9. Pump Installation

7/25/2019 9. Pump Installation

1/11

1LP 1205 GB

June 2000

This instruction is valid for all standard low pressure pumps:LPD, ACD, ACE, ACG/UCG, ACF/UCF, LPQ and ABQ

Contents Page

Pump identification 2Installation 3Start-up 8Trouble shooting 10

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Before commencing any work, read this instruction carefully! Failure to comply

with these instructions may cause damage and personal injury!

LP 1205 GBJune 2000

Low pressure pumps

Installation and Start-up Instruction

A Member of the

COLFAX PUMP GROUP

Screw pumps


2/11

2LP 1205 GBJune 2000

These instructions are valid for all low pressure pumps as specified in the Pump identification chart below.

Pump identification

ABQ

LPQ

ACF/UCF

ACG/UCG

ACE

ACD

LPD 015020

025

025032038

045052060070

080

090100110125

100110125140

160

180

N

LN

KLN

KN

K

LN

LNP

B

LN

1

6

3

6

4

1

5

I

IN

N

IN

I

N

I

I

V

VT

VT

VT

R

V

R

R

B

B

B

BF

B

F

Y

Y

P

P

EGOP

E

OP

P

O

P

A101

A101A327A020A385

A020

A084A087A101

A328

P

J

Q

Pump name Rotorlead(1)

Shaft-seal

design(1)

Mounting(2)

Valve(3)

Alsovalid foroption

Comments

Pumpunitwithout shaftcoupling

O = max 5 bar

(1) See Product description or Service instruction for specifiedpump model

(2) B = Flange mountingF = Foot mountingY = Vertical foot mounting

(3) E = Without valveG = Valve with external returnO = Valve with internal return for reduced pressure rangeP = Valve with internal return for total pressure range

OptionA020 Pump with surface treated casing(s)A084 Pump with lifetime greased ball bearingA087 Pump with CCW-rotation and lifetime greased ballbearingA101 Pump with CCW-rotation, when not standardA327 Pump with Tuning

A328 Pump with TuningA385 A101 + A327

Materialpump-body(1)

Size(1)

O = max 6 bar

O = max 10 bar

Designmodification

Pumpunitwithout shaftcoupling


3/11

3LP 1205 GB

June 2000

Fig. 2 Lifting of pump

max 90

min 60

max 90

min 60

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Failure to comply with these instructionsmay cause damage and personal injury!

Transport and storageAlways protect the pump against ingress of waterand other impurities. Store the pump in a clean, dryand warm environment. The pump is delivered withthe internals oiled and with protective covers overthe pipe connections and drain openings. Thesecovers should remain in place for as long as possibleduring the mounting and installation procedure butmust be removed before start up.

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All work carried out on the pump has to beperformed in such a manner that risks forpersonal injury are observed!

Lifting of pump

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All pumps should be lifted with strapssecurely attached to the pump or pump unit,

so that the center of gravity is located be-tween the straps in order to avoid tipping ofthe pump.

Use two eye bolts (M 20) securely fastened to thefront cover for pumps LPQ and ABQ. Pump andconnecting frame are lifted together using two eye

bolts securely fastened to the top of the connectingframe. (Thread dimension is M 16, except for framesize 600, where it is M 20).

Identification of safety instructions

Non compliance of safety instructionsidentified by the following symbol -could affect safety for persons.

Safety instructions whereelectrical safety is involved,are identified by:

Safety instructions which shall be considered forreasons of safe operation of the pump or pumpunit and/or protection of the pump or pump unititself are marked by the sign:

ATTENTION

max 90

min 60

Fig. 1 Clean and dry environment.

InstallationBEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!

Design limitations and technical data for each pump are found in the Product description.Installation of IMO AB low pressure pumps does not require special skills. However, these instructionspresume that the work is carried out by experienced fitters.Maintenance and service instructions, which are specific for each pump are presented in a separate docu-ment.


4/11


Lifting of the complete pump unit with the liftingdevice attached to the motor, should be avoided asthe motors lifting provisions may not be able tocarry the combined weight of the pump and motor.

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Lifting a complete pump unit, using slingsor hooks attached to the pump or connecting

frame may be dangeroussince the centre ofgravity of the pump unit may be higher thanthe points of attachments.

MountingThe pump must be securely mounted on a firmstable foundation and positioned so that it is easilyaccessible for inspection and servicing.Provisions for collecting oil spillage when servicingthe pump should be considered.

ATTENTION

The installation must always be designed tominimise damage. Should an operational orfunctional failure occur. E.g. precautionsshould be considered to collect oil spillagedue to a broken pipe or pump housing, tostop pump operation if overheating shouldoccur or if the oil volume is below a mini-mum tank level.

Alignment and shaft couplings

The pump shall be connected to its driver via aflexible shaft coupling. Pumps of type ACG/UCGand ACF/UCF may also be driven via gears orpulleys as specified in the Product Description,provided the radial forces are kept within thespecified range.

An angular misalignment of 0.1corresponds toapprox. 0.2 mm deviation/100 mm.The coupling and alignment shall be selected not totransmit any axial or radial loads on the shaft ends.IMO AB standard couplings shall have a distance

between the coupling halves as per table, fig 4. thecoupling halves shall be secured by lock screws.

For other types of couplings, please refer to respec-tive makers manual.

Fig 4. Distance between coupling halves. (IMO AB standard coupling)

When fitting the shaft coupling, do not use ahammer or similar as this may damage theball bearing and shaft seal.Use some kind of press tool.

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When handling liquids that may harm skinuse gloves and/or protective clothing.

When handling liquids which may involvefire hazards appropriate precautions to avoiddanger are to be taken.

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Outer diameter Distance between Outer diameter Distance between

of coupling coupling halves of coupling coupling halves

(D mm) (t mm) (D mm) (t mm)

A B A B

50 26 2.0 8 148 3.567 40 2.5 16 168 3.582 55 3.0 18 194 3.597 65 3.0 20 214 4.0

112 80 3.5 24 240 4.0128 95 3.5 26

Fig. 3 Alignment of the IMO AB standard coupling

t

D4 max 0.3 mm

D6 max 0.4 mm

E4 max 0.4 mm

max

0.1

D

See table below An angularmisalignment of0.1corresponds toapprox. 0.2 mmdeviation/100 mm.

Angularalignment

Distancebetweencoupling halves

Circularrun-out

A

XY x = y - t


5/11

5LP 1205 GB

June 2000

Fig. 8 Deaeration

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Measures shall be provided to avoid acci-dental contact with the rotating shaft cou-pling. Any installed coupling guardshall permit easy access to the pump shaftfor maintenance and inspection of thepump bearing and seal housing.

Pipe connectionsThe pipe work shall be installed and supported sothat no pipe stresses are transfered to the pump

body.The pipe work should be tight in order to avoidleakage and infiltration of foreign particles and/orair.Shut off valves should be installed in both suctionand discharge pipes, so that the pump can be hy-draulically isolated.

Suction lineThe suction pipe should be designed so that the totalpressure drop, measured at the pump inlet flange,does not exceed the suction capability of the pump.Make a proper calculation of the suction line includ-ing components such as valves, strainer, pipe bendsetc. Generally, the pressure drop in the suction lineshould be as low as possible, which is achieved if thesuction pipe is short, straight and has a suitablediameter.

The velocity in the suction line should be kept in therange 0.5 - 1.2 m/s. For L.O. circulating systems, werecommend to keep it as low as possible.The suction line must be equipped with a port thatallows filling the pump before start.

Discharge lineThe discharge line should be dimensioned to keepthe velocity in the range 1 - 3 m/s.

DeaerationIn installations with negative suction head, wherethe pump might be started against a pressurizedsystem, a deaeration pipe with an orifice (2-3 mmrecommended) has to be installed. The deaerationpipe should be connected to the outlet pipes highestpoint.This must also be installed when the pump is usedas an stand-by pump.

Fig.7 Suction line

Fig. 6 Pipe connections

For direct driven pumps the alignment betweenpump and motor shafts must be kept within thefollowing limits:

Max run-out Max angularmisalignment

(mm) (degrees)

Type LPDand ACD (n/a short coupled)Other types 0.3 0.1

Fig 5.


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Fig. 11 Liquid trap

Fig. 9 Strainer

StrainerThe pump has to be protected from foreign matter,such as weld slag, pipe scale, etc., that could enterthe pump via the suction line. If the cleanliness ofthe system cannot be guaranteed, a strainer must beinstalled in the inlet pipe near the pump. For practi-cal reasons a suction strainer with 0.5 - 2 mm meshopenings is recommended:Small pumps (LPD, ACD, ACE) 0.5-0.8 mmLarge pumps (ACG/UCG, ACF/UCF, LPQ,/ABQ)0.8-2.0 mmThe size of the strainer should be selected so that itis large enough to allow adequate pressure at thepump inlet. The pressure drop across the strainershould preferably not exceed 0.1 bar at max. flowrate and normal operating viscosity. A vacuumgauge between the strainer and the pump inlet isrecommended to indicate when the strainer needscleaning.

Shaft seal drainThe pump should be installed so that any leakagefrom the shaft seal does not become a hazard. As theshaft seal has to be lubricated a small amount of oildripping cannot be avoided.Provisions to collect the leakage from the shaft sealmust be made.A drain pipe can be connected to the drain connec-tion on the pump, (not applicable to pump seriesLPD). However, when pumping heavy fuel oil orany other liquid that is likely to become very viscousat ambient temperature, we recommend that the

liquid is allowed to drop freely from the drainopening.

SealGuardFor heavy fuel oil high temperature applications, aSealGuard should be applied to the pump. Furtherinformation about SealGuard, read the Installationand Start-up Instruction for SealGuard.

Liquid trapIn some mounting arrangements the pump may notretain the liquid at stand still. In such installationsthe suction pipe should be arranged so it forms aliquid trap together with the pump, keeping thepump half filled with liquid. See fig. 11.

, , , ,

, , , ,

, , , ,

, , , ,

, , , ,

, , , ,

Fig. 10 Shaft seal drain


7/11

7LP 1205 GB

June 2000

bar

Fig. 12 Gauges

GaugesGauges for monitoring the pumps working condi-tions are recommended. These gauges should beplaced readable as close to the pumps in- and outletflanges as possible. On standard pumps, series ACE,ACG/UCG, ACF/UCF and LPQ, there are gaugeconnections for both in- and outlet.

Pressure relief valveAll systems with screw pumps must be equipped

with a pressure relief valve installed immediatelyadjacent to the pump.In the standard versions of IMO AB low pressurepumps, this pressure relief valve is an integral partof the pump to protect the system against excesspressure.When liquid is circulated through the valve it heatsup in proportion to the set pressure level and thepercentage of by-passed liquid. 100% by-pass canonly be tolerated for less than about 3 minutes, 50 %

by-pass generally for unlimited periods of time.If more than 50% recirculation is anticipated, a valuespecific to each application should be determined byclosely monitoring the pump body temperature.

If the pump is operating in line with a separatepressure control valve (see fig. 13), the setting of therelief valve should be high enough so as not tointerfere with the control valve. Likewise, if twopumps are operating in parallel, the setting should

be such that interference between the two valves isavoided.

Pressure testing and flushingThe system must be flushed and pressure tested

before connecting the pump. If corrosive liquid, suchas water is used, the system must be thoroughlydrained, dried and protected against corrosion afterhaving been flushed.

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Oil leakage may make the floor slippery andcause personal injury.

Fig. 13 Pressure relief valve

Fig. 14 External control with pressure relief valve


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Start-up

Before startingAfter installation and whenever it can be assumedthat the pump has been emptied, the pump must be

thoroughly filled with liquid. See fig 15.For ACE Generation 3, ACG Generation 6 and ACFGeneration 4 delivered after 1997, the pumps has

been fitted with deaeration plugs making venting ofthe shaft seal compartment easy before start-up.In installations with positive suction pressure: Afteropening the inlet and outlet valves, simply open thedeaeration plug a few turns until oil sips out.Tighten the plug.In installation with negative suction pressure: Afteropening the inlet and outlet valves, remove thedeaeration plug and fill the shaft seal compartmentwith oil. Fit and tighten the plug. See fig. 16.Note! Not applicable on LPQ/ABQ.

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Make sure the prime mover is locked outand can not be started accidentally.

Rotate the shaft by hand while filling the pump, toensure that the rotor bores and the shaft seal cavityis filled. On the smaller pumps: (LPD, ACD, ACE,ACG/UCG), this is done by rotating the fan on theelectric motor after removing the fan cover.

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Do not forget to fit the motor fan cover againbefore making start of motor possible.

On the ACF/UCF, LPQ and ABQ pumps, the pumpcan be turned using the shaft coupling. If the suctionpipe cannot be completely filled, it is important toensure that the trapped air is evacuated without anypressure build up. (See fig. 8 Deaeration).

ATTENTION

Starting a dry pump is likely to causedamage, especially to the shaft seal.

Direction of rotationWhen the pump is ready to be started, switch themotor briefly on and off and check that the drivemotor rotates in the correct direction as indicated bythe rotation arrow.

The arrow is placed on different spots depending onthe pump series.

ATTENTION

Don't mix up with arrow for inlet and outlet!

Fig. 15 Filling the pump

Fig. 17 Direction of rotation

Fig. 16 Deaeration plugs

ACG

ACF

ACE

Deaerationplug

Deaeration plug

Deaerationplug

Deaerationplug


9/11

9LP 1205 GB

June 2000

Fig. 18 Adjusting the tuning

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If operating temperature exceeds 60C

(149F), appropriate measures to avoidskin contact shall be provided.

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Use hearing protections whenever highnoise can be expected from pump, motorand/or environment.

3. Turn the upper screw and continue to reduce thenoise level. (If turned too much the noise willincrease again).

4. Repeat item 2. and 3. in order to achieve thelowest possible noise level.

Setting of tuning of the ACG/UCG and ACF/UCF:

1. Before starting the setting, check that the setting

screw (8 mm: ACG/UCG, 12 mm: ACF/UCF,socket head cap screw on the discharge side) areclosed.

2. Turn the screw CCW until the noise level be-comes the lowest (if turned too much the noisewill increase again).

Once set, the tuning needs no further adjustment,providing the operating conditions stay the same.

NOTE: It s not possible to accidentally turn thetuning spindle too far.

StartingCheck that all valves necessary for the operation arefully opened in both discharge and suction lines.The first time, the pump should be started with theadjusting spindle of the pressure relief valve tight-ened to half of the available turns (the valve settingis increased when the spindle is turned clockwise).By monitoring the pressure gauge it can be deter-mined when the suction line is primed and thepump begins to work. Should the pump not operatenormally soon after start, stop the pump within halfa minute. Start again after about 3-5 minutes (theshaft seal must have time to cool off) and run forhalf a minute. This procedure may need to berepeated a couple of times if the suction line isextremely long. Should the pump still not work, itmust be assumed there is a problem in the systemthat needs to be remedied. Check the suction linecalculation on page 5 and/or see Trouble shoot-ing, page 10.

Setting the pressure relief valveThe setting of the opening pressure is made asfollows: Tighten the valve spindle by rotatingclockwise to the maximum extent. The systempressure is regulated by throttling to required value.The pressure relief valve is eased until the pressureis just beginning to decrease by turning the spindle

CCW. The valve is now preset for desired openingpressure. Open the throttling valve entirely.

NOTE: The set screw on LPD is hidden behind aplate.

Adjusting the tuningThe tuning adjustment, which is a standard featureon ACF/UCF and LPQ (option on ACG/UCG andABQ) pumps, is a device for minimizing the effectsof dissolved and free air in lube oil systems. Thetuning principle is described in the Product Descrip-tion.The tuning should be adjusted while the pump isworking under normal operating conditions. This isdone by turning the tuning spindle with an Allenkey (size 8 mm for ACG/UCG and LPQ, 12 mm forACF/UCF ) to a position where the noise levelcomes to a minimum. On a double acting pump likethe LPQ pump, there are two tuning valves, whichmust be adjusted individually.

Setting of tuning of the LPQ:

1. Before starting the setting check that both settingscrews (8 mm socket head cap screw on the

discharge side) are closed.2. Turn the lower screw until the noise level obtains

a minimum.(If turned too much the noise willincrease again).

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Pumps with external ball bearing includinggrease nipple, must be regreased after onehour of running, while the pump isoperating


10/11

10LP 1205 GBJune 2000

Trouble shooting

Reverse the terminal connectionon electric motor.

Connecting and discon-necting of electric cablesmust be done only bypersonnel authorized todo such work.

See above.

Check all components in suctionline. The inlet condition should

be checked with a vacuumgauge at the pump inlet.

Check the suction line.

See the chapter on Deaeration(see page 5).

See above.

Readjust the pressure reliefvalve to a value above counterpressure.

Readjust the pressure reliefvalve

Check all components in thesuction line (strainers, valvesetc.).

See the chapter on Noise andVibration. ( Page 11).

Readjust the pressure reliefvalve.

Check the components in thedischarge line inclusive therecipients.

Check the valve. See Mainte-nance and Service instruction forrespective pump.

Check all components in thesuction line (strainers, valvesetc.).

See the chapter on Noise andVibration. ( Page 11).

Contact your IMO ABrepresentative.

- Electric cables to motor wronglyconnected.

- Wrong direction of rotation.

- Suction line is not open orpressure drop in the suction lineis too high.

- Major air leakage into thesuction line.

- The pump cannot evacuate theair through the discharge linedue to excessive counterpressure.

- The pump is not primed.

- The pressure relief valve is setbelow the counter pressure.

- The pressure relief valve is settoo low (Discharge pressure alsolow).

- Something is restricting the flowin the suction line. (This wouldusually cause noise).

- The pumped liquid contains asignificant amount of compressible gas, such as free air.(This would usually causenoise).

- The pressure relief valve is settoo low.

- Counter pressure in the dis-charge line is too low due to amajor leakage.

- The valve piston is stuck in openposition.

- Something is restricting the flowin the suction line. (This wouldusually cause noise).

- The pumped liquid contains asignificant amount of com-pressible gas, such as free air.(This would usually cause

noise).- A too small pump has been

chosen.

Wrong direction of rotation

What to doProblem Cause

No flow

Flow too low

Pressure too low

The pump cannot be primed


11/11

11LP 1205 GB

June 2000

What to doDisturbance CausePressure too high

Drive motor difficult to startor tends to stop by trippingthe motor overload relay

Noise and vibrations

Monitor the pumpfunction and shut downif any sign of mal-function is noticed.

- The pressure relief valve is settoo high.

- The oil is too cold (or has higherviscosity than anticipated).

- Counter pressure in the dis-charge line is too high.

- Counter pressure too high.

- Liquid too cold.

- Motor is undersized for theprevailing conditions.

- Electrical power supply faulty.

- Motor overload relay set too lowor is faulty.

- Incorrect setting of Y/D starter.

- The flow to the pump is insuffi-cient.

- Insufficient support of pipe

work.

- Bad alignment

- Air leakage into the suction line.

- Free air in the liquid or gascavitation.

- Faulty electrical supply.

Readjust the pressure relief valve.

Reduce the pressure setting untiloperational temperature has beenreached.

Check the discharge line.

See above: Pressure too high.

Readjust the pressure relief valveto a lower value. Thus the powerconsumption for the pumping is

relieved and overloading due tothe high viscosity may beavoided. When the liquid hasreached normal temperature andthus flows easily, the relief valveis reset to normal pressure.

Check the motor.

Check the motor and motorconnection.

Readjust or replace the relay.

Readjust the setting of the start-ing sequence. The time before themotor overload relay is trippedshould not exceed 10-15 seconds.

See chapter: The flow is too low.

Check for pipe vibrations in the

pump connections. Check thatthe pipes are sufficientlyclamped.

Check alignment, see page 4.

Check the suction line for airleakage.

For pumps with Tuning:Adjust the Tuning. If this doesnot help or for pumps withoutTuning: Contact your IMOrepresentative or IMO service

dept.

Check all three phases of thesupply.

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Documents

9. Pump Installation