Installation, Care and maintenance DOCK-LOCK TM, Lifting system 892434/04
CONTENTS Safety 2 Guarantee 3 Data plate interpretation 3 Product description 4 Materials 4 Dimensions 4 Operation 8 Safety precautions 8 Operating sequence 8 Searching sequence 10 Practical handling advises 11 Parts List 12 Installation 5 Safety precautions 5 Handling precautions 5 Installation 5 SAFETY This manual contains basic information on the installation, operating 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. Qualifications of personnel An authorized (certified) electrician and mechanic shall carry out all work. Safety regulations for the owner/operator All government regulations, local health and safety codes shall be complied with. All dangers due to electricity must be avoided (for details consult the regulations of your local electricity supply company). Identification of safety and warning symbols General Danger: Non-observance given to safety instructions in this manual, which could cause danger to life have been specifically highlighted with this general danger symbol. Unilateral modification and spare parts manufacturing. Modifications or changes to the unit/installation should only be carried out after consulting with 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. WARNING! High Voltage: The presence of a dangerous voltage is identified with this safety symbol. Non-observance to this warning could damage the unit or affect its function. Dismantling and re-assembly 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 coolant must be appropriately disposed of. Coolant spills must be cleaned up and emissions to the environment must be reported. The pumping station must be kept tidy and in good order at all times. All government regulations shall be observed.
GUARANTEE Flygt undertakes to remedy faults in products sold by Flygt provided: that the fault is due to defects in design, materials or workmanship; that the fault is reported to Flygt or Flygt s representative during the guarantee period; that the product is used only under conditions described in the care and maintenance instructions and in applications for which it is intended; that installation is done by personnel trained by Flygt; Hence, the guarantee does not cover faults caused by deficient maintenance, improper installation, incorrectly executed repair work or normal wear and tear. Flygt assumes no liability for either bodily injuries, material damages or economic losses beyond what is stated above. The manufacturer reserves the right to alter specification or design without notice. DATA PLATES INTERPRETATION Lifting device Line tension drum 3
PRODUCT DESCRIPTION The DOCK-LOCK Lifting device is intended to be used for retrieving (searching and lifting) Flygt large pumps in pump stations. The pumps have to be equipped with the drive units series 605-985. For pumps equipped with other drive units, please contact your Flygt representative. The DOCK-LOCK Lifting device is available in two versions depending on the lifting weight: 5 tons Part no. 596 45 00 10 tons Part no. 596 46 00 Part no. Line tension drum CP, CS-installation only 602 49 00 Guide wire PL-, LL-installation only 673 00 00-03 Materials Hook Steel, Class 8 Housing and link Heavy steel plate, HARDOX 400, (SSAB) Spring Sandvik 11R51 & 12R10 Line guide Stainless steel, DIN 17440, X5CrNi 18 10 BS 970:1, 304S15 AISI/ASTM: 304 Dimensions Measurements DOCK-LOCK in mm 5 t 10 t A 386 509 B 279 340 C 100 106 D 125 204 E 269 403 F 67 68 G 7 9 H 36 48 Weights in kg 7 15 Line tension drum (CP-, CS-installation) Line dimension: 8 mm Line capacity: max. 60 m Line material: Polyester Guide wire (PL-, LL-installation) Wire dimension: 4 mm Wire capacity: max. 16 m Wire material: Stainless steel 596 45 00, 5 tons 596 46 00, 10 tons E F E G F ØH ØH C G C B B A A D D 4
INSTALLATION Safety precautions Follow all health and safety rules and local codes and ordinances. For extra safety and in order to minimize the risk of accidents in connection with operation, service and installation work, the following rules should also be followed: 1. Make sure there are no poisonous gases within the work area. 2. Check the explosion risk before welding or using electric hand tools. 3. Bear in mind the risk of electrical accidents. 4. Make sure that the lifting equipment is approved and in good condition. DO NOT hold, stand on or stand within a loop of either the nylon line or motor cables during lifting or lowering. Connect the DOCK-LOCK hook onto the lifting link while the pump is standing outside the pump sump before being lowered into place. The line tension drum can be mounted in a temporary bracket or be suspended in a separate lifting hook. The tension drum line capacity is 60 m. NOTE! Use only line of 8 mm diameter. Place the drum in a position so that the guide line attains the correct angle on the correct side of the lifting device and at such a height that it is accessible for handling the drum lock pin (TD1). See Fig 1. Pull out the guide line fully from the tension drum. Insert the locking pin into one of the four holes (TD2) to lock the drum. The guide line should be adjusted to required length to fit each individual pump installation. Handling precautions Suitable lifting equipment is required for handling the pump. The lifting equipment shall be able to hoist the pump straight up and down in the sump. The minimum height between the lifting hook and the access frame/cover/floor is individual for every installation. For further information, please contact your Flygt representative. Make sure that the lifting equipment is securely anchored. The total weight of the pump is stated on the data plate for the hydraulic unit. Installation Warning! Handling Risk Risk for trapping when handling the hook. Mind the external link mechanism when setting different operating positions 485 TD2 TD1 X Z B Consult your nearest Flygt representative regarding: sizing of sump, pumping station and access frame. choice of ancillary equipment. other aspects of installation. E Mounting of guide line with or without line tension drum (for CP- and CS-installations) This instruction describes link-up of the DOCK-LOCK, the first time it is installed. Connect the DOCK-LOCK to the lifting equipment and make sure that the DOCK-LOCK opens properly without stacking in the lifting equipment. Fig 1 D 5
Connect the guide line end Z to the DOCK-LOCK line at B. (The other end of the guide line marked X on the adjacent figure is connected to a shackle in the line tension drum). The DOCK-LOCK lifting system is now ready for operation. Equip the station with hooks for suspension of guide line. See Fig 2. Mounting of guide wire (for PL- and LL-installations) This instruction describes link-up of the DOCK-LOCK, the first time it is installed. Connect the DOCK-LOCK hook onto the lifting link while the pump is standing outside the pump column before being lowered into place. Connect the guide wire end Z to the DOCK-LOCK line at B. The other end of the guide wire marked X should be secured. X X Z Z B E Fig 2 Mounting of the guide line without the tension drum should be done by connecting the guide line end Z to the DOCK-LOCK line at B. The other end of the guide line marked X should be connected to a fixed point. D Z Fig 3. Fully winded line tension drum 6
Installing and re-installing pump Connect the guide line (CP, CS)/guide wire (PL, LL) to the hook and the tension drum (if used). Note! Always disengage the tension drum locking pin during lifting and lowering sequence. Lower the pump into operation position. Please note that the main lifting wire/chain will slacken when the pump is in final position. At the same time as this occurs slacken the guide line/wire by hand. Make sure that the DOCK-LOCK has disengaged from the pump top, see "Practical handling advises" how to facilitate the release moment. Raise the DOCK-LOCK out of the sump/station. Before disconnection the guide line make sure that the tension drum is locked with the locking pin. After the lifting operation is completed, disconnect the guide line then store away the DOCK-LOCK and the tension drum until further use. Where applicable, the ends of the guide line/wire should be hooked onto the storage hooks until they are used the next time (see Fig 2, page 6). NOTE. Make sure that the ends of the guide line/wire are marked with "X" and "Z". Install the cables according to "Flygt Cable Handling System". 7
OPERATION Safety precautions WARNING! Before starting work on the pump, make sure that the pump is isolated from the power supply and cannot be energized. NOTE! This applies to the control circuit as well. Follow all health and safety rules and local codes and ordinances. Operating sequence F A This chapter describes the operating sequence when the DOCK-LOCK lifting system has already been installed and is to be used again. Link-up with the line tension drum Mount the DOCK-LOCK lifting device onto the lifting equipment (1). Mount or position the tension drum (6). Set the tension drum in pretension position. NOTE! Use the stop pin to secure the drum. Link-up the guide line end "X" (see Fig. 2, page 6) to the tension drum (6). Connect the guide line end "Z" to the DOCK-LOCK line (3), at shackle B. The DOCK-LOCK system is now ready to collect the pump. Warning! Handling Risk Risk for trapping when connecting the line to hook and tension drum! Note! Do not release the tension of the cables before the DOCK-LOCK hook has entered the lifting eye of the pump. 6 F 5 E D 1 2 A 3 B E D 4 C C B Z 1. Lifting equipment 2. DOCK-LOCK lifting device 3. DOCK-LOCK line 4. Lifting link 5. Guide line 6. Line tension drum 8
Link-up without the line tension drum Mount the DOCK-LOCK lifting device onto the lifting equipment (1). Connect the guide wire end "Z" to the DOCK-LOCK line (3), at shackle B. The DOCK-LOCK system is now ready to collect the pump. Note! Make sure that the guide wire end "X" is secured to a fixed point. 5 1 E 2 A D A 3 B E B 4 C D C Z 1. Lifting equipment 2. DOCK-LOCK lifting device 3. DOCK-LOCK line 4. Lifting link 5. Guide wire 9
Retrieval and Lifting Gradually lower the DOCK-LOCK lifting device towards the pump. Make sure that the guide line is tense and not obstructed. When the hook docks with the pump top the guide line should be given an extra pull by hand to engage the hook. Lift the pump approx. 300 mm, then release the cable suspension. Recommendation: Mark the line at the docking level to make connection easier! Lift the pump out of its place. WARNING! Keep out from under suspended loads. Warning! Handling Risk Use gloves and face shield to avoid contamination and frictional damage when manually operating the line. Before removing the line from the pump top/hook make sure that the tension drum is locked with the attached locking pin. Warning! Whiplash Risk Always use tension drum locking pin to avoid line whiplash during installation and link-up. NOTE! Before starting service on the pump, make sure that the motor has cooled down sufficiently to carry out the service work. Warning! Always lift the pump by its lifting link, never by the motor cable or other parts. 10
Searching (fishing) sequence The DOCK-LOCK lifting device can also be used for searching (fishing) a pump when the lifting connecting line is missing. Note! Applicable only when the lifting link of the pump is visible. Mount the DOCK-LOCK lifting device onto the lifting equipment. Adjust the DOCK-LOCK hook to "fishing" position. Connect a line to the guide eye E on the DOCK- LOCK device. Lower the lifting hook into the station to the level of the searched pump top. Then pull the line so that the hook enters the pump's lifting link. By lifting carefully, the DOCK-LOCK will be automatically locked into position and the pump can be lifted. The pump and the pump station can now be equipped with a guide line for proper use of the DOCK-LOCK lifting device in the future. For further information, please contact your Flygt representative. It is also recommended that the DOCK-LOCK lifting system should be used in shallow pump stations where visible contact with the pump is possible and in L and P pump installations. 11
Practical handling advises The use of the DOCK-LOCK lifting device needs practise before use to ensure smooth and safe operation. In this chapter you can find some usefull experiences from the field. After lowering the pump in its final position, difficulties in releasing the DOCK-LOCK hook from the lifting link on the pump can occur. To solve that, a nylon rope can be attached to the DOCK-LOCK hook for easier release. Pull the attached rope when the DOCK-LOCK hook has opened. For easier handling of the cables when lifting the pump, use a lifting chain connected to the DOCK- LOCK. When the DOCK-LOCK is connected to the lifting link on the pump, lift the pump approx. 300 mm to avoid lifting in the cables. Connect a lifting string between the hook of the cable suspension and the lifting chain. Use a schackle for connecting the string to the chain. For easier handling when the DOCK-LOCK is connected to a large lifting equipment, use a 1 m long lifting chain between the DOCK-LOCK and the hook. 1 m 12
PARTS LIST 596 45 00 601 16 00 601 76 00 596 46 00 596 43 00 601 76 00 13
Part No. Denomination Quantity 5 ton 10 ton 596 45 00 LIFTING DEVICE, COMPLETE 1 596 46 00 LIFTING DEVICE, COMPLETE 1 ROPE GUIDE,COMPLETE 1 596 43 00 1 601 16 00 1 601 76 00 Rope, complete (L=1000 mm) 1 1 14
NOTES 15
Lift. equipm. Dock-Lock.01.04. Eng. 11.04 ITT FLYGT AB Printed in Sweden 892434 www.flygt.com