Operating Instruction ZLND

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Programme

Range: ZLND

Volute casing pump complying with EN 733 / DIN 24255

**

PUMP DESCRIPTION: ______________________________

SERIAL NUMBER: ____________________

For local contact details: For local contact details: www. sterlingfluidsystems.com www. sterlingfluidsystems.com

In the search to

In the search to improve continuously its products,improve continuously its products, Sterling Fluid Systems reserves the right to modify its Sterling Fluid Systems reserves the right to modify its

products at any time

products at any time without prior noticewithout prior notice

�

� (Sterling Fluid Systems BV) 2001 (Sterling Fluid Systems BV) 2001

Operating instructions

Safety

Safety issues

issues

Chapter

Chapter 1

1

Safety instructions and compliance Safety instructions and compliance

Intended

Intended application

application

Chapter

Chapter 2

2

Application, des Application, descriptioncription

Planning

Planning the

the installation

installation

Chapter

Chapter 3

3

Requirements

Requirements, , piping system, piping system, accessoriesaccessories

Unpacking,

Unpacking, storage,

storage, transport

transport

Chapter

Chapter 4

4

Supply, interim storage,

Supply, interim storage, corrosion protectioncorrosion protection

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5

Assembly at si

Assembly at site, tools, checkste, tools, checks

Start-up

Start-up and

and shut-down

shut-down

Chapter 6 Chapter

6

Important requirements Important requirements

Maintenance,

Maintenance, dismantling,

dismantling, assembly

assembly

Chapter

Chapter 7

7

Intervals, cleaning Intervals, cleaning

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If something does not work If something does not work

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9

Dimensions, permissible values Dimensions, permissible values

Annex

Chapter

Chapter 10

10

Technical data, dimensions table, sectional drawings Technical data, dimensions table, sectional drawings

**

With certain exceptions – see Technical Catalogue With certain exceptions – see Technical Catalogue Attention:

Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technicalBoth the pump and/or the pump set must be installed and commissioned by qualified technical personnel only and these installation, commissioning and operating instructions must be strictly observed. personnel only and these installation, commissioning and operating instructions must be strictly observed. Failure to do so could result in:

Failure to do so could result in:

•• dangerdanger to you and your colleagues,to you and your colleagues,

•• the pumpthe pump or or the pump unit the pump unit may bemay bedamageddamaged,, Note that the manufacturer is not

Note that the manufacturer is not liableliable for damages resulting from failure to observe these instructions. for damages resulting from failure to observe these instructions. Please be aware of your responsibility to your colleagues when working on the pump or the pump set! Please be aware of your responsibility to your colleagues when working on the pump or the pump set!

Safety

Safety instructions instructions marked marked with with included included in in this this Operating Operating Instructions Instructions and and in in thethe Supplemen

Supplementary Operating Instructions, which must be tary Operating Instructions, which must be attached to this attached to this Operating Instruction, have toOperating Instruction, have to be considered in particular when operating this pump in potentially explosive atmospheres!

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This operating manual gives basic instructions, This operating manual gives basic instructions, which must be observed during installation, which must be observed during installation, operation and maintenance of the pump. It is operation and maintenance of the pump. It is therefore imperative that this manual is read by therefore imperative that this manual is read by the responsible personnel / operator(s) prior to the responsible personnel / operator(s) prior to assembly and commissioning. It must always be assembly and commissioning. It must always be kept available at the site of pump installation. kept available at the site of pump installation. It is not only the general safety instructions It is not only the general safety instructions contained in this chapter “Safety” which must be contained in this chapter “Safety” which must be observed, but also the specific information observed, but also the specific information provided in the other chapters.

provided in the other chapters.

1.

1.1

1 Id

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symbols in the operating

instructions

Safety symbols are given in these operating Safety symbols are given in these operating instructions. Non compliance with these would instructions. Non compliance with these would affect safety and are identified by the following affect safety and are identified by the following symbol

symbol

Danger symbol as per DIN 4844-W9 Danger symbol as per DIN 4844-W9

(ISO 3864 - B.3.1) (ISO 3864 - B.3.1)

Or in case of danger of electric current with: Or in case of danger of electric current with:

Danger symbol as per DIN 4844 W-8 Danger symbol as per DIN 4844 W-8

(ISO 3864 - B.3.6) (ISO 3864 - B.3.6) The word The word ATTENTION ATTENTION

identifies those safety regulations where identifies those safety regulations where non-compliance may pose a danger to the pump and compliance may pose a danger to the pump and its function.

its function. It is It is imperative that imperative that the appropriatethe appropriate safety information is attached to the pump/pump safety information is attached to the pump/pump set, for example:

set, for example:

•• an an arrow arrow indicating indicating the the direction direction of of rotationrotation

•• symbols symbols indicating indicating fluid fluid connectionsconnections

•• the the identification identification plateplate

and that these are kept legible. and that these are kept legible.

1.

1.2

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personnel

The personnel responsible for operation,

maintenance, inspection and assembly must be maintenance, inspection and assembly must be adequately qualified. The scope of responsibility adequately qualified. The scope of responsibility and supervision of the personnel must be exactly and supervision of the personnel must be exactly defined by plant management. If the staff do not defined by plant management. If the staff do not have the necessary knowledge, they must be have the necessary knowledge, they must be trained and instructed. This task may be trained and instructed. This task may be performed by the machine manufacturer or performed by the machine manufacturer or supplier on behalf of the plant management. supplier on behalf of the plant management. Moreover, plant management must ensure that Moreover, plant management must ensure that the contents of the operation instructions are fully the contents of the operation instructions are fully understood by plant operators and other relevant understood by plant operators and other relevant personnel such as maintenance staff.

personnel such as maintenance staff.

1 1..3

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compliance with safety

instructions

Non compliance with the safety instructions may Non compliance with the safety instructions may result in risk to personnel as well as to the result in risk to personnel as well as to the environment and the pump/pump set and result in environment and the pump/pump set and result in the loss of any right to claim damages.

the loss of any right to claim damages.

For example, non-compliance may result from, or For example, non-compliance may result from, or lead to, the following:

lead to, the following:

•• failure failure of of important important functions functions of of the the pump/pumppump/pump set/plant

set/plant

•• failure failure of of specified specified procedures procedures of of maintenancemaintenance and repair

and repair

•• exposure of exposure of people to people to electrical, mechanicalelectrical, mechanical and chemical hazards

and chemical hazards

•• danger danger to to the the environment environment owing owing to to hazardoushazardous substances being released.

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relating to safety at work

When operating the pump the safety instructions When operating the pump the safety instructions contained in this manual, the relevant national contained in this manual, the relevant national accident prevention regulations and any other accident prevention regulations and any other service and safety instructions issued by plant service and safety instructions issued by plant management must be observed.

management must be observed.

1.

1.5

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•• If high If high or low or low temperature pump/pump settemperature pump/pump set components involve hazards, steps must be components involve hazards, steps must be taken to avoid accidental contact.

taken to avoid accidental contact.

•• Guards for Guards for moving moving parts (e.g. parts (e.g. couplings) mustcouplings) must not be removed from the pump/pump set while not be removed from the pump/pump set while in operation.

in operation.

•• Any leakage of Any leakage of hazardous (e.g. explosive,hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must toxic, hot) fluids (e.g. from the shaft seal) must be drained safely so as to prevent any risk to be drained safely so as to prevent any risk to

persons or the environment. Statutory

regulations are to be complied with. regulations are to be complied with.

•• Hazards from Hazards from electricity are electricity are to be to be avoided byavoided by the user (see for example the the user (see for example the VDE-specifications and the bye-laws of the local specifications and the bye-laws of the local power supply utilities).

power supply utilities).

1.

1.6

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maintenance, inspection and

assembly work

It is the plant manegement’s responsibility to It is the plant manegement’s responsibility to ensure that all maintenance, inspection and ensure that all maintenance, inspection and assembly work is performed by authorized assembly work is performed by authorized personnel who have adequately familiarised personnel who have adequately familiarised themselves with the subject matter by studying themselves with the subject matter by studying this manual in detail.

this manual in detail. Any work

Any work on the on the machine must machine must only be only be performedperformed when it is at a standstill. It is imperative that the when it is at a standstill. It is imperative that the procedure for shutting down the machine procedure for shutting down the machine described in this manual is followed.

described in this manual is followed.

Pumps and pump sets, which convey hazardous Pumps and pump sets, which convey hazardous media, must be decontaminated.

media, must be decontaminated.

On completion of the work all safety and On completion of the work all safety and protective guards must be re-installed and made protective guards must be re-installed and made

operative again. Prior to re-starting the machine, operative again. Prior to re-starting the machine, the instructions listed under “first commissioning” the instructions listed under “first commissioning” are to be observed.

are to be observed.

1.7

1.7 Safety

Safety instructions

instructions for

for the

the use

use in

in

areas with explosion hazard

In this section information is given for operation in In this section information is given for operation in areas where an explosion hazard exists.

areas where an explosion hazard exists.

1.

1.7.

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If the pump is combined with other mechanical or If the pump is combined with other mechanical or electrical components in one set, the category of electrical components in one set, the category of the complete unit will correspond, based upon the the complete unit will correspond, based upon the Directive 94/9/EC, only to that category with which Directive 94/9/EC, only to that category with which all of its components comply.

all of its components comply. Note:

Note:

These comments are of particular importance These comments are of particular importance when pumps, which conform to a given category when pumps, which conform to a given category of Directive 94/9/EC, are powered by a driver of Directive 94/9/EC, are powered by a driver which is not in the same category.

which is not in the same category. Although

Although the the pump pump may may bear bear the the Ex Ex sign, sign, the the setset should not be used in areas with an explosion should not be used in areas with an explosion hazard when the motor is not classified for this hazard when the motor is not classified for this application.

application.

This means that plant management personnel This means that plant management personnel should always check that all elements of the set should always check that all elements of the set comply with the Directive 94/9/EC.

comply with the Directive 94/9/EC.

1.7.2 1.7.2 Execution

Execution of

of coupling

coupling guards

guards

Coupling guards

Coupling guards that are to be that are to be used in areas withused in areas with an explosion hazard, have to fulfil one of the an explosion hazard, have to fulfil one of the following criteria:

following criteria:

•• consist consist of of non-sparking non-sparking material, material, e.g. e.g. brass.brass.

••

if they consist of sparking material, e.g. steelif they consist of sparking material, e.g. steel

sheet, they must be designed in such a way sheet, they must be designed in such a way that the rotating parts will not come in contact that the rotating parts will not come in contact with any part of the guard if errors, that could with any part of the guard if errors, that could be foreseen, are committed by the user, e.g if be foreseen, are committed by the user, e.g if a person steps on the guard.

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parameters

When using pumps in areas with an explosion When using pumps in areas with an explosion risk, the operator must check the following risk, the operator must check the following parameters regularly:

parameters regularly:

•• leakage leakage of of shaft shaft sealsseals

•• bearing bearing temperaturetemperature

•• that the that the pump is pump is always filalways filled with led with liquid duringliquid during operation

operation

•• that that the the pump pump does does not not operate operate against against aa closed valve for any length of time. closed valve for any length of time.

The operator must ensure that pumps, which The operator must ensure that pumps, which show evidence of abnormal operation, are show evidence of abnormal operation, are

switched off and not started again until the cause switched off and not started again until the cause of the abnormal operation has been eliminated. of the abnormal operation has been eliminated.

1.7

1.7.4 .4 Avo

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In areas with a risk of explosion the operator must In areas with a risk of explosion the operator must ensure that the pumps and or pump set is not ensure that the pumps and or pump set is not subjected to external impacts e.g by heavy subjected to external impacts e.g by heavy objects.

objects.

1.

1.8

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production of spare parts

Modifications may be made to the pump/pump set Modifications may be made to the pump/pump set only after consultation with,and written approval only after consultation with,and written approval from, the manufacturer. Using spare parts and from, the manufacturer. Using spare parts and accessories authorized by the manufacturer are in accessories authorized by the manufacturer are in the interests of safety. Use of other parts may the interests of safety. Use of other parts may exempt the manufacturer from any liability.

exempt the manufacturer from any liability.

1.

1.9

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The reliability of the pump/pump set can only be The reliability of the pump/pump set can only be guaranteed if it is used in the manner intended guaranteed if it is used in the manner intended and in accordance with the instructions of this and in accordance with the instructions of this manual. The specified limit values must under no manual. The specified limit values must under no circumstances be exceeded.

circumstances be exceeded.

1.

1.10 10 Wa

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Sterling Fluid Systems guarantee satisfactory Sterling Fluid Systems guarantee satisfactory operation if:

operation if:

•• the pump is installed and operated in the pump is installed and operated in compliance with these instructions and in compliance with these instructions and in operating conditions approved by Sterling Fluid operating conditions approved by Sterling Fluid Systems

Systems

•• modifications modifications are are only only undertaken undertaken with with SterlingSterling Fluid Systems’ written agreement.

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IInntteennddeed d aapppplliiccaattiioonn PPaagge e 1 1 oof f 33 CChhaapptteer r 22

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The pump is to be used only for the operating The pump is to be used only for the operating conditions stated by the customer and confirmed conditions stated by the customer and confirmed by the supplier. Guarantee is assumed within the by the supplier. Guarantee is assumed within the scope of the

scope of the Sterling Fluid SystemsSterling Fluid Systems conditionsconditions of sale.

of sale.

Appropriate application

Appropriate application and operating conditionsand operating conditions are contained in the attached data sheets.

are contained in the attached data sheets.

2 2..1

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•• The The pump pump may may only only be be used used for for thethe

application(s) stated. Otherwise hazards for application(s) stated. Otherwise hazards for people and environment may arise.

people and environment may arise.

•• Do Do not not exceed exceed fluid fluid density density stated.stated.

Otherwise, there is a the danger of motor Otherwise, there is a the danger of motor overload.

overload.

•• The The pump pump must must not not be be operated operated beyond beyond itsits characteristic curve – otherwise there is a characteristic curve – otherwise there is a danger of cavitation and motor damage. danger of cavitation and motor damage.

2 2..2

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The accessories included in the scope of supply The accessories included in the scope of supply are indicated in the delivery note or in the order are indicated in the delivery note or in the order confirmation. The corresponding operating and confirmation. The corresponding operating and installation instructions are also indicated in the installation instructions are also indicated in the Annex relating to accessories.

Annex relating to accessories.

If it is intended to mount other accessories on the If it is intended to mount other accessories on the pump or on the pump set, please inform the pump or on the pump set, please inform the manufacturer in advance in order that appropriate manufacturer in advance in order that appropriate technical advice can be given.

technical advice can be given.

2 2..3

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operation

ZLND pumps are horizontal, single-stage volute ZLND pumps are horizontal, single-stage volute casing pumps with nominal outputs and flange casing pumps with nominal outputs and flange dimensions meeting EN 733 / DIN 24255. Their dimensions meeting EN 733 / DIN 24255. Their back pull out construction allows the disassembly back pull out construction allows the disassembly of the complete bearing unit towards the drive of the complete bearing unit towards the drive side without removing the pump casing from the side without removing the pump casing from the pipework.

pipework.

ZLND pumps are preferably used when pure or ZLND pumps are preferably used when pure or turbid liquids, not containing solid particles, are to turbid liquids, not containing solid particles, are to be handled.

be handled.

Impurities up to a grain size of 3 mm can be Impurities up to a grain size of 3 mm can be handled, but shorten the service life.

handled, but shorten the service life.

ATTENTION

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Intended application Page 2 of 3 Chapter 2

For local contact details: www. sterlingfluidsystems.com

In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its

products at any time without prior notice

� (Sterling Fluid Systems BV) 2001

2.4 Description

Type

size Hydraulic + Bearing Shaft seal Material design Casing gasket

ZLND 32125

to 300500

A• First hydraulic B• Second hydraulic D• Double volute •B Two ball bearings greased for life (2Z) • C Two ball bearings oil lubricated

• 2 Oil lubrication configurations with CLO •S One double row

angular contact bearing plus one ball bearing, grease lubricated

•T One double row ball bearing plus ball bearing, oil lubricated

041: Self-sealed, uncooled packing rings

052: Uncooled packing rings, external seal liquid BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton

0B: Cast iron GG25 0C: Cast iron GG25, Bronze G-CuSn10 impeller 0E: Cast iron GG25, Stainless steel 1.4408 imp. 4B: Stainless steel 1.4408 2: confined flat gasket of EWP 210 material 4: confined flat gasket of PTFE A or B 32160, 32200 A 32125 to 200315, 250315 D 200400 to 300500 Alternatively B, C, 2, S or T Alternatively 041,052,BJ3,C23,AF3,AX3,AY3,A93,BJS,C2S, AFS,AXS,AYS,A9S,BJJ,C2J,AFK,AXK,AYK,A9K Alternatively 0B, 0C, 0E, 4B Alternatively 2, 4

Codes AX3, AXS, AXK: are equivalent to AF3, AFS, AFK respectively plus quench Codes AY3, AYS, AYK: are equivalent to AF3, AFS, AFK respectively plus heating

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Intended application Page 3 of 3 Chapter 2

Example of a pump designation:

1-3 4 5-7 8-10 11 12 13-15 16-17 18

ZLND 125 250 A C 041 OB 2

2.5 Shaft sealing

Depending on the application, different shaft sealing executions are offered (see 2.4)

• a stuffing box with lantern ring (executions

041, 052, and optionally 051) or mechanical seals according to DIN 24960 are utilised in the following cases:

• if the pump draws from a suction line,

• if the pump is fed by a feed line with a

pressure of less than 0.5 bar or

• if the pumped liquid is at or near its boiling

point.

Provision of the sealing liquid is as follows:

• 041: Internal self sealing ISO 5199 plan 01

• 052: External self sealing ISO 5199 plan 08

• 051: External self sealing ISO 5199 plan 09

• Mechanical seal: ISO 5199 plan 02. API plan

11

• Mechanical seal execution plus external

flushing: ISO 5199 plan 08, API plan 32 Mechanical seal execution plus quench: ISO 5199 plan 09. API plan 62.

Section 2.4 does not contain the codes for all variations of mechanical seals. Where the code is not included or replaced by QQQ, consult the relevant data sheet of the mechanical seal

supplier (e.g. special execution of the mechanical sealing in a back to back position).

ATTENTION

Casing gasket Construction Shaft sealing Bearings:B,C,S,T or 2 Impeller size Nominal discharge Pump series Hydraulic: A/B/D

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Planning the installation Page 1 of 2 Chapter 3

products at any time without prior notice.

3.0 Planning the installation

3.1 Piping system

• Note the arrows on the pump branches

indicating the direction of flow.

• Choose nominal widths of the pipelines

according to the nominal widths of the pump branches or larger ones with the

corresponding reductions.

• Flange sealing must not protrude on the

inside.

• Ensure that the pipework is clean before

installing of the pump.

• Support the pipework in order to avoid

distortions at the pump components (risk of damage to pump components)

• Avoid abrupt changes of cross section and

direction.

• Where different diameter pipework is to be

used, connection should be by eccentric transition pieces. This will avoid the formation of air pockets in the pipework.

• For difficult pumping on the suction side, to

stabilise the flow, a pipe length 15 times the diameter of the suction branch should be installed before the suction branch.

• The flow rate in the suction line or inflow line,

must not exceed 2 - 3 m/s.

3.1.1 Suction line / inflow line

See the sketches below for the optimum layout of pump installation for flow and suction lift

operation.

positive suction head operation suction lift operation

Ensure that air pockets cannot be created.

Unequal nominal widths of the suction branch and suction line must be compensated by eccentric transition pieces.

Flow straightener

Connection of eccentric pipe transitions It is recommended that a filter is installed in front of the pump with a filter surface of at least 3 times the pipe cross section (approx. 100 meshes/cm²). The suction opening of the suction line should be well below the liquid level, and a strainer should be used.

The strainer must be far enough from the bottom to avoid excessive inlet losses, which could impair pumping performance. It is advisable to check that there is no leakage. ATTENTION 4 4 3 6 1 2 7

1 Eccentric reducer ( suction line ) or concentric reducer ( feed line ) 2 Shut-off valve

3 Suction line 4 Bend

5 Foot valve with suction strainer 6 Check valve

7 Regulating valve 5

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Planning the installation Page 2 of 2 Chapter 3

A shut-off valve should be installed in the feed line. It must be closed for maintenance work. It should be installed in order to avoid air pockets forming in the spindle cap, i.e. with the spindle in a horizontal position or pointing vertically

downward.

3.1.2 Discharge line

For flow regulation, a valve must be installed behind the pump. If non-return valves are used, they should close smoothly. Pressure shocks must be avoided.

3.1.3 Inlet and outlet connections

The various connecting points are shows in the drawings. (See Annex, Chapter 10, point 10.1).

3.1.4 Pressure control

For consistent control of pressure, it is advisable to install in the pipework a measuring point in front of, and behind the pump.

3.2 Electrical connections

For the drive motor a mains connection is required which complies with the European Regulations and Directives for the Standards in Industry and with the instructions of the local power supply utilities of the country concerned.

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Unpacking, storage, transport Page 1 of 2 Chapter 4

For local contact details: www.sterlingfluidsystems.com

4. Unpacking, storage, handling

4.1 Safety measures

• Never stay below the suspended load.

• Keep a safe distance while the load is being

transported.

• Use only approved lifting appliances, which

are in good condition.

• Adjust the length of the lifting appliances in

such a way that the pump and/ or the pump set, is suspended horizontally.

• Do not use the eyebolts on the pump

components for lifting the assembled pump or the complete set.

• Do not remove documents, which are

attached to the pump.

• Do not remove the protection covers from the

pump suction/discharge. Otherwise, there may be a risk of contamination.

4.2 Unpacking

Before unpacking, a visual check of the packing is recommended. If transport damage is visible, the extent should be noted on the receipt or on the delivery note. Potential claims must be lodged immediately with the carriers or the insurance company.

4.3 Interim storage

If the pump or the pump unit is not installed immediately after delivery, it must be stored free from vibration in a dry room.

4.4 Handling

The pump or pump set must be lifted and handled as shown in the following sketches.

Pump without motor

Pump set

4.5 Protection against corrosion

In general, a protective coating is only applied to the following executions: OB, OC and OE.

4.5.1 Removal of protective coating

To remove the protective coating, the pump should be filled and drained several times using appropriate agents, e.g. solvent naphtha, diesel oil or alkaline detergent. Flush with water, if necessary.

The pump must be installed and started up immediately afterwards.

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Unpacking, storage, transport Page 2 of 2 Chapter 4

4.5.2 Renewing corrosion protection

If the pump has been supplied with a protective coating and has to be stored, a new protective coating should be applied after six months.

For suitable protective coatings, contact Sterling

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Installing the pump Page 1 of 3 Chapter 5

5. Installing the pump

5.1 Requirements

The pump and the pump set, must have been unpacked and handled as described in Chapter 4.

5.2 Use of trained staff

Only appropriately trained staff must undertake the work described in this chapter.

5.3 Safety measures

• Connect the pipework carefully to prevent the

pumped liquid escaping during operation and endangering operating personnel.

• Ensure that the suction or inflow line, and the

discharge line are closed by valves.

• Ensure that all electrical connections are

“dead”. Otherwise, there is a risk of electric shock.

• Pay attention to relevant internal plant

regulations.

• Avoid accidental contacts with hot

components.

ATTENTION

• Remove the protective coating by following

the instructions of Chapter 4. Otherwise there is a danger of contamination .

5.4 General information

5.4.1 Assembly tools

Special tools are not required for assembly and installation.

5.4.2 Permissible ambient conditions

The ambient temperature can be from -20 °C to +60 °C. The atmospheric humidity should be as low as possible in order to avoid corrosion.

5.4.3 Base, foundation

The pump must be installed on a flat floor or foundation free from vibration. In case of doubt use vibration dampening feet.

The pump set must be correctly mounted on the foundations. To avoid distortion of the pump set and/or the foundation, parallel shims must be used between the base plate and foundation. Prior to installing, checks should be made with regard to:

- possible damage to the pump or the pump set that may occur in transit

- ease of running ( check that the shaft is free to rotate by hand )

- the foundation dimensions.

The following preparatory work must be carried out before to placing the pump:

- roughen and clean foundation surface - remove shuttering/cores from the anchor holes

- blow the anchor holes clean

- check the position and dimensions of the anchor holes against the arrangement drawing.

5.4.4 Installation of the set

The complete set mounted on the base plate must be placed on the foundation with its foundation (rag) bolts hanging below the baseplate.

5.4.5 Space required

The space required for the pump set is set out in the foundation plan or installation drawing.

Ensure easy access to the shut-off and regulation valves as well as to any measuring instruments.

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5.4.6 Position

In principle the ZLND pumps are installed horizontally.

5.5 Motor

Before assembly check the direction of rotation of the motor (indicated by an arrow on the pump casing). If this is not possible the direction of rotation of the complete unit can only be checked only if the pump is filled.

In any event, the operating instructions of the motor manufacturer must be followed, since the motor is generally incorporated by STERLING FLUID SYSTEMS into the pump set.

5.6 Alignment of the set

Place shims under the base plate on both sides of the foundation bolts, 10 mm from the base plate edge. Use a spirit level to align the set.

If necessary, place shims between the foundation bolts to prevent the base plate from sagging. Care should be taken to minimize distortion of the base plate during installation. The location of the driver must not be higher than that of the pump. The

max. deviation from the shaft centre line is ± 0.1

mm.

The foundation bolts should be embedded in concrete using quick-setting grout.

5.7 Coupling

Install the coupling avoiding hard blows, if necessary in warm condition. Arrange the pump and motor on a level base. The shaft ends must be aligned exactly. The distance between each

half of the N-EUPEX B ( FLENDER ) coupling must be 2 - 3 mm (see fig.).

If other manufacturer’s couplings are used, follow the manufacturer’s instructions. After installation on the foundation and connecting the pipework, the coupling alignment must be checked and re-aligned, if necessary. Moreover, after reaching the operating temperature the alignment of the

coupling must be checked again.

The coupling requires a guard that meets DIN 31001 in order to avoid accidental contact during operation.

In any event, the operating instructions of the coupling manufacturer must be followed, since the

coupling is a component incorporated by Sterling

Fluid Systems.

ruler

The following is required a = a1 and b = b1

5.8 Checking before installation

Before installing the pump on the plant, the following points must be checked:

1. is the electrical current to the drive motor switched off?

2. are suction and discharge lines emptied and closed by valves?

3. Is it possible to rotate the pump easily by hand (for this purpose turn the fan of the motor or the coupling)?

4. Have the latest internal/plant instructions been observed?.

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5.9 Mounting the pump and

installation into pipework

The following instructions must be carried out: 1. remove the protective covers from the pump

flanges and the auxiliary pipework connections.

2. correctly insert the flange seals. 3. connect the suction or feed line. 4. connect the discharge line

The pump must be aligned with the pipework. The pipework must be supported so that distortion cannot occur when connecting the pump.

5.10 Final work

The following final steps must be undertaken: 1. check the tightness of the connecting flanges. 2. check for easy running of the pump (for that

purpose turn the motor fan or the coupling). 3. check the coupling alignment.

4. install the coupling guard.

5.11 Hydrostatic pressure test

When subjecting the piping system to a

hydrostatic pressure test, exclude the pump from the pressure test.

If it is not possible to test the pipework without the pump, ensure that foreign material cannot enter the pump.

• The max. permissible pressure for a

pressure test is 1.3 times the nominal

pump pressure.

• The nominal pump pressure is indicated

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Starp-up and shut-down Page 1 of 3 Chapter 6

� (Sterling Fluid Systems) 2001

6. Start-up and shut-down

operations

6.1 Requirements

The pump or the pump set, must be installed acc. to the instructions of Chapter 5.

6.2 Use of trained staff

Only appropriately trained staff must carry out the work described in this chapter.

6.3 Safety measures

• Electrical connections must be made

according to the European Regulations and Directives for the Standards in Industry and in compliance with the instructions of the local power supply utilities of the country

concerned.

• Only appropriately authorized personnel may

carry out this work.

ATTENTION

• Fill the pump correctly; otherwise the shaft

seal could be destroyed.

• Fill the supply lines correctly.

• Check the direction of rotation only when the

pump is filled.

• Fill the pump slowly if hot media are being

pumped in order to avoid distortions or heat shock.

• When handling explosive, toxic, hot,

crystalline or corrosive media, ensure that there is no risk to people or the environment.

• Control the output at constant speed at the

discharge side only. The valve at the suction side must always be completely open during operation to avoid the risk of cavitation.

• If there is no bypass line, do not run the

pump with the control valve closed for any length of time.

• Safety measures should be taken by the

end user to ensure (for example by means of a relief valve) that the

permissible pump casing pressure is not exceeded during operation

• Repeat the alignment of the coupling at

operating temperature. Re-align the pump or the motor, if necessary.

6.4 Electrical connection

The motor must be connected at set out in the circuit diagram in the terminal box.

6.5 Checks before switching-on

Before switching on the pump unit, the following points should be checked:

1. is all pipework connected and are the unions tight?

2. is the pump including the pipework filled properly?

3. is the shut-off valve in the discharge line closed?

4. is the shut-off valve in the suction line completely opened?

5. is the motor ready for operation? 6. is the direction of rotation of the motor

correct?

(check by running the motor for a short time) 7. is the coupling aligned exactly?

8. has the shaft seal been installed?

9. are the supply lines, if any, to the shaft seal open?

10. in the case of oil lubrication - has the bearing housing been correctly filled with oil?

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� (Sterling Fluid Systems) 2001

6.6 Start-up operation

For starting proceed as follows:

1. open fully the valve on the suction side 2. close the valve on the discharge side 3. switch on the motor

4. check the pressure gauges at the pressure measuring points

If the pumping pressure does not increase

consistently with increasing speed, switch off the motor again and vent the pump one more.

5. After reaching operating speed, regulate the operating point of the pump by adjusting the valve in the discharge line (see technical data for permissible range of operation).

6. For “running in” the packing, the gland should be tightened only slightly (even in the case of considerable leakage initially). After approx. 30 minutes tighten the gland to such an extent that it leaks only slightly. Check it several times, until leakage from the packing is about 20 to 40 drops a minute. In extreme operating conditions and high temperatures this rate may be higher.

Pumping against a closed valve in the discharge line is permitted only if a minimum output via a bypass line is guaranteed.

6.7 Switching frequency

Size Permissible number of starts equally spaced per hour 32-125, 32-160, 32-200, 32-250, 40-125, 40-160, 40-200, 40-250, 50-125, 50-160, 50-200, 65-125, 65-160, 65-200, 65-250, 80-160, 80-200, 80-250,100-160, 100-200, 100-250, 100-315, 125-200, 150-200, 150-250 15 40-315, 50-250, 50-315, 65-315, 80-315, 80-400, 100-400, 125-250, 125-315, 125-400, 150-315, 150-400, 150-500, 200-250, 200-315, 200-400, 200-500, 250-300, 250-315, 250-400, 250-500, 300-400, 300-500 8

6.8 Special instructions

During operation the following points must be observed:

- control the speed and the delivery head - ensure that the pump runs without vibration - control the liquid level in the suction line and/or

inflow tank

- control the bearing temperature (max. temperature 100 °C)

- control the pressure in the supply lines according to the following limits:

External flushing:

• Impeller size 125

Buffer pressure = pW + 0,5 bar

• Rest of impeller sizes:

Buffer pressure = pW + H + 2,5 bar

• Flow = 0,1 – 0,2 m 3/h

pW = suction pressure, in bar

H = differential pressure of pump, in bar Quench

Maximum pressure = 4 bar Heating

Maximum pressure = 4 bar, with water steam to 140 C

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� (Sterling Fluid Systems) 2001 - shaft seal

Executions with stuffing box:

For correct operation of the shaft seal a slight leakage (20 - 40 drops per minute) is essential. If the leakage is reduced too much by retightening the packing, it will be destroyed.

If the pump is equipped with code 052 or code 051, the supply lines to the stuffing box have to be open before the pump is started.

Executions with mechanical seal:

During running-in slight leakage may occur. If the pump is equipped with an external flush, quench or heating, the flush, quench or heating supply has to be switched on before the pump is started. The mechanical seal must be allowed to cool before the next re-start.

ATTENTION

For executions with stuffing box: If the leakage increases considerably and cannot be adjusted by retightening the gland, the packing is worn and must be replaced by a new one.

For executions with mechanical seal: If the initial leakage does not disappear within 5 minutes of operation, stop the pump, dismantle the seal and check for damage of the seal faces and auxiliary sealing.

6.9 Shutting-down

Before shutting down close the valve on the discharge side.

After shutting down, all valves may be closed. The valves of the auxiliary pipework connections, (quench, heating, external flush, code 052, code 051), have to be closed in the last place.

If there is a risk of very low ambient temperatures, remove the pump and then drain it using the threaded plug 90.30.

When handling explosive, toxic, hot, crystalline or corrosive media, ensure that people and the environment are not endangered. Even if the pump has been drained using the threaded plug 90.30, residues can remain in the pump. For transport, the pump must be free from any

dangerous material. In case of extended periods out of service, protect the pump against corrosion.

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Maintenance, dismantling, assembly Page 1 of 10 Chapter 7

7. Maintenance, dismantling,

assembly

7.1 Requirements

The pump or the pump set must have been shut down in the manner described in Chapter 6.

7.2 Use of trained staff

Only appropriately trained and skilled staff should undertake the work described in this chapter. Only authorised personnel must undertake

electrical work associated with maintenance of the pump/pump set.

7.3 Safety measures

• For explosive, toxic, hot, crystalline as well as

different pumping media ensure that people and the environment are not endangered.

• Flush the pump with clean liquid before

dismantling.

• The working place for disassembly or

assembly must be clean.

• Before reinstallation, the pump must be free of

any dangerous material.

7.4 Maintenance and inspection

The pump requires only limited maintenance.

7.4.1 Bearing with grease lubrication

The pumps with bearing brackets 25, 35 and 45 use an antifriction bearing, lubricated for service life, on the drive side and on the pump side. The pumps with bearing brackets 55 and 65 must be greased through grease nipples 63.60.

Grease lubrication:

The bearings receive their first engreasing at the supplier plant.

Grease amount per ball bearing:

bearing housing 55: (shaft end diameter at the

driving side 50 mm) 30 gramme

bearing housing 65: (shaft end diameter at the

driving side 60 mm) 40 gramme

lubrication low activity middle and high intervals activity

for grease n ≤ 1500 1/min 1500 < n ≤ 3000 1/min lubrication every 5000 hours every 2500 hours

at the latest after 12 months

After about 10000 hours of activity or the latest after two years, the bearings have to be disassembled, washed and refilled with grease. Under extremely unfavourable circumstances (wet or dusty environment or high temperatures of the environment) the lubrication intervals have to be chosen considerably shorter.

For renewing or adding lubrication grease, only lithium soap bearing grease have to be utilised (e.g. Mobilux 2, Shell Aero Grease 16, Esso Unirex N3).

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7.4.2 Bearing with oil lubrication

The pump is supplied empty (no oil). Before the initial start up, pour oil into the oil inlet hole until the oil level reaches the mark on the dipstick.

Oil drainage Oil filling

Constant level oiler

As an additional accessory, it is possible to connect a constant level oiler. In this case, the bearing support must be filled with oil through the oil inlet hole, until the oil is visible in the screw-in elbow, the oil reservoir having been removed. Subsequently the oil reservoir should be filled with oil and put into its correct position.

The bearing housing will be supplied with oil from the constant level oiler with the correct amount as long as there is oil in the reservoir.

See sketch of oiling system below 1. Oil reservoir

2. Screw-in elbow 3. Fill in oil here

4. Never fill with oil here, always use the oil inlet hole.

Oil change intervals

If the bearings are new, change the oil after about 200 hours and subsequently annually. These intervals only apply if the bearing temperature does not exceed 50 ºC. If the bearing temperature during operation is above 50 ºC but below 80 ºC and/or if there is danger of contamination, the oil should be renewed about every six months. Oil properties:

t

Oil quantities:

BearingBracket Oil ( litre )

25 0.22

35 0.38

45 0.57

55 1.50

65 2.00

The lubricating oil must be extremely pure, resistant to ageing, must have good viscosity-temperature behaviour, good water separating properties and corrosion protection.

ATTENTION Type of lubrication DIN 51517 Kinematic viscocity at 50ºC in mm2/s Neutralisation figure Ash ( as Ash Oxide ) Water content Suitable motor oil

Operating temp. of bearing up to 80ºC n≤1500 rpm n>1500 rpm Ambient temp. < 0ºC CL22 CL46 CL68 61.2 to 74.8 41.8 to 50.8 19.8 to 24.2 Maximum 0.15 mg KOH/g Maximum 0.02% weight Maximum 0.1% weight

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7.4.3 Stuffing box

If leakage makes it necessary, the packing rings should be retightened. After extended periods and frequent retightening, the packing rings gradually lose their shape and elasticity. We therefore recommend replacing the packing material at regular intervals. As a typical indication, after an operating time of approx. 2500 hours or when the gland has been retightened by approximately half the width of a packing ring.

Repacking

When repacking, the stuffing box rings used up, as well as, the lantern ring are to be removed carefully from the shaft seal chamber. The shaft and shaft protection sleeve must not be

damaged.

Otherwise perfect sealing cannot be guaranteed and the shaft sleeve would then need replacing. If the pump is installed, cut soft packing rings diagonally, bend them in a spiral shape, position them on the pump shaft and bend them carefully into a ring form.

Push the packing rings as well as the lantern ring by means of the gland into the shaft seal

chamber. The cut joints should be staggered by 180°. Tighten the nuts at the gland steadily until resistance is felt when rotating the pump shaft by hand. Remove the gland again and fasten the nuts slightly. If the pump is removed in order to carry out repacking, it is useful to push the packing rings in the delivered condition, that means closed over the shaft sleeve.

Lantern ring

Packing rings

7.4.4 Mechanical seal

The mechanical seal should have little or no visible leakage. Where there is considerable leakage, check the mechanical seal. To do this, it is necessary to dismantle the rotating part(s).

50.40

16.10 43.30

21.10

7.4.5 Drive motor

The drive motor must be maintained according to the instructions of the manufacturer.

7.5 Dismantling

7.5.1 Preparation for the dismantling

Proceed as follows:

• disconnect power to the motor

• drain the plant, at least within the pump area,

i.e. between the valves on the suction- and discharge side

• if necessary, disconnect any measuring

probes or control devices and remove them

• drain liquid from the pump by means of the

drain plug

• dismantle shaft seal supply lines, if any.

If oil lubricated bearings are used, drain the oil from the bearing housing.

• the pump casing must not be detached from

the pipe union

• remove motor mounting bolts and move the

motor so that there is sufficient space to remove the back pull out unit. When using a spacer coupling repositioning of the motor is not necessary.

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• dismantle guard coupling, pump feet and

coupling.

7.5.2 Replacement parts

The item numbers necessary for ordering spare parts are provided in the component parts list in the Annex.

7.5.3 Dismantling the pump

• For executions with bearing housings 25,35

and 45.

90.10 40.00

10.20

90.30

1. Mark the position of the parts in relation to each other by a coloured pencil or a scribing tool.

2. Remove the hexagonal screws 90.10.

3. Remove the back pull out unit from the volute casing 10.20. .1 .1 90.13 68.10 . . . 1

4. Remove flat gasket 40.00.

5. Remove hexagonal screws 90.13 and remove protective screen 68.10.

6. Loosen impeller nut 92.20.

7. Remove impeller 23.00 and key 94.01.

Design with stuffing box

1. Remove the Allen head screws 91.40 and detach the casing cover 16.10.

1. Detach hexagonal nuts 92.01 and studs 90.21.

2. Loosen hexagonal screws 90.23 and detach packing housing 45.10 and gland 45.20 with the pressure ring 45.70.

3. Detach packing ring 46.10 and lantern ring 45.80.

4. Detach the shaft sleeve 52.40.

. . . . . 92.01 . . 45.20 90.21 55.40 92.01 46.10 45.80

Design with a mechanical seal 1. Detach the distance ring 50.40.

2. Remove the rotating part of the mechanical seal 43.30.

3. Remove the Allen head screws 91.40 and detach the casing cover 16.10.

.

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Design with quench (AX3, AXS, AXK)

Detach the cover 16.50, O-ring 41.23 and lip seals 42.11.

.

16.10 . .

Design with heating (AY3, AYS, AYK) Detach the cover 16.50, O-rings 41.22 and 41.23.

16.10 41.22 41.23 16. 50

4. Remove the static part of the mechanical seal 43.30 and pin 56.10.

56 .10

43.30 16.10

Bearing design B, C or 2 :

1. Release hexagonal screws 90.11, remove V-seal 42.20 in case of grease lubrication, dismantle bearing cover 36.00 and flat gasket 40.02. Remove the lip seal 42.10 if pump is oil lubricated.

2. Release the thrower 50.70

3. Undo hexagonal screws 90.12, remove washer 93.01 and dismantle the pump foot 18.30.

4. For oil lubricated pumps, remove the oil dip stick 91.60 and remove the constant level oiler (CLO) 63.80 if any.

42.10 91.60 40.02 42.10 90.11 42.20 90.12 93.01 18.30 33.00 42.20 36.00 0.70 94.00

5. Pull out complete shaft 21.00 with both ball bearings 32.10 and support washers for ball bearing 50.50 if any.

6. Remove ball bearings 32.10 and support washers for ball bearing 50.50.

21.00 50.50 32.10 50.50

2.10

• For executions with bearing housings 55 and

65:

10.20 90.20 40.00 92.00 90.80 92.06

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1. Mark the position of all parts with a colour pen or scribing tool in order to be able to

reassemble the pump correctly. 2. Unscrew hexagonal nuts 92.00.

3. Withdraw pull out assembly from the volute casing 10.20. Withdraw the flat gasket 40.00. The wear ring 50.20, if it is necessary can be removed.

90.22 92.02

16.10 92.20

93.00 40.03 23.00 94.01

4. Loosen impeller nut 92.20 and helicoil 93.00. 5. Remove impeller 23.00, key 94.01 and flat

gasket 40.03. Unscrew hexagonal nuts 92.02 and detach the casing cover 16.10.

Design with a stuffing box:

1. Remove hexagonal nuts 92.01 and studs 90.21.

2. Detach the gland 45.20, the packing ring 46.10 and the lantern ring 45.80.

3. Detach shaft sleeve 52.40 and flat gasket 40.01.

4. Detach the pin 56.00 and then, the wear ring 50.21 92.01 55.40 90.21 45.80 46.10 16.10 45.20 40.01 52.40 56.00 50.21 90.22

Design with a mechanical seal:

1. Loosen hexagonal screws 90.24 and withdraw the mechanical seal cover 47.10 with the flat gasket 40.06, static part of the mechanical seal 43.30 with pin 56.10.

2. Remove the shaft sleeve 52.30 with the distance ring 50.40, the rotating part of the mechanical seal 43.30 and the flat gasket 40.01.

3. Loosen grub screw 56.00.

4. Detach the pin 56.00 and then, the wear ring 50.21. 50.21 56.00 90.22 56.10 40.01 52.30 50.40 16.10 40.06 47.10 90.24 43.30 Bearing design S or T : 1. Release the thrower 50.70

2. Release hexagonal screws 90.11 and 90.14, dismantle bearing covers 36.00, 36.01 and flat gaskets 40.02. Remove the lip seals 42.10. 3. Release hexagonal screws 90.12, remove

washer 93.01 and dismantle the pump foot 18.30.

4. For oil lubricated pumps, remove the plug 67.20 and the constant level oiler (CLO) 63.80 if any. 90.12 93.01 18.30 93.21 40.02 36.00 63.60 94.00 50.70 33.00 42.10 90.11 0.14 36.01 63.60 42.10 40.02

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5. Pull out complete shaft with both ball bearings 32.10 and 32.11 and circlip 93.21.

7.6 Post dismantling activities

7.6.1 Hints for cleaning.

• Clean all parts.

• Clean the clearances and sealing surfaces

with an appropriate liquid.

7.6.2 Points to be checked

The following pump components, if installed, must be checked:

• Mechanical seal : If the running faces are

damaged or worn, replace the mechanical seal.

• Shaft and shaft sleeve : Check the shaft

within the stuffing box. If the shaft has worn badly and is grooved, a new shaft or shaft sleeve should be used.

• Clearances : The difference in diameter

between impeller clearance area and casing or cover clearance area should be 0.3 mm to 0.5 mm. In the case of excessive wear in the clearance area, wear rings must be installed.

• Radial seal ring : If the radial seal ring is

damaged, it must be replaced.

7.7 Assembly

7.7.1 Tightening torque

When tightening the bolts the following torques must be used:

7.7.2 Pump assembly

Proceed as follows:

Bearing design B, C or 2 :

• For executions with bearing housings 25,35

and 45:

1. Prior to installing bearings, the support washer for ball bearing 50.50 must be replaced, (only bearing housing 25). Install ball bearings (use new ball bearings, if necessary). Before installation, the ball bearings must be heated to 80ºC in an oil bath.

(Only bearing design C or 2).

2. For a pump with oil lubrication, using a tool, press lip seal 42.10 in the bearing housing 33.00. When lip seals are used, the lip should point towards the drive end.

21.00 50.50 32.10 50.50

32.10

3. Insert the shaft assembly into the bearing housing from the drive end towards non-drive end. Thread Torque M8 M10 M12 M16 M20 M24 M30 M36 12 Nm 25 Nm 40 Nm 90 Nm 175 Nm 300 Nm 500 Nm 700 Nm 32.11 21.00 93.21 32.10

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4. Attach the bearing cover 36.00, with its radial seal inserted, if it is oil lubricated, and the flat gasket 40.02;( the lip of the radial seal ring should point towards the non drive end). Then fasten hexagonal screws 90.11. In case of grease lubrication, mount the V- seals 42.20 in the shaft and lean one against the bearing housing 33.00. Insert the key 94.00.

5. Insert the oil dip stick 91.60 and the CLO 63.80 if any. 42.10 91.60 40.02 42.10 90.11 42.20 90.12 93.01 18.30 33.00 42.20 36.00 0.70 94.00

6. Fasten pump foot 18.30 and insert the thrower 50.70.

• For executions with stuffing box:

7. Position the shaft sleeve 52.40 on the shaft. 8. Insert the packing housing 45.10 with the

gasket 40.05 in the casing cover 16.10. 9. Install one of the packing rings 46.10 in the

packing housing, the lantern ring 45.80 and then, the remaining packing rings.

10. Fasten hexagonal screws 90.23 , fix the studs 90.21 and hexagonal nuts 92.01.

45.80 46.10 45.20 90.21 55.40 92.01 45.70 90.23 92.01 45.10 40.05 52.40 16.10

11. Finally, install the pressure ring 45.70 and the gland 45.20. Fix the washer 55.40 and the following hexagonal nuts 92.01.

12. Adjust the stuffing box as described in Chapter 7.4.3.

• For executions with mechanical seal:

7. Insert the static part of the mechanical seal 43.30, with the pin 56.10 if any, in the casing cover 16.10.

56 .10

43.30 16.10

Design with quench (AX3, AXS, AXK)

Insert the lip seals 42.11 and the O-ring 41.23 in the cover 16.50.

16 .50 6.10 41.23 42.11

Attach the cover 16.50 and casing cover 16.10.