Centrifugal Pump, ACP series Erection Work, Operating and

117 Pages·2014·3.67 MB·English

by  Zou Lisheng

Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

Erection Work, Operating and Maintenance Instructions

Centrifugal Pump, ACP series
Machine:

Issued: Revision:
Checked: Checked:

Rev.0, Printed: 2010.08
Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or
partly reproduced without authorization by Andritz AG. Contraventions shall entail damage claims and
may have penal consequences. All rights shall also be reserved for any patents granted, registration
of trade marks and technical modifications without prior notification.

© 2010 Andritz
Rev.0, Printed: 2010.08
Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

TABLE OF CONTENTS

1 INTRODUCTION ....................................................................................................... 6
1.1 Use ..................................................................................................................................................... 6
1.2 Standards and guidelines ................................................................................................................... 6
1.3 How to use the manual ...................................................................................................................... 7
1.4 Warranty and guarantee .................................................................................................................... 8
1.5 Manufacturer’s name and address .................................................................................................... 9
1.6 Copyright ............................................................................................................................................ 9
2 SAFETY .................................................................................................................. 10
2.1 General safety regulations ............................................................................................................... 10
2.2 Danger and warning signs ............................................................................................................... 10
2.3 Designated use ................................................................................................................................ 11
2.4 General remarks on machine/plant safety ....................................................................................... 11
2.5 User’s obligations ............................................................................................................................. 12
2.6 General obligations of personnel ..................................................................................................... 14
2.7 Safety devices .................................................................................................................................. 15
2.8 Personal protective apparel ............................................................................................................. 17
2.9 Safety at the machine installation site ............................................................................................. 18
2.10 Temperature ..................................................................................................................................... 18
2.11 Noise ................................................................................................................................................ 18
2.11.1 Noise levels (dB(A)) ............................................................................................................................... 19
2.12 Electrical equipment ......................................................................................................................... 20
2.13 Fluids (liquids, gases, vapor or smoke) ........................................................................................... 20
2.14 Oils and greases and cleaning agents ............................................................................................. 21
2.15 Chemicals ........................................................................................................................................ 21
3 TECHNICAL DESCRIPTION .................................................................................. 23
3.1 General description .......................................................................................................................... 23
3.1.1 Field of application ................................................................................................................................. 23
3.1.2 Design ..................................................................................................................................................... 24
3.2 Main components of the centrifugal pump ....................................................................................... 25
3.2.1 Centrifugal pump with base frame ......................................................................................................... 25
3.2.2 Centrifugal pump .................................................................................................................................... 26
3.2.3 Bearing support ...................................................................................................................................... 27
3.3 Type of seal ...................................................................................................................................... 29
3.3.1 Andritz cartridge mechanical seal - single .............................................................................................. 31
3.3.2 Andritz cartridge mechanical seal - double ............................................................................................ 32
3.3.3 Standard cartridge mechanical seal - single ............................................................................................ 34
3.3.4 Standard cartridge mechanical seal - double .......................................................................................... 36
3.3.5 Single standard mechanical seal ............................................................................................................. 38
3.3.6 Tandem standard mechanical seal........................................................... Error! Bookmark not defined.
3.3.7 Stuffing box packing............................................................................................................................... 40
3.4 Type specification ............................................................................................................................ 42
3.4.1 Applicable standards............................................................................................................................... 42
3.4.2 Model designation .................................................................................................................................. 42
3.5 Application limiting values ................................................................................................................ 43
3.6 Performance limits for bearing supports for different shaft material ................................................ 48
3.7 Technological description ................................................................................................................. 49
4 ERECTION AND TRANSPORT .............................................................................. 50
4.1 General ............................................................................................................................................ 50
4.2 Safety regulations ............................................................................................................................ 50
4.3 Haulage ............................................................................................................................................ 51
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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

4.4 Storage ............................................................................................................................................ 55
4.5 Installation ....................................................................................................................................... 56
4.5.1 Erection of the centrifugal pump ............................................................................................................ 57
4.5.2 Pipework ................................................................................................................................................. 60
4.5.3 Aligning the coupling ............................................................................................................................. 61
4.6 Instruments ...................................................................................................................................... 62
4.7 Electrical equipment ........................................................................................................................ 63
4.8 Cold test .......................................................................................................................................... 64
5 START-UP .............................................................................................................. 66
5.1 General ............................................................................................................................................ 66
5.2 Safety regulations ............................................................................................................................ 66
5.3 Prerequisites for start-up ................................................................................................................. 67
5.4 Start-up ............................................................................................................................................ 69
5.5 Certificates....................................................................................................................................... 70
6 OPERATION ........................................................................................................... 71
6.1 General ............................................................................................................................................ 71
6.2 Safety regulations ............................................................................................................................ 71
6.3 Control via DCS ............................................................................................................................... 72
6.4 Starting ............................................................................................................................................ 72
6.5 Checks after initial start-up .............................................................................................................. 73
6.6 Normal operation ............................................................................................................................. 74
6.7 Centrifugal pump requirements (delivery head and flow rate) ........................................................ 75
6.8 Shutdown ......................................................................................................................................... 76
6.9 Operating malfunctions and troubleshooting ................................................................................... 77
7 MAINTENANCE ..................................................................................................... 81
7.1 General ............................................................................................................................................ 81
7.2 Safety regulations ............................................................................................................................ 81
7.3 Regular maintenance ...................................................................................................................... 82
7.4 Maintenance schedule .................................................................................................................... 84
7.5 Fasteners......................................................................................................................................... 85
7.6 Lubrication ....................................................................................................................................... 87
7.6.1 Oil lubrication......................................................................................................................................... 87
7.6.2 Grease lubrication ................................................................................................................................... 90
7.7 Aligning the coupling ....................................................................................................................... 92
7.8 Installing and removing the pull-out unit .......................................................................................... 93
7.8.1 Removing the pull-out unit ..................................................................................................................... 94
7.8.2 Mounting the pull-out unit...................................................................................................................... 95
7.9 Changing the impeller and the front lining ....................................................................................... 96
7.10 Trimming the impeller ...................................................................................................................... 99
7.11 Changing the shaft seals ............................................................................................................... 100
7.11.1 Changing the Andritz cartridge mechanical seal-single and double ..................................................... 100
7.11.2 Changing the standard cartridge mechanical seal-single and double ................................................... 102
7.11.3 Changing the single standard mechanical seal ..................................................................................... 104
7.11.4 Changing the tandem standard mechanical seal ................................................................................... 106
7.11.5 Changing the stuffing box packing and the shaft protection sleeve ..................................................... 108
7.12 Changing the anti-friction bearings ............................................................................................... 112
7.13 Disassembly and disposal ............................................................................................................. 114
8 TECHNICAL DATA ............................................................................................... 116
8.1 Data sheet ..................................................................................................................................... 116
8.2 Characteristic curve ....................................................................................................................... 116
8.3 Dimensional drawing ..................................................................................................................... 116
8.4 Coupling ........................................................................................................................................ 117
8.5 Shaft seal ....................................................................................................................................... 117
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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

1 INTRODUCTION

This manual is part of the ANDRITZ AG technical documentation for the
pump. It is intended to provide the operator with the basic knowledge
required for proper, safe and economical use of the equipment delivered
by ANDRITZ AG. Observing these instructions helps avoid hazards and
reduce repair and downtime costs, as well as increasing the reliability
and useful life of the machines.

1.1 Use
Target group This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator of
the mill and his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This
refers in particular to the following tasks:
Handling, starting and stopping

Troubleshooting

Maintenance and upkeep

Haulage

Maintenance and disposal of process materials, cleaning of machine

and area around the machine.
The following sections are especially important:
The Chapter on SAFETY,

The safety instructions contained in various other chapters

Supplementary The mill operator shall complete this manual by adding national
instructions regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned
to the job shall also be added. This also includes instructions on
supervising and reporting obligations.
Safekeeping Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2 Standards and guidelines
The pump is delivered together with a CE declaration of conformity
according to Machinery Directive 2006/42/EC Annex II, 1.A. It is
confirmed that European standards (harmonized) EN 809 and EN ISO
12100, Parts1 and 2, have been observed. Auxiliary electrical equipment supplied,
such as motors, measuring instruments, ... carry a CE marking
(if they fall within the scope of a guideline, for example the low-voltage or
EMV guideline).

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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

1.3 How to use the manual
Presentation  Chapter and paragraph headings are printed in capitals in the
continuous test
SAFETY
Designations of indicating and handling elements are written in inverted

commas in the continuous text.
Operate switch “xxx”
Lists without numbering do not require operations to be carried out in a

certain order.
Pictograms The following pictograms are used in the manual:
Warning signs.
Warning signs are shown with an explanation of the type
of the hazard.
The meaning of the different graduations of hazards is
described in the Chapter on SAFETY.
Marks an instruction on handling of the machine of
system.

Marks a useful piece of information

 Marks a cross-reference to another Chapter with absolute
path indication.
e.g.  /ACP-Pump/SAFETY
Work steps Work steps are presented in tables. Work steps are numbered and must be
(operations) carried out in the order specified.

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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

Item numbers 411.2 The item numbers shown in this format refer to the assembly
drawing and the parts list.
Numbering of Pages consecutive numbering of Chapters 2-1
pages, tables and
Tables Tab. + Continuous numbering of Chapters Tab.2-1
figures
Figures Fig. + Consecutive numbering of Chapters Fig.2-1
Abbreviations Tab. Table
Fig. Figure

1.4 Warranty and guarantee
Andritz AG’s general terms of delivery and sale shall apply.
Guarantee and liability claims on Andritz AG shall become void if personal
injury or material damage is caused by one or several of the following:
Use of the machine/system for any purpose other than its designated

use.
Non-conformity of erection work, start-up and handling of the

machine/system.
Non-observance of the safety instructions in the manual.

Non-authorized structural changes to the machine/system.

Non-observance of the maintenance and upkeep instructions.

In the event of a claim for repair under guarantee, ANDRITZ AG reserves the
right to assess the damage to the machine/system.
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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

1.5 Manufacturer’s name and address

Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our service department will be pleased to help you and can be contacted at:

Andritz AG
Stattegger Strasse 18
A-8045 Graz
Service department for pumps
Tel.: [phone]
Fax: [phone]
Email: [email protected]
In case of emergency outside working hours
Tel.: [phone]
1.6 Copyright
The operating manual is protected by copyright. All usual rights reserved. It
must not be wholly or partly reproduced without authorization by Andritz. All
rights shall also be reserved for any patents granted, registration of trade
marks and technical modifications without prior notification.
2010 Andritz AG
Rev.0, Printed: 2010.08 Page 9 of 117
Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions

2 SAFETY
2.1 General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
In addition, the chapters in the operating manual contain further safety
regulations. These are marked by DANGER SIGNS.
Safety instructions on components not supplied by Andritz AG are contained in
the descriptions of the components ( /ACP-PUMP/SUPPLIER
DOCUMENTATION). The safety instructions supplement ANDRITZ AG’s
operating instructions.
All safety instructions must be observed. Disregarding the safety instructions
may cause a risk to life and limb, environmental pollution hazards and damage
to property.
2.2 Danger and warning signs
The entire SAFETY chapter is of extreme importance and relevant to safety. The
information in this chapter, therefore, is not marked with special danger
symbols.
The Chapters on ERECTION WORK, START-UP, OPERATION and
MAINTENANCE in this Manual are marked by a pictogram. The following
warning signs are used:
This symbol indicates there may be a risk to life and limb.
Non-compliance with the warning signs may lead to serious health
problems or even fatal injuries, and can cause extensive damage to
DANGER property.
This symbol points to an imminent health risk, as well as a risk of
environmental pollution and of damage to property.
Non-compliance with the warning sign may cause moderate health
WARNING problems and/or extensive environmental pollution and damage to
property.
This symbol points to a dangerous situation.
Non-observance of these signs may cause environmental pollution and
damage to property.
CAUTION

Further symbols and pictograms used are described under INTRODUCTION.

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