e2-0-00-000 Page 1
In case hot or cold machine parts may lead to any danger, they have to be secured by user against
touching.
Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.
Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be
disposed of in such a way as to prevent any endangering of people and environment. Legal regulations
have to be observed.
Endangering by electricity has to be excluded (details see for example in the regulations by the VDE and
local energy suppliers).
The special safety instructions in the following paragraphs of this operating manual have to be observed.
The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by
authorized and skilled personnel only, who have been adequately informed by studying the operating
manual carefully.
Basically any works on the machine may be carried out only during shut-down of the machine. The
procedure described in the operating manual for the shut-down of the machine has to be strictly adhered
to. The machine has to be locked against unauthorized or involuntary start-up.
Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be worn.
There is a risk of injury as a result, for example, of such objects getting caught or pulled in.
Immediately following the end of the works, all safety and protective devices have to be reassembled
respectively have to be put to work again.
On a repeated start-up all points given in the paragraph initial commissioning have to be observed again.
Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer.
Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee safety.
The use of other parts may lead to a loss of the manufacturer's liability for the consequences.
The operational safety of the delivered machine is only guaranteed by proper use acc. to the data under
item 1.4 of the operating manual.
The limits given in the data sheet must not be exceeded in any case.
Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g.
electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at
separately.
Improper operating methods that result in the specified temperatures being exceeded (exceeding or falling
short of the operating data, falling short of the minimum delivery flow, reduction or failure of cooling water
or circulation delivery, etc.) should be avoided at all costs.
Before starting the pump make sure that the pump system (suction pipe, pump casing and shaft seal) is
completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere in the
system.
Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters,
ammeters, etc.).
Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe
operation.
0000/e2-0-00-000 Page 2
3.
3.1
Transport / Lifting
A. General remarks
For all transport jobs the general rules of engineering and regulations on the prevention of accidents have
to be strictly observed.
These are especially
VBG 1
- General regulations
VBG 5
- Power-driven working devices
VBG 8
- Lifting devices
VBG 9
- Cranes
VBG 9a - Load suspension device with hoists and conveyors
The above regulations are applicable in the area of the Federal Republic of Germany, in other countries
the appropriate regulations have to be observed.
For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.
B. Transport
Transport devices (including vehicles) have to be checked for the admissible load weight. Total
weight of the delivered goods see dispatch documents. The load has to be secured during
transport against shifting.
C. Lifting
Sling rope as
market on
crate
Sketch 3.1-1
Sketch 3.1-3
Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete
assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened
parts during assembly and disassembly
M000/e3-0-00-000 Page 1
3.2
A. General remarks
This information will enable you to store your pump effectively and safely. Should further information be
desired, or should particular problems arise which are not covered sufficiently please contact your nearest
Sulzer representative.
The following storage instructions apply only to the pump and may not be appropriate to furnished auxiliary
equipment. Follow manufacturers instructions for all other components of the pump system.
The preservation measures required for storage depend on the despatch preservation applied. The pump
unit can be stored in a dry warehouse without maintenance measures up to the time given by the dispatch
preservation.
Seaworthy packing
The pump is despatched with PE-foil welding and with added moisture absorber. Sea-worthy packed pumps
can be stored up to one year without any special maintenance if the packing is not damaged.
Special packing
On special request the pump can be packed in aluminium foil (with moisture absorber). In this case the
preservation time amounts to 2 years without special maintenance.
If the seaworthy or other special package is removed, only the standard preservation is
ATTENTION effective, i.e. if no further measures are taken, the max. storage period will be 6 months.
C. Intermediate storage
Pumps which are not installed and commissioned immediately after delivery can be stored for the period
determined by the dispatch preservation.
ATTENTION To avoid the forming of condensate and consequently corrosion (especially in the gap
areas), bearing damage and contamination, a dry room, possibly with constant temperature
as well as a clean, shock- free storage space has to be selected.
In each case unfavourable climatic circumstances will have a negative influence on period of
ATTENTION proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed:
ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand,
etc.) the connection flanges of the pumps have to be plugged airtight.
In case of long term storage a number of precautions must be observed to prevent pump damage. It is
recommended to enter all storage inspections and preservation measures in an log.
0000/e3-0-00-000
Medium delivered
Neutral
Hydrocarbon, ...
B
B
B
B
Water, ...
A
A
Aggressive
Seawater, ...
Acids, ...
B
A
B
A
A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium and
after draining (and drying) be protected with a preservative. For this purpose the disassembly of the
hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure
described below in section 2. to 4.
B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure for
the bearing housing as described in the sections below.
Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the manufacturers.
This protective film can be removed by means of solvents or alkaline cleansing agents (see section V.).
We recommend rust preventatives
- Tectyl 506 from VALVOLINE
- Rust Ban 397 from ESSO
Other rust preventatives of the same quality may however be used as well. The average time of protection is
1-3 years. Rust preventatives are rust-preventing agents which however do not remove rust.
For this reason, it is a prerequisite for the application of rust preventatives that the parts to be protected are
clean and rustfree. The surface of the parts has to be cleaned carefully before the respective rust
preventative is applied.
0000/e3-0-00-000
Rust preventative
- Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
Ethylene-propylene (EPDM):
Preservation packing material recommended: Synth. fibres, with PTFE impregnation (e.g. Chetra 1711
GS or Hecker 1820). The packing chamber is filled completely with the separate packing rings.
Pump casing
At first the raised faces of the pump flanges have to be cleaned thoroughly and preserved with one of the
rust preventatives mentioned under I. On smooth flanges and those with annular tee-slots, flat gaskets
should be placed; in case of slotted flanges, 2 gaskets should be placed in the slot, and all the sockets have
to be closed tightly by means of metal covers. The connections for the cooling water/circulation lines etc.
should also be closed by means of normal steel plugs, using Molykote. Then fill (or spray) pump casing with
rust preventative (see 3.). While filling in this agent, turn pump shaft manually several times (observe sense
of rotation). Generally speaking in practical handling the casing interior of bigger pumps usually is only
sprayed, in this case the preservation has to be repeated every 6 months.
Bearing housing
If present: Drain lubrication oil thoroughly. Remove filler plug on the top of bearing housing and fill bearing
housing with rust preventative (see II.) up to the correct oil level. During filling rotate the pump shaft by hand
in the proper direction. If present: Fill also constant level oiler bottle with rust preventative.
0000/e3-0-00-000
10
If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than after 6
months.
F. De-preservation procedure
Surface protected parts
In most cases the protection film must not be removed. If required remove rust preventative by the following
cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be used.
Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety
precautions specified by the manufacturers.
Note: Do not use nitro thinners!
Pump casing
Drain pump casing thoroughly, it may be required to lift the pump to fully drain the pump casing (see job
specific drawings). If required flush pump casing, turn pump rotor by hand in the proper direction of rotation.
For absolutely cleaning (pumping of clean product) the disassembly of the hydraulic part of the pump
becomes necessary in most cases.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer seals
are subject to material specific and time-based alteration (aging) witch might reduce the efficiency of the
seal, therefore we recommend after a storage time for more than 3 years to change the seal rings.
Packing: Before commissioning, make sure that the preservation packing is removed and replaced by
packing rings of the quality provided for operation.
Bearing housing
Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the
preservation oil thoroughly. Flush bearing housing with lubrication oil and allow to drain. Mount constant
level oiler (if removed) and refill bearing housing with lubricating oil as given in the pump operating manual.
Dispose of rust preventive oil according to statutory regulations. Do not put into waste water
by any means.
G. Additional Information
When the pump is removed from storage special care have to be taken. Clean pump and equipment
surfaces (piping, coupling, driver,) and inspect:
Minimum checks