Installation, Care and Maintenance. Self-priming centrifugal pumps

Transcription

1 Installation, Care and Maintenance Self-priming centrifugal pumps

2 CONTENTS Safety... 2 Warranty... 4 Product description... 4 Transportation and storage... 5 Installation... 5 Operation... 7 Care and Maintenance... 9 Inspection... 9 Replacing worn-out parts Fault tracing Service log SAFETY This manual contains basic information on the installation, operation and maintenance and should be followed carefully. It is essential that these instructions are carefully read before installation or commissioning by both the installation crew as well as those responsible for operation or maintenance. The operating instructions should always be readily available at the location of the unit. This manual provides general information concerning the pumping unit but does not include detailed instructions for the drive units (diesel or electric motor); these instructions can be found on the specific manuals which must be provided with this manual and form an integral part of it. Identification of safety and warning symbols WARNING! General Danger: Non-observance given to safety instructions in this manual, which could cause danger to life have been spefically highlighted with this general danger symbol. Non-observance to this warning could damage the unit or affect its function Qualifications of personnel All activities must be carried out by authorized (certified) instructed personnel. Safety regulations for the owner/operator WARNING! All safety and hygiene rules and local regulations must be observed. All dangers related to mechanical equipment and moving parts must be avoided. Follow all the warning labels fixed on the unit When operating near the pumping unit, avoid wearing loose-fitting clothes, or other things that could get caught (like armlet, chains, etc.) and gather any long hair. Periodically check the presence and readability of the warning labels. Check the presence, correct fixing and perfect condition of the fixed protections applied. When the machine is running, do not put anything into the pump through the inlet/outlet or from the inspection cover as there is the risk of contact with moving parts (impeller). In order to avoid danger to the personnel operating near the pumping unit, check correct connection and tightening of the inlet/outlet before starting up. 2

3 WARNING! The pumping unit must not be used in places where there is the danger of explosion and/or fire, in mines and tunnels and in places with poor ventilation unless special precautions are taken by the user. The pumping unit must never be used to treat liquids intended for human or animal consumption (alimentary use). The pumping unit is provided with a bolt for earth connection to ensure equipotentiality and prevent static electricity. The pumping unit must be installed in a workplace with sufficient lighting for the task to be performed; the lighting must permit correct identification of the controls and optical signals on machine board in addition to performance of the cleaning, adjustment and maintenance operations and topping up of liquids. Dismantiling and re-assembly WARNING! If the pump has been used to pump hazardous media, care must be taken that, when draining the leakage, personnel and environment are not endangered. All waste and emissions such as used oil must be appropriately disposed of. Oil spills must be cleaned up and emissions to the environment must be reported. The working area must be kept in good order at all times. All government regulations shall be observed. The pumping units equipped with diesel engine and/or with vacuum pump are provided with oil vent pipes. Suitable devices must be provided to prevent dispersion in the ground. Unilateral modification and spare parts manufacturing Modifications or changes to the unit/installation should only be carried out after consulting ITT Flygt. Original spare parts and accessories authorized by the manufacturer are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation. 3

4 WARRANTY ITT Flygt undertakes to remedy faults in products sold by ITT Flygt provided: - that the fault is due to defects in design, materials or workmanship. - that the faults are reported to ITT Flygt or ITT Flygt s representative during the warranty period. - that the product is used only under condition described in the Installation, Care and Maintenance manual and in applications for which it is intended - that the monitoring equipment incorporated in the product is correctly connected and in use. - that all service and repair work is done by a work shop ITT Flygt - that genuine ITT Flygt parts are used. Hence, the warranty does not cover faults caused by deficient maintenance, improper installation, incorrectly executed repair work or normal wear and tear. ITT Flygt assumes no liability for either bodily injuries, material damages or economic losses beyond what is stated above. ITT Flygt guarantees that spare parts will be kept for 10 years after that the manufacture of this product has been discontinued PRODUCT DESCRIPTION Introduction Thank you for buying an ITT Flygt pump. In this Installation Care and Maintenance manual you will find general information on how to install and service the pumping unit to give it a long and reliable life. Applications The pumping unit is intended to be used for: For further information on applications, contact your nearest ITT Flygt representative. Liquid temperature : max. 70 C. Liquid density : max kg/m 3 The ph of the pumped liquid : 5,5 9 - pumping of ground water - lowering the groundwater level with Wellpoint system (only for version with vacuum pump) - pumping of raw or clean water - pumping heavy, abrasive or saline liquids - drainage - dewatering - water supply from wells and canals (only for non-alimentary uses) - pumping of liquids and mud with solid parts in suspension (within the limits of the technical specifications) - transfer of bentonite slurry 4

5 TRANSPORTATION AND STORAGE The pumping unit may be transported and stored in a horizontal position. WARNING! Always lift the pumping unit by its lifting system; never use the delivery or suction pipe or the hooks on the pump and/or on motor unit. WARNING! Make sure that the pump cannot roll or fall over and injure people or damage property During towing in the site, check that the tow bar is fixed by means of the stop pin and that the latter is locked through the locking device. Although fitted on wheels, the pumping unit is not approved for use on roads. Towing is therefore forbidden on public roads. On specific request, the pumping unit can be fitted on a trolley approved for road use. During handling on site, ensure that the diesel tank (fitted on pumping unit base stand) is not subjected to impact or abrasion which can cause fuel leakage. The pump is frost-proof as long as it is operating. If the pump doesn t work when the temperature is below the freezing point, the water freezes and the pump housing can break. Never leave the water in the priming chamber if there is the risk of freezing: empty the pump through the inspection cover. For longer periods of storage, the pump must be protected against moisture and heat. After a long period of storage, the pump should be inspected before it is put into operation. Pay special attention to the shaft seal and the drive unit. Follow the instructions under the heading Before starting in the chapter Operation. INSTALLATION Handling equipment Always pay extra attention to safety aspects when working with lifting equipment. Check that the lifting system is in good condition. - Stay clear of suspended loads WARNING! Suitable lifting equipment is required for handling the pump. The lifting equipment shall be able to hoist the pumping unit straight up and down preferably without the need for resetting the lifting hook. Oversize lifting equipment could cause damage if the pump should stick when being lifted. Make sure that the lifting equipment is securely anchored and in good condition. 5 - Always lift the pump by its lifting handle In order to guarantee adequate stability of the pumping unit and prevent it from accidentally moving during operation, it must be installed in a flat position longitudinally and with a maximum gradient of 10% crosswise. You should therefore avoid positioning it on steep ground.

6 Safety precautions Put the pump in a horizontal position. The suction pipe must be the straightest possible. It s free end, at a distance of, at least, twice the diameter from the bottom of the excavation, is attached to a strainer to avoid the suction of materials which could damage the pump. In order to minimize the risk of accidents in connection with service and installation work, the following rules should be followed : 1. Never work alone. Use a lifting harness, safety line and a respirator as required. Do no ignore the risk of drowning. 2. Make sure there are no dangerous gases within the work area. 3. Check the explosion risk before welding or using electric hand tools. 4. Before the pump is installed check that all the parts have not been damaged during the transportation. 5. Observe strict cleanliness. Do not ignore health hazards. 6. Bear in mind the risk of mechanical accidents. 7. Make sure that the lifting equipment is in good condition and comply to local ordinances. 8. Provide a suitable barrier around the work area, eg. a guard rail. 9. Make sure you have a clear path of retreat. 10.Use safety helmet, safety goggles and protective shoes. 11. A first-aid kit must be close at hand. Follow all health and safety rules and local codes and ordinances. Pumping units with diesel engine The pumping unit must be installed in adequately ventilated environments in order to provide sufficient air for combustion and dissipation of the heat generated. Pumping unit with electric motor The user must protect the electrical power supply line and the pumping unit against short circuits and overloads by connecting an adequate thermal magnetic circuit breaker. In order to avoid the risk of electrocution due to direct or indirect contacts with energized parts the user must protect the pumping unit from direct and indirect contacts, in compliance with current regulations, taking account of the ambient utilisation conditions that increase electrical risks (e.g. differential circuit-breaker Idn 30 ma on building sites); in particular the pumping unit must not be positioned inside narrow conducting environments, i.e. with good earth connection (e.g. damp or wet underground site or walls of a narrow excavation) and reduced volume. Damage to the power supply cable and housing can involve contact with energized parts and life risk; before starting: Check the power cable and the control panel condition. Check that the power cable size is right and it s protected against mechanical damage. If the power cable or unit is damaged, do not operate! Replace the damaged power cable with a new one. Use plugs with suitable protection rating according to the environment where the unit is operating (min. IP 55). Check that the direction of rotation direction is according to the direction indicated on the electrical motor; if not, change the connection of two phases (before this operation, make sure that the electrical circuit is not energized). If the pumping unit provided with diesel engine is installed in a closed place, the exhaust gases must be conveyed to the outside. The pumping unit must be installed at least at a distance of 4 meters from combustible and flammable materials or from pressurised containers. 6

7 OPERATION Before starting Check that the visible parts of the pump and installation are undamaged and in good condition. Before starting work on the pump, make sure that the pump cannot be energized In case of emergency, stop the pumping unit via the mushroomhead push button on the control panel (electrical motor) or via the lever stop system (diesel engine). Make sure that the pump cannot roll or fall over and injure people or damage property. In some installations the pump surface and the surrounding liquid may be hot. Bear in mind the risk of burn injures The noise level of 70 db may be exceeded On specific request the pumping unit can be provided with soundproof enclosure. 1 2 Before starting the unit, fill the pump casing with water up to the lid (Tab.5 a page 10). Then make sure there are no water leakages in the mechanical seal or in the suction valve. In the first case they would prevent the pump from working properly and they would prolong pumppriming times. After this simple check, start the drive unit. Remember that internal combustion engines must be warmed up for some minutes till they reach the optimum temperature. Do not change or modify the engine calibration in any way. Never operate the pump without water. Possible causes of unsuccessful pump-priming - Pump-casing without water or with a level of the water too low. - Air passing through suction pipe, connectors etc. - Broken or worn-out tang of the volute (see Tab.2, part.4) - Wrong number of drive unit revolutions. - Broken or worn-out impeller. 7

8 - Clogged "re-circulation" pipe (Tab.1, part. 1), Check through cleaning door (Tab. 1, part. 2) with pump not working. How the pump works 3 - Air passing through the mechanical seal. This can be noticed thanks to water seepages from the mechanical seal when the pump is not working. float outlet vacuum pump Note: For any other cause, see "Fault tracing" intake Vacuum pump (options) No vacuum in the unit - possible causes Air intake from the unit: - Make sure that all unions are properly shut and O-rings in perfect conditions. Outlet valve (Tab.3, part.1) does not shut properly: - Check if the seat is dirty (Tab.3, part.2). - Make sure that the seat and the valve itself are not damaged. Should it be necessary, replace them. - The vacuum pump tank level is insufficient (top up) Air Water self-priming centrifugal pump 1) Outlet valve 2) Valve seat 3) Driving belt Vacuum pump does not run or runs slowly: - The driving belt is broken (Tab.3, part. 3).Take off the faulty links and install the belt again. - The driving belt has loosened. Take off one more links till you get the right state of tension once again. Vacuum pump blades are worn-out: - Replace the 4 blades (Tab. 4, part.9). 8

9 CARE AND MAINTENANCE ITT Flygt recommends a preventive maintenance program based on Intermediate and major Services at regular intervals. The time between Major Service could vary considerably depending on operating conditions and the need for a Major Service will be determine during the regular Intermediate Services. For routine maintenance of the diesel engine or electric motor, follow the instructions in the manuals provided. Pumping units with diesel engine During maintenance, ensure that no metal or other conducting object can short-circuit the battery terminals with consequent danger of explosion of the battery. If you have to isolate the battery, first disconnect the negative pole and then the positive pole (the negative pole is earthed and if the positive pole is disconnected first, it increases the risk of accidental short-circuit). Inspection (version with oil vacuum pump) - Drain the condensate in the oil tank (Tab. 4, part.10), through the cock at least once a day. - For the suction pump use SAE 15W40 ENGINE OIL. - Every 1000 working hours wash oil suction filter with gas/fuel oil (Tab. 4, part.11). - Every 1000 working hours replace oil filter (Tab. 4, part.12) - Every 1000 working hours replace air filter (Tab. 4, part.13) Before starting work on the pump make sure that it cannot be started, even accidentally. 4 Pumping units with electric motor During maintenance of the pumping unit, isolate it by disconnecting the socket from the plug placed on the control panel. 1) Pump casing 2) Impeller 3) Mechanical seal 4) Pump/motor coupling box 5) Vacuum pump oil tank 6) Complete vacuum pump 7) Outlet valve 8) Float to tank 9) Blade 10) Cock 11) Oil suction filter 12) Oil filter 13) Air filter 9

10 The following points are important in connection with work on the pump. The pump is designed for use with liquids which can be a health risk. In order to prevent injury to the eyes and skin, observe the following points when working on the pump: WARNING! Make sure that the pump has been thoroughly cleaned; Beware of the risk of infection; WARNING! Observe local safety regulations. Always wear goggles and rubber gloves Rinse the pump thoroughly with water before starting work. WARNING! The oil chamber may be under pressure. Hold a rag over the filling plug to prevent splatter. WARNING! Proceed as follows if fluid have splashed into your eyes: - Rinse your eyes immediately in running water for 15 minutes. Hold your eyelids a part with your fingers. - Contact an eye specialist. on your skin: - Remove contaminated clothes - Wash your skin with soap and water - Seek medical attention, if required Rinse the components in water after dismantling. REPLACING WORN-OUT PARTS 5 Disassembling pump-motor coupling box (Tab 5) Coperchio acqua Take off the pump casing by unscrewing assembling nuts (part.4) and lever between pump and coupling box. 10

11 Replacing the impeller (Tab 6) 6 Unscrew the self-locking nut (part.18) and the impeller (part.17) in anticlockwise direction (part.1). Lock the shaft. Be careful because you will take out half the mechanical seal (part.14) which must not be damaged. While taking the seal off the impeller hub ( if the seal itself does not need replacing) handle the rubber bellows with care. They must not be subjected to a torsional stress higher than that caused by the impeller rotation on the fixed counterface. To install the seal, follow instructions. 1) Shaft 14) Mechanical seal 17) Impeller 18) Self-locking nut Replacing the mechanical seal Remove the screws (Tab.7, part.1), take the wear plate out of its seat (Tab.7, part.2), work with a screwdriver on the grooves (Tab.8, part.2) until half of the stationery seal (counterface) comes out of its seat N.B.: As for the assembly, clean the seat throughly (Tab.8, part.1), and insert the counterface in its seat by gentle pressure (Tab.8, part.1). Part.2 7 IMPORTANT! Detail 4 protrude for 5 mm compared to the tungsten carbide surface (part.5). Do not install counterfaces and seal devices manually. Use sleeves so as to avoid any contact with lapped surface and get regular and uniform thrust. Before assembling the parts, clean the seal and sliding counterface faces thoroughly. Standard seal may be used for impure water. For other liquids refer to ITT Flygt. Part.2 11

12 Replacing front and rear wear plate 8 Remove all screws (Tab.7, part.1), pull out the wear plate (Tab.7, part.2). For reassembly, work in reverse and make sure that seat is perfectly clean (Tab. 8, part.3). Impeller and wear plates 9 Check that measurements on the pump do not differ greatly from the following ones.a difference would imply reduced capacity and hydraulic efficienty as well as stalling the engine because of friction on the fixed part of the pump casing. Minimum space. (A) Tab. 9 (mm 0,3 max 1,5) Minimum space (B) Tab. 9 (mm 0,7 max 2) 12

13 FAULT TRACING Fault tracing should be performed with the machine in stand-by ensuring that the pumping unit cannot re-start, even accidentally. Always make sure that there is no-one near the pump when it is started. Use the following checklist as an aid to fault tracing. It is assumed that the pump and installation have been carried out as instructed. Follow local safety regulations and observe recommended safety precautions. Problems Cause Solution The drive unit overheats A) The fan belt has loosened or is broken. B) Motor suction filter is clogged A) Tension it or replace it B) Clean it or replace it C) For any cause other than A or B read the manual "Care and maintenance" of the engine No pump-priming. The vacuometer gives no values A) Defective tightness of the pump or of the suction pipe. B) The strainer is not completely submerged. C) The mechanical seal is broken A) Check the pump tightness after disconnecting the suction unit. Connect the pump again and check all connections and pipes. Replace any faulty parts B) Put the strainer deep down into the water C) Replace the mechanical seal No pump-priming even though the vacuometer shows sufficient vacuum Flow interruption after temporary stop of the pump. A) Clogged bottom strainer B) The inner rubber coating of the pipe has came off clogging it. A) Water leakage in the suction pipe because of defective retaining quality A) Take it up and clean B) Replace it A) Check the mechanical seal B) Make sure that no liquid is coming out of the suction valve The pump has inadeguate capacity or stops working A) Insufficient engine speed B) Clogged bottom strainer C) Clogged pump casing D) The inner rubber coating of the suction pipe has come off E) Impeller and wear plates are wornout A ) Increase engine speed to reach the correct range of revolutions B) Clean the bottom strainer C) Clean impeller and diffusers through the cleaning door or dismantle the pump casing D) Replace suction pipe E) Replace the parts 13

14 SERVICE LOG Most recent service date Pump N. Hours of operation Remarks Sign. 14

15 Self-priming centrifugal pump Eng.09.04