TC Manual Fluid Pumps

7/27/2019 TC Manual Fluid Pumps

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Prepared By: Justin Day

Temperature Control ManualFluid Pumps

Engineering Department

TC Manual Fluid Pumps.doc Aggreko Australia Pacific

Temperature Control Manual

FLUID PUMPS


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TABLE OF CONTENTS

Section Page

1 INTRODUCTION....................................................... ........................................... .............. 31.1 Description............................. ........................................... ........................................... ..... 31.2 Equipment......... ........................................... ........................................... .......................... 41.2.1 Stationary Components................................................................................................41.2.2 Rotating Components ........................................... ........................................... ............ 61.3 Applications.......................................... ............................................ ................................ 8

2 TECHNICAL DATA...........................................................................................................9

3 INSTALLATION, OPERATION AND MAINTENANCE (IOM) ............................... 223.1 Introduction................................... ............................................ ...................................... 223.2 Installation ........................................ .......................................... .................................... 223.2.1 Location .......................................... ............................................ ............................... 22

3.2.2 Foundation .............................................. ........................................... ........................ 223.2.3 Suction and Discharge Hoses ........................................ ............................................ 223.3 Commissioning ............................................ ........................................... ........................ 243.3.1 Priming ............................................ ........................................... ............................... 243.3.3 Starting the Unit...................................... .............................................. ..................... 243.4 Operation .......................................... ........................................... ................................... 253.4.1 Operational Checks.................................... ........................................... ..................... 253.4.2 Principal of Operation ................................... ........................................... ................. 253.5 Decommissioning ............................................... ........................................... ................. 263.6 Maintenance Procedures........................................ ........................................ ................. 263.6.1 Overhaul ...................................... ............................................. ................................. 263.6.2 Change of Mechanical Seal .................................. ........................................... .......... 273.6.3 Leakage Test.......... ............................................... ............................................... ...... 27

3.6.4 Examination of Internal Components..................................... ................................... 273.6.5 Lubrication...................................... ............................................ ............................... 273.6.6 Spanner sizes and recommended torques ........................................ .......................... 273.6.7 Service Reports.......... ........................................... ........................................... .......... 273.6.8 Service Requirements for the Fluid Pumps ................................... ............................ 283.6.9 Maintenance Schedules .................................... ............................................ ............. 283.7 Troubleshooting........................................... ........................................... ........................ 31

4 ELECTRICAL ............................................ ........................................... ............................ 32


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1 INTRODUCTION

1.1 Description

Aggrekos Centrifugal Pumps are manufactured by Grundfos ISO LINE, Link Pumpsand Regent Pumps. Difference between these types of pumps will be highlighted furtherin this document.

Aggreko utilises six variations of flow rates with two different means of coupling. Thepumps range from 3 litre/second to 125 litre/second pumps. These pumps, in particular

the Grundfos ISO LINE are an end-suction, back pull out pump. This type of pump is

interchangeable with other ISO pumps of the same size, which conforms to theinternational standard ISO 2858.

a. Casing- The pump casing is a highly efficient volute type configuration. Thedesign has been aided with computer technology for high stress resistance and

maximum performance. The flanges have been drilled to AS2129 table E(standard) and include tapped connections for suction and pressure gauges.

b. Impeller- The impeller is fully enclosed is hydraulically and dynamically balancedand features double curvature vanes for highly efficient suction performance.

c. Back-plate- This features an O ring seal for positive leak proof connections withthe pump casing. Positive location is maintained between the casing and the

housing because of the metal to metal face contact thus ensuring that the pump is arigid structured unit.

d. Shaft- The shaft is a heavy duty 431 stainless steel, which provides maximumprotection against deflection at high speeds. The shaft includes a taper mounted

and keyed impeller for easy removal during servicing and positive locking during

operation.

e. Housing- It is a rigid single piece casting with a positive no gap location, with thecasing and ensures accurate coupling alignment.

f. Bearings- As a standard arrangement, sealed for the life greased packed, deepgroove, single row ball bearings have been provided. Lip-seals are fitted to preventthe ingress of dust, etc.

DischargePressure GaugeDischarge Manifold

DischargeButterfly Valve

Bearing Housing

Shaft Seal Volute Casing

Suction Manifold


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1.2 Equipment

1.2.1 Stationary Components

1.2.1.1 Casing

There are generally two types of casings, the volute type and the circular type.

The volute casings build a higher head, whilst the circular casings are used for low head

and high capacity.

A volute is a curved funnel increasing in area to the discharge port. As the area of the

cross-section increases, the volute reduces the speed and increases the pressure of the

liquid.

One of the main purposes of a volute casing is to balance the hydraulic pressure on the

shaft of the pump, this occurs best at the manufactures capacity.

Running volute-style pumps at a lower capacity than manufacturer recommendation canplace lateral stress on the shaft and increase wear and tear on the seals, bearings and on

the shaft itself. Double volute casings are used when the radial thrusts become significant

at reduced capacities.

Circular casings have stationary diffuser vanes surrounding the impeller periphery thatconvert velocity energy to pressure energy. Conventionally, the diffusers are applied to

multi-stage pumps.

The casings can be designed either as a solid or split casing. Solid casings imply a design

in which the entire casing, including the discharge nozzle is all contained in one casting

or fabricated piece. A split casing implies two or more parts are fastened together. When

the casing parts are divided by a horizontal plane, the casing is described as horizontallyor axially split.

When the split is in the vertical plane perpendicular to the rotation axis, the casing is

described as vertically or a radially split casing. Casing wear rings act as the sealbetween the casing and the impeller.

1.2.1.2 Suction and discharge Nozzles

The suction and discharge nozzles are part of the casings itself. They commonly have thefollowing configurations;

a. End Suction/ Top Discharge The suction nozzle is located at the end of, andconcentric to the shaft, while the discharge nozzle is located at the top of the caseperpendicular to the shaft. This pump is always of an overhung type and typically

has a lower NPSHr (Net Positive Suction Head required), because the liquid feeds

directly into the impeller eye.

b. Top Suction/ Top Discharge The suction and discharge nozzles are located at thetop of the case perpendicular to the shaft. This pump can either be an overhung

type or between-bearing type but is always a radially split case pump.


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1.2.1.3 Seal Chamber and Stuffing Box

The Seal Chamber and Stuffing Box both refer to a chamber which is either integral with

or separate from the pump case housing. This forms the region between the shaft and

casing and is where the sealing media are installed.

When sealing is achieved by means of a mechanical seal, the chamber is commonly

referred to as a Seal Chamber. When the sealing is achieved by means of a packing, thecamber is referred to as a Stuffing Box.

Both the seal chamber and the stuffing box have the primary function of protecting the

pump against leakage at the point where the shaft passes through the pump pressurecasing. When the pressure at the bottom of the pump is below atmospheric, it prevents

air leakage into the pump and when the pressure is above atmospheric, the chamber

prevents liquid leakage out of the pump.

The seal chambers and stuffing boxes are also provided with cooling or heating

arrangements for proper temperature control. The diagram below depicts an externallymounted seal chamber and its parts.

1.2.1.4 Gland

The gland is a very important part of the seal chamber or stuffing box. It gives thepacking or the mechanical seal the desired fit on the shaft sleeve. It can be easily

adjusted in the axial direction. The gland comprises of a seal flush, quench, cooling, drain

and vent connection ports.

1.2.1.5 Throat Bushing

The bottom or inside end of the chamber is provided with a stationary device called a

throat bushing that forms a restrictive close clearance around the sleeve (or shaft)

between the seals and the impeller.

1.2.1.6 Throttle Bushing

This refers to a device that forms a restrictive close clearance around the sleeve (or shaft)at the outboard end of the mechanical seal gland.


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1.2.1.7 Internal Circulating Device

This is a device that is located in the seal chamber to circulate the seal chamber fluid

through a cooler or barrier fluid reservoir. This is commonly known as a pumping ring.

1.2.1.8 Bearing House

The bearing housing encloses the bearings mounted on the shaft. The bearings keep the

shaft or rotor in the correct alignment with the stationary parts under the action of radialand transverse loads. The bearing house also includes an oil reservoir for lubrication,

constant level oiler and a jacket for cooling by circulating cooling water.

1.2.2 Rotating Components

There are three main rotating components in a centrifugal pump, these being;

a. Impeller;

b. Shaft; andc. Coupling.

1.2.2.1 Impeller

The impeller is the main rotating part that provides the centrifugal acceleration to the

fluid. They are often classified in many ways;

a. Based on major direction of flow in reference to the axis of rotation,

- Radial flow,

- Axial flow,

- Mixed flow.

b. Based on suction types,

- Single suction: liquid inlet on one-side,

- Double Suction: liquid inlet to the impeller symmetrically from both sides.

c. Based on mechanical construction (Fig 3.),

- Closed, shrouds or sidewall enclosing the vanes

- Open, no shrouds or wall to enclose the vanes, semi open or vortex type.

Closed impellers require wear rings and these wear rings present another maintenance

problem. Open and Semi-open impellers are less likely to clog, but need manual

adjustment to the volute or back plate to get the proper impeller setting and prevent

internal recirculation.

Vortex pump impellers are great for solids and stringy materials but are up to 50 percent

less efficient than conventional designs. The number of impellers determines the number

of stages in the pump. A single stage pump has a single impeller and is best for low headservices.

A two stage pump has two impellers in a series for medium head service. A multi-stage

pump has three or more impellers in series for high head service.


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Wear rings provide an easy and economically renewable leakage joint between theimpeller and the casing. If clearance becomes too large, the pump efficiency will be

lowered causing heat and vibration troubles.

Most manufacturers require that you disassemble the pump to check the wear ringclearance and replace the rings when this clearance doubles.

1.2.2.2 Shaft

The basic purpose of a centrifugal pump shaft is to transmit the torques encountered when

starting and during operation, while supporting the impeller and other rotating parts. It

must do this job with a deflection less than the minimum clearance between the rotatingand stationary parts.

Shafts are usually protected against erosion, corrosion, wear at the seal chambers, leakagejoints, internal bearings and the waterways by a component called a renewable sleeve.

Unless otherwise specified, a shaft sleeve, where there is an issue with the above

conditions, shall be provided to protect the shaft. The shaft shall be sealed at one end.The shaft seal assembly shall extend beyond the outer face of the seal gland plate.

Leakage between the shaft and the sleeve should not be confused with leakage through

the mechanical seal.

1.2.2.3 Coupling

This component can compensate for axial growth of the shaft and transmit torque to the

impeller. Shaft couplings can be broadly classified into two groups, rigid and flexible.

a. Rigid couplings are used in applications where there is absolutely no possible roomof misalignment

b. Flexible shaft couplings are more prone to selection, installation and maintenanceerrors. Flexible shaft couplings can be divided into two basic groups, elastomeric

and non-elastomeric.

- Elastomeric couplings use rubber or polymer elements to achieve flexibility.These elements can either be in shear or compression. Tire and rubber sleevedesigns are elastomer in compression couplings.


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- Non-elastomeric couplings use metallic elements to obtain flexibility. Thesecan be one of two type; lubricated or non-lubricated. Lubricated designs

accommodate misalignment by the sliding action of their components, hence

the need for lubrication. The non-lubricated designs accommodate

misalignment through flexing. Gear, grid and chain couplings are examplesof non-elastomeric, lubricated couplings. Disc and diaphragm couplings are

non-elastomeric and non-lubricated.

1.3 Applications

The Grundfos ISO LINE single stage centrifugal pump is suitable for a wide range ofapplications including;

a. Water supply

b. Boosting

c. Circulation of Hot and Cold water

d. Transfer, circulation and boosting of water/glycol mixture (up to 50 percent)solution or glycol based anti-freeze with similar physical and chemical properties.

e. Other thin, non-explosive and non-oleaginous liquids.

While pumping liquids with densities higher than water, motors with corresponding

higher outputs should be used.


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2 TECHNICAL DATA

aggrekoPrepared by: Adam Hentschel Date: 08.10.2001 Revision: A Page 9 of 32

Discipline: Fluid Pumps Document number

Section: FP 3 au5.3

1. INTRODUCTION

Liquid pumps are used in the refrigeration industry to circulate chilled water or brine.

Aggreko has a complete range of centrifugal pumps, adapted to the chiller andair handler rental fleet.

Quick camlock fluid connections ensure easy and leakage free connections.The pumps are mounted in a heavy galvanised frame.

2. KEY-DATA

Design Flow 3l/sDesign Pressure head 30 mAbsorbed Power at duty point 3.5 kWInstalled Motor Rating 5 kWDimensions

Length 1710 mmWidth 530 mmHeight 1210 mm

Weight 284 kg

3. LAYOUT


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Discipline: Fluid Pumps Document numberSection: FP 3 au5.3

4. TECHNICAL SPECIFICATIONS

ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow 1)

DesignHead Pressure 1)

Maximum Head Pressure 50Hz / 60 Hz

Maximum Flow50 Hz / 60 HzSelf Suction

Maximum Working Pressure

Minimum / Maximum Fluid Temperature

Minimum / Maximum Ambient Temperature

Regent

l/s

m

m

l/s

kPA

C

C

40-320

D132M

3

30

32

5No

1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Bronze

416 Stainless

Electrical Data

Absorbed Power At Duty Point 1)

Installed PowerPump RPM

Supply Voltage 3 phase

Maximum Current

Starting Current

Cable Connection

kW

kW1rpm

V

A

A

Male Socket

3.5

55.5

1450

9.5

57

Clipsal 32A

Noise Data

Sound Pressure Level at 1 Metre

Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall Height

Weight

Fluid Connections

mm

mm

1mmkg

mm / inch

1710

530

1210

284

50 / 2" Camlock

NOTE: Contact Technical Department If Application Conditions Differs From DesignConditions1)Design conditions at 1460 RPM, 50 Hz supply


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1. INTRODUCTION


Aggreko has a complete range of centrifugal pumps, adapted to the chiller and air handler rentalfleet.


2. KEY-DATA

Design Flow 10 l/sDesign Pressure head 30 mAbsorbed Power at duty point 6.5 kWInstalled Motor Rating 7.5 kWDimensions

length 1710 mmWidth 530 mmHeight 1210 mmWeight 335 kg

3. LAYOUT

aggre


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koPrepared by: Adam Hentschel Date: 14.04.1999 Revision: A Page 12 of 32



ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow1)

DesignHead Pressure1)


Maximum Flow 50 Hz / 60 HzSelf Suction




Southern Cross

l/s

m

m

l/s

kPA

C

C

10x50-315

D132M

10

30

43

12.5No

1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Zinc Free

Bronze

416 Stainless

Electrical Data

Absorbed Power At Duty Point1)

Installed Power

Pump RPM


Maximum Current

Starting Current

Cable Connection

kW

kW

rpm

V

A

A

Male Socket

6.5

7.5

1450

415

14.1

84.6

Clipsal 32A

Noise Data


Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall Height

Weight

Fluid Connections

mm

mm

mm

kg

mm / inch

1710

530

1210

335

100 / 4"

NOTE: Contact Technical Department If Application Conditions Differs From DesignConditions1)

Design conditions at 1460 RPM, 50 Hz supply


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1. INTRODUCTION




2. KEY-DATA



3. LAYOUT


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ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow1)



Maximum Flow 50 Hz / 60 Hz

Self SuctionMaximum Working Pressure



Southern Cross

l/s

m

m

l/s

kPA

C

C

80 - 160

D160L

30

30

33.5

45

No1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Zinc Free

Bronze

416 Stainless

Electrical Data


Installed Power

Pump RPM


Maximum Current

Starting Current

Cable Connection

kW

kW

rpm

V

A

A

Male Socket

11.8

15

1450

415

27.7

166.2

Clipsal 32A

Noise Data


Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall HeightWeight

Fluid Connections

mm

mm

mmkg

mm / inch

1710

610

1210493

100 / 4"




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1. INTRODUCTION


Aggreko has a complete range of centrifugal pumps, adapted to the chiller and airhandler rental fleet.


2. KEY-DATA



3. LAYOUT


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ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow1)



Maximum Flow 50 Hz / 60 HzSelf Suction




Regent

l/s

m

m

l/s

kPA

C

C

125 - 320

D160L

50

30

33.5

65No

1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Zinc Free Bronze

416 Stainless

Electrical Data


Installed Power

Pump RPM


Maximum Current

Starting Current

Cable Connection

kW

kW

rpm

V

A

A

Male Socket

18.8

22

1450

415

38.2

229.2

Clipsal 50A

Noise Data


Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall HeightWeight

Fluid Connections :Discharge

:Suction

mm

mm

mmkg

mm / inch

mm / inch

1770

610

1210624

100 / 4"

male camlock

2 X 100 / 4

female camlock




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1. INTRODUCTION




2. KEY-DATA



3. LAYOUT


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ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow1)







Regent

CMG

l/s

m

m

l/s

kPA

C

C

150 - 320

SGA 225m-4

75

30

32

120

No1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Zinc Free Bronze

416 Stainless

Electrical Data


Installed Power

Pump RPM


Maximum CurrentStarting Current

Cable Connection

kW

kW

rpm

V

AA

Cable box m12

35

45

1450

415

78350

3 phase + E

Noise Data


Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall Height

Weight


:Suction

mm

mm

mm

kg

mm / inch

mm / inch

2270

800

1490

HOLD

2X 100 / 4"

male camlock

3 X 100 / 4fmale camlock




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Discipline: Fluid Pumps Document numberSection: FP100 au5.6

1. INTRODUCTION


Aggreko has a complete range of centrifugal pumps, adapted to the chiller and airhandler rental fleet.

Quick camlock fluid connections ensure easy and leakage free connections.

The pumps are mounted in a heavy galvanised frame.

2. KEY-DATA


length 2270 mmWidth 800 mmHeight 1490 mmWeight 947kg

3. LAYOUT


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ITEM UNITS VALUE

Performance Data

Pump Type

Motor Type

DesignFlow1)







Regent

CMG

l/s

m

m

l/s

kPA

C

C

150 - 320

SGA 225m-4

75

30

32

120

No1400

-15 / 95

-15 / 40

Pump Material

Casing

Impeller

Pump Shaft

Cast Iron

Zinc Free Bronze

416 Stainless

Electrical Data


Installed Power

Pump RPM


Maximum CurrentStarting Current

Cable Connection

kW

kW

rpm

V

AA

Cable box m12

35

45

1450

415

78350

3 phase + E

Noise Data


Sound power level

dB(A)

dB(A)

63

70

Physical Data

Overall Length

Overall Width

Overall Height

Weight


:Suction

mm

mm

mm

kg

mm / inch

mm / inch

2270

800

1490

HOLD

3 X 100 / 4"

male camlock

4 X 100 / 4fmale camlock




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aggrekoPrepared by: l Date: 08.10.2001 Revision: A Page 21 of 32


1. INTRODUCTION


Aggreko has a complete range of centrifugal pumps, adapted to the chiller and air handlerrental fleet.

Quick camlock fluid connections are available to ensure easy and leakage free connections.

The pumps are mounted in a heavy painted steel frame.

2. KEY-DATA


length 1930 mmWidth 830 mmHeight 1560 mmWeight 912kg

3. LAYOUT


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3 INSTALLATION, OPERATION AND MAINTENANCE (IOM)

3.1 Introduction

Installation of our pumps is of utmost importance. The operating life will be greatlydetermined on how the pumps are positioned.

The ground must be compact and level and various factors must be considered ie: if the

discharge hoses have not been secured to the main frame and carry their own weight.This will place added radial stress on the shaft and will also wear bearings and shaft seals

causing premature breakdown of the units.

3.2 Installation

3.2.1 Location

The pump should be located in a dry, well ventilated and frost free area. The unit should

be as near as possible to the source of the liquid that is being pumped, which is to involvethe smallest suction lift and the shortest length of suction hose.

Care should be taken to ensure that the pump module is at least 150mm (6) clear of

obstructions and that adequate air supply reaches the motor casing cooling fan.

3.2.2 Foundation

A solid foundation is required for the positioning of the unit. A suitable level base, be it

concrete, compacted gravel or soil should be sought.

If the unit is required to be situated at an elevated position, the structure should be able to

support at least 1 times the accumulated weight (this includes associated piping and

fluid).

3.2.3 Suction and Discharge Hoses

All hose/pipe-work should be adequately supported so that there is no external loadimposed on the pump body as shown below. The shaft must be free to turn after the

pump has been installed and the hoses/ pipe-work connected.

Suction piping must be free from air leaks and should be short as possible. The hoses

should be rigid and the internal roughness of the hose should be minimal. They should

gradually fall away from the pump to the liquid source to maintain suction pressure

efficiency.

Discharge piping should be selected of a size suitable to carry the required capacity, suchthat the friction head created is not excessive.


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Secure discharge

hoses here.

This will minimisethe load on the shaft

and shaft seal.

Try and keep the suction

hose length short as possible

Try and keep the hoses straight as possible.

Bends are not to be aggressive.

Minimise Head Pressures

Fluid Pump


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3.3 Commissioning

Prior to a Fluid Pump being brought on line, the flex hose associated with the unit, should

be flushed through (where possible). This will clear any deposits that may of accumulated

in the hose from the previous job or from transport. If this is not accomplished, there maybe a possibility of damaging the impeller or shaft seal.

3.3.1 Priming

Centrifugal pumps must not be run dry or part full. The fine internal clearances depend

upon the pumped liquid for lubrication. If this occurs, galling or seizure of internal

components can result. The mechanical seal will also be severely damaged by any dryrunning.

The pumps are not a self priming unit, and therefore require the following before startingthe unit;

a. Once all hoses are connected, open all vent cocks whilst filling to expel trapped airin the water system.

b. Where possible, the pump shaft should be rotated slowly to expel air trapped in thecasing/ impeller. It should not be necessary to re-prime the pump before

subsequent starts if the integrity of the suction line remains intact.

c. Where rotation of the shaft is not possible, jogging the unit (as for the direct-driveunits) will accomplish the same as hand rotation.

3.3.3 Starting the Unit

Prior to starting the unit, the following pre-start checks are required to be carried out;

a. Ensure the priming procedures have been carried out correctly.

NOTE: To avoid damage, do not run the pump with the discharge valve in the fully

closed position for pro-longed periods

b. Ensure the discharge valve is fully closed.

c. Apply power to the unit. Test all emergency stops, alarm trips and inter-locks areoperational and set to correct values.

d. Ensure that the direction of rotation conforms with directional arrow located onpump casing.

Once all pre-start checks have been completed the unit can be started. When the pump

reaches full speed, slowly open the discharge valve until the desired capacity is reached.

If there is no delivery of fluid shut-down the pump immediately.

CAUTION- Opening the discharge valve too quickly may result in over-loading of the

pump driving unit, especially if the pump is discharging into an empty system, as the

delivery pressure may fall below the designed pressure.


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3.4 Operation

3.4.1 Operational Checks

Once the unit is in operation, it is important to carry out the following checks;a. Ensure pump is not generating less than its rated delivery pressure.

b. Listen for abnormal noise and visually inspect mechanical shaft-seal for leaks.

c. Record pressures, temperature of bearings and ammeter readings on rounds sheets.

NOTE: The Ideal running temperature of a bearing is 40-60deg C. This can be

slightly exceeded providing that the temperature is steady and not rising, however

the temperature is not to exceed 80 deg C.

d. Complete a thorough visual inspection of all hose connections for leaks.

e. Check emergency stop action

3.4.2 Principal of Operation

All centrifugal pumps use an impeller and volute to create the partial vacuum and

discharge pressure necessary to move water through the casing. The impeller and volute

form the heart of the pump and help determine its flow, pressure and solid handling

capability.

In order for a centrifugal pump, or self priming, pump to attain its initial prime the casing

must first be manually primed or filled with water. Afterwards, unless it is run dry or

drained, a sufficient amount of water should remain in the pump to ensure quick primingthe next time it is needed.


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3.5 Decommissioning

The decommissioning procedure is as follows:

a. Start to close the discharge valve until it is 75% closed. This will reduce the load

on the unit. Leave for a few minutes.

b. Stop the unit.

c. When the pump has come to rest, fully close the discharge valve.

d. Fully close the suction valve (where fitted, or isolate buffer tank).

e. Slowly drain water.

f. Cap all suction inlets and discharge outlets when hoses have been disconnected.

3.6 Maintenance Procedures

3.6.1 Overhaul

NOTE: If spacer type coupling has been fitted between the pump and the driver, thepump casing can remain bolted to the suction and the discharge pipes.

The following is required for a complete overhaul:

a. Remove the back-plate to casing bolts. Jacking screw holes are provided in theback-plate to facilitate removal of the bearing housing shaft element;

b. Unscrew the impeller nut (two turns should be sufficient, but can vary), drive a pairof wooden or metal wedges gently between the impeller and back-plate to prevent

distortion of the impeller. Using a soft-face hammer, hit the impeller nut in order

to spring the impeller from the taper. Remove impeller nut and sealing washer and

lift off impeller. Lift out impeller key and slide the moving section of the

mechanical seal from the shaft.c. Remove the bearing housing to back-plate bolts and remove the back-plate.

NOTE: Some pumps do not have separate housing to back-plate bolts and these

would have been removed in Step 1.

d. Remove stationary face of mechanical seal by tapping out gently with a piece ofwood.

e. Remove the bearing cover to bearing housing bolts. By tapping the shaft on thedrive end with a piece of wood the shaft/bearing assembly and bearing cover can be

removed.

A pump that has become worn in the body, impeller or back-plate may be repaired by

fitting bronze wear rings. These rings, with full instruction for machining the pump partsand fitting rings are obtainable from the nearest GRUNDFOS sales office or dealer.

NOTE: Unnecessary removal of the bearings should be avoided as frequent removal can

cause deterioration of the interference fit. Bearings should only be removed if they need

closer inspection.


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3.6.2 Change of Mechanical Seal

If a leak of 1-2 drops per minute or more is found in the seal, it will have to be replaced.

This type of seal is not adjustable, and therefore a leak is a sign of a damaged seal.

3.6.3 Leakage Test

After the assembly is complete, fill the pump with water and connect to the pressure

network (max 10bar) to check for leakage.

3.6.4 Examination of Internal Components

With the pump and rotating element dismantled, the internal components and the

clearances can be checked.

a. Casing Wear Ring- Use an internal micrometer to measure the bore of the casingwear ring, taking measurements at intervals around the circumference to check for

uneven wear. Compare dimensions with the impeller neck and refer to the

allowable clearances. New wear rings can be fitted in order to restore designdimensions and obtain the design hydraulic performance.

b. Impeller- Inspect the impeller for mechanical damage, corrosive pitting andcavitation. If damage is extensive the impeller may need replacing. Examine the

eye at neck portion for grooving. Slight grooving is acceptable, however deep orprofuse grooving is not, and requires machining of the impeller and then fitting the

neck ring.

c. Shaft- This should be checked for mechanical damage and corrosion. If the shaft isnot true within 0.1mm TIR, it should be replaced or repaired.

3.6.5 Lubrication

The bearings are grease packed and sealed for life and need no further lubrication.

3.6.6 Spanner sizes and recommended torques

a. No. 1 Shaft Module: Pump Driven End Diameter 24mm. 13mm, 17mm and19mm AF spanner and a 19mm Socket for the impeller Nut. Impeller Nut torque

30nm.

b. No. 2 Shaft Module: Pump Driven End Diameter 32mm. 13mm, 17mm, 19mmand 24mm AF Spanners and a 5/8 Whit socket for the Impeller Nut. Impeller Nuttorque 74nm.

c. No. 3 Shaft Module: Pump Driven End Diameter 42mm. 17mm, 19mm, 30mmAF Spanners and a 3/4 Whit socket for the Impeller Nut. Impeller Nut torque

144nm.

3.6.7 Service Reports

Service reports play a very important role in monitoring machinery, developing trends

and enabling proper planning of corrective maintenance. The deterioration of theequipment will become inevitable without monitoring the service reports.


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3.6.8 Service Requirements for the Fluid Pumps

The service for the fluid pumps is an A service. This is to be conducted every three (3)

calendar months (where possible) and on return to depot after hire.

Before commencing, complete a review of the most recent service reports for any

abnormalities or defects.

CAUTION Ensure that the pump is isolated from its electrical supply beforecommencing with the shutdown inspections. A Danger Tag should be fitted to all

machinery that work is being conducted on.

3.6.8.1 Operation

The service requirements for the operation are as follows:

a. Complete thorough leak search;

b. Record motor current in full operation;c. Observe for any abnormal sound or vibration; and

d. Check Emergency stop action.

3.6.8.2 Shutdown

The service requirements for the shutdown of the units are as follows:

a. Complete thorough cleaning of pump housing and frame;

b. Check for any visual damage;

c. Inspect and grease bearing/s as required;

d. Check control panel wiring;e. Check safety inter-locks;

f. Inspect condition of contactors;

g. Confirm contactor over load settings;

h. Confirm contactor action;

i. Flush through and clean drain valve; and

j. Complete full wash down of unit.

3.6.9 Maintenance Schedules

The following are the Maintenance Schedules for the Aggreko Fluid Pumps:


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Maintenance Schedule for Aggreko's Centrifugal Liqu id Handling Pumps No: FP3,FP10, FP30, FP50, FP75, FP100 and FP125:

ItemNo.

Operation and Maintenance InstructionsOn Hire

andInstallation

Monthlyor at 750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiringand

Decomm.

At 36CumulativeMonths ofOperation

Note:for detail descripttion of installation, commissioning, start-up, trouble-shooting, etc., please refer to Installation and OperatingInstructions booklet of Grundfos Pumps contained in this IOM manual.

1For the placement & installation of the modular pump assemblychoose a horizontal and well-ventilated site free from debris, dust,water, obstructions, etc.

X

2Ensure to allow access for installation and connection of suctionand discharge piping, power supply cabling, and drainage. Allowaccess and space for service & maintenance at all times.

X X X

3

Check and ensure that all safety warning signs and instructions are

intact and clearly visable to the occupants in the vicini ty and to theauthorised technicians to work on the pump assembly.

X X X

Prior to starting the pump check and ensure that:

1. protective safety guards are securely in place.

2. pump coupling is aligned and tightened.

3. all shaft bearings are properly lubricated.

4. pump priming is properly carried out.

5. discharge valve is closed.

6. suction valve is fully open.

7. power supply for the electric motor is available

8. all electrical contactors, relays, alarm trips, indicators,circuitbreakers, etc., are operational and set to their correctoperating values and tolerances.

4

9. direction of the electric motor shaft rotation is the same as thedirection of arrow on the pump.

X

5

Start the pump only upon after checking, inspecting, and ensuringproper and safe operation of the pump and the other equipment inthe system set-up. When the pump reaches full speed, open thedischarge valve gradually until the desired liquid flow rate isreached.

X

6 If no liquid is being pumped, shut down the unit immediately. X

Upon reaching specified full flow rate and stable running, check andensure that:

1. pump is delivering not less than its rated delivery pressure.

2. discharge pressure gauge andf suction and dischargepressure differential pressure gauge are both showing normal orspecified operating conditions.

3. no excessive vibrations generated by the motor-pumpassembly.

4. no excessive heating generated by the pump seals and themotor bearings.

5. no exceptional noise generated by the pump seals and themotor bearings.

6. no leaks from suction and discharge valves.

7

7. leaks from valve glands and/ or connections are stopped.

X X

8 Check full load amps against nameplate rating. X X


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ItemNo.

Operation and Maintenance InstructionsOn Hire

andInstallation

Monthlyor at 750

Hours

6-Monthlyor at 4300

Hours

Completionof Hiring

andDecomm.

At 36CumulativeMonths ofOperation

9Check and ensure that pump and associated pipeworks are ventedand free of any air entrapment.

X X

10Check the pressure gauge readings and ensure that the strainer isclean.

X X X

11 Clean pump strainer by physically removing basket. X

12Inspect pump gland adjust the leakage to one drop per minute. Ifthe packing cannot be adjusted any further replace the gland topump manufacturer's recommendation.

X X

13Check and ensure that the gland well and the gland drain line areclear of any obstructions.

X X

14With pump running, lightly lubricate bearings for pump and motor,as necessary.

X

15 Check, clean, and lubricate/ grease pump and motor bearings. X X X

16 Check pump-motor coupling buffer material and replace if worn. X X X

17 Clean pump generally. X X

18 Check and readjust pump and motor alignment. X X X

19 Megger motor windings. X X

20Check coupling bushes for wear. If worn, replace bushes and checkpump-motor alignment.

X X

21Inspect exposed surfaces for corrosion, repair paintwork, asnecessary.

X X

22

Apply complete overhauling by dismantling, inspecting, repairing,replacing, reassembling, and testing. Please see overhaulingprocedures of Installation and Operating Instructions booklet of

Grundfos Pumps in this IOM manual.

X


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3.7 Troubleshooting

Problem Possible Cause

Failure to deliver water or operating below ratedcapacity

Suction and discharge piping- Long suction, short delivery (Minimum discharge head of

1.5m will help emilinate)- Obstruction in line (closed valve, suction strainer blocked,

low water level, loss in pipes- Air leaks in suction piping or joints, worn or damaged

mechanical seal

Pump - Pump not properly primed- Speed too low- Discharge head beyond pumps rating.-

Excessive suction lift- Incorrect rotation direction- Impeller blocked- Air or gas in liquid handling

Hot Bearings- Incorrect alignment of coupling- Unsupported pipes adding stress to pump- Bent shaft- Worn Bearings

Power consumption to o high - Total head lower then estimated (causing too much water)Therefore need to throttle capacity using a gate valve

- Pump speed too high- Density of liquid greater then water- Bent shaft- Pump jammed

- Misalignment

Excessive Vibration - Misalignment- Foundation not rigid- Impeller blocked- Worn bearings- Unbalanced coupling or pulley

Excessive internal wear of Pump - Cavitations from air or gases in liquid- Abrasion caused by solid particles- Corrosive action of liquid pumped

Noisy operation - Foreign body jammed in impeller or body- Impeller binding in body- Pump not primed- Cavitations noise


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4 ELECTRICAL

The following schematics are based on the latest supply of the fluid pumps (3l/s, 10l/s,

30l/s, 50l/s, 75l/s and 100l/s)

Note: The 75l/s and 100 l/s pumps have the same drawing as the motors are the same

size. The 75 l/s and below are capable of operating on 50 or 60Hz power, where the

100l/s is strictly 50Hz.

The combined panel drawings for Aggrekos fluid pumps are as follows;

a. 3 l/s pump 5.5kW Starter NHP Drg No MCL10443 Rev 0

b. 10 l/s pump 7.5kW Starter - NHP Drg No MCL10444 Rev 0

c. 30 l/s pump 18.5kW Starter - NHP Drg No MCL10445 Rev 0

d. 50 l/s pump Awaiting from manufacturer.

e. 75 l/s pump 45kW Starter NHP Drg No MCL10085 Rev 1

f. 100 l/s pump 45kW Starter - NHP Drg No MCL10085 Rev 1

Documents

TC Manual Fluid Pumps