OPERATORS HANDBOOK MECHANICAL PRIME (SY) RANGE OF PRIMING EQUIPMENT FOR CENTRIFUGAL PUMPS SYPrim e.cd r ACME Dynamics, Inc. P. O. Box 1780 Plant City Florida 33564-1780 Telephone: (813) 752-3137 (800) 622-9355 Fax: (813) 752-4580 Document No: W78-001E Revision No:... 2 Revision Note No: R 26389 Date Issued. Sept. 2000 Produced at ACME Dynamics, Inc.
DECLARATION OF INCORPORATION FOR: DYNAPRIME RANGE OF PRIMING EQUIPMENT FOR CENTRIFUGAL PUMPS Types - SY18, SY25 & SY60 Serial Number Responsible Person Manufacturer REFER TO THE PUMP NAMEPLATE Sterling Fluid Systems Ltd. Sterling Fluid Systems Ltd. It is hereby certified that this equipment is intended to be incorporated into, or assembled with other machinery to constitute relevant machinery to comply with the essential health and safety requirements of the 'Council Directive 89/392/EEC - 'Machinery Directive'. The machinery covered by this declaration must T be put into service until the relevant machinery into which it is to be incorporated has been declared in conformity with the provisions of the 'Council Directive 89/392/EEC - 'Machinery Directive' Harmonized Standards: EN 292 Part 1 Part 2 pr EN 809: Safety of Machinery - Basic Concepts and General Principles for Design Pumps & Pump Units for Liquids - Safety Requirements B Millward Signed: (Chief Engineer - Authorized to sign on behalf of Sterling Fluid Systems Limited) A MEMBER OF THE STERLING FLUID SYSTEMS GROUP
Operators Handbook for Manual No/Rev CONTENTS Section... Page 1 General Information & Safety Instructions...1 2 Transport Handling and Storage...2 3 General Description...2 4 Assembly and Installation...2 5 Commissioning and Operation...3 6 Maintenance and Service...3 7 Faults and Remedial Action...7 8 Supplementary Documents...8 After Sales Service... Back Cover Introduction This manual gives the safety, installation, operation and maintenance instructions for the ACME Dynamics DYNAPRIME SY range of priming equipment for use with end suction, centrifugal pumps. The priming equipment may be identified by the ACME Dynamics, Inc. code typically in the form 'SY60'. This manual applies to the following priming systems. SY18, SY25 & SY60 SY18 has an 18cfm vacuum pump; similarly SY25 and SY60 have 25 & 60cfm vacuum pumps. Section 1 General Information and Safety Instructions The products supplied by ACME Dynamics, Inc. have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimised by the use of guards and other design features. Some hazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover all circumstances; YOU are responsible for using safe-working practices at all times. 1.1 ACME Dynamics, Inc. products are designed for use in appropriate locations which are to be kept free of obstructions that may restrict safe access to the controls and maintenance access points. Should accidental loss or damage occur, contact ACME Dynamics, Inc. immediately. 1.2 Access to the equipment should be restricted to the personnel responsible for installation, operation and maintenance and they must be trained, adequately qualified and supplied with the appropriate tools for their respective tasks. 1.3 ACME Dynamics, Inc. requires that all personnel that are responsible for installation, operation or maintenance of the equipment, have access to and study the product instruction manual BEFORE any work is done and that they will comply with all local and industry based safety instructions and regulations. 1.4 Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe levels. Safety glasses or goggles should be worn where working with pressurised systems and hazardous substances. Other personal protection equipment must be worn where local rules apply. 1.5 Do T wear loose or frayed clothing or jewellery, which could catch on the controls or become trapped in the equipment. 1.6 Note any limits to the pump application specified in the contract documentation. Operation of the equipment outside these limits will increase the risk from hazards noted below and may lead to premature and hazardous pump failure. 1.7 Clear and easy access to all controls, gauges and dials etc. MUST be maintained at all times. 1.8 IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THIS ACME Dynamics, Inc. PRODUCT COULD RESULT IN INJURY OR DEATH. 1.9 Within the manual, safety instructions are marked with safety symbols. Hazard This symbol refers to general mechanical aspects of safety. A nameplate is fitted to each pump unit and must not be removed as it identifies the priming equipment supplied with the pump. Loss of this plate could make identification impossible. This in turn could affect safety and cause difficulty in obtaining spare parts. Page 1
Manual No/Rev Operators Handbook for ATTENTION Hazard This symbol refers to electrical safety. This symbol gives warning of a hazard to the equipment itself, which in turn could cause a risk to personal safety. Section 2 Transport Handling and Storage Instructions 2.1 Transport DYNAPRIME equipment is despatched fully assembled but for overseas orders the lubricating oil is drained. Equipment is protected against corrosion and packed for transport by normal road, rail and sea carriers. 2.2 Handling Crushing Hazard When lifting, use lifting equipment having a safe working load rating suitable for the weight specified. Use suitable slings for lifting any item not provided with lifting points. The use of suitable forklift truck and fourchain crane sling equipment is recommended but locally approved equipment of suitable rating maybe used. Priming equipment is normally supplied on pallets, which may be lifted by forklift truck. 2.3 Storage Section 3 General Description ACME Dynamics DYNAPRIME SY Priming Equipment is designed to be used with a variety of end suction centrifugal pumps to handle dirty water, industrial effluents, and sludge etc, including solids. There are three main components: 3.1 Priming Tank Assembly The priming tank assembly is fitted to the suction branch of the pump. It provides for removal air drawn from the suction line and contains protection devices to prevent water from getting to the vacuum pump. 3.1 Vacuum Pump & Coalescer Belts drive the vacuum pump from the pump drive shaft; this draws air from the priming tank and passes it to the coalescer. The vacuum pump is lubricated by oil, some of which mixes with the air. The coalescer is required for the larger vacuum pumps to separate the oil from the air thus discharging clean air to atmosphere and recycling the oil for lubrication. 3.3 Non Return Valve The non-return valve is fitted to the discharge of the pump to prevent back flow or entry of air when priming the system. Section 4 Assembly and Installation 4.1 Initial Inspection for Damage 2.3.1 Temporary Storage If the equipment is not to be used immediately it should be stored carefully in a horizontal position, in a sheltered, dry location. Additional rust preventative should be applied to all unpainted carbon steel or cast iron parts, and should not be removed until final installation. 2.3.2 Exposed or Extreme Conditions Storage For exposed storage or extreme variants in atmospheric or environmental conditions, please refer to ACME Dynamics, Inc. for special storage instructions to suit the conditions applicable. During transport and storage, accidental damage to the equipment may have occurred. Prior to installation, or in the event of a handling accident, carefully check that no damage has been sustained before installation and commissioning. 4.2 Pump Mounting Abrasion and Entrapment Hazard Do T touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they MUST be replaced before operating the equipment. The pump is to be mounted as per instruction in the pump manual. Suitable drive pulleys for the vacuum pump are usually to be fitted on the pump shaft between the bearing housing and the coupling. Guarding for the belt drive is Page 2
Operators Handbook for Manual No/Rev required to meet local safety standards. 4.3 Shaft Alignment Shaft alignment is to be set and checked as per instructions in the pump or coupling instruction manual. 4.4 Coalescer Mounting The coalescer is designed for mounting below the pump-bearing bracket, but may be fitted in any other suitable position giving clear access to the maintenance points. 4.5 Priming Tank Mounting The priming tank was designed to be mounted directly to the suction branch of the pump. It must be maintained within 10 degrees of vertical for satisfactory operation. 4.6 Suction Pipework ATTENTION Collapsible hoses must not be used on the suction side of the pump. A correctly sized filter or strainer is recommended to hold back larger items. 4.7 Non Return Valve and Discharge Pipework The non-return valve is usually fitted in the discharge line close to the pump to prevent the pump from excessive back-pressure and reverse rotation and to prevent air from entering when the pump is being primed. Section 5 Commissioning and Operation 5.1 Commissioning Checks These checks must be done before testing and first use and after priming system maintenance, which required disassembly. Abrasion and Entrapment Hazard Do T touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they MUST be replaced before operating the equipment. The following checks refer only to the priming equipment, pump and driver checks must be done as per their manuals. Fill the coalescer with the recommended oil to the level of the filler cap. Check the tension of the vacuum pump drive belts. Check that the non-return valve is seating properly and that there is no debris in the chamber to prevent correct operation. Check that the surge control valve is fully screwed in. This is the large knurled nut surrounding the back flush knob on the top of the priming tank. 5.2 Starting Procedure Cold Conditions Hazard Do T operate water pumps in temperatures below freezing point, without first checking that the pumped fluid is not frozen and the pump is free to turn. Start the pump as per the pump instruction manual. The pump should prime automatically, if not refer to the Fault Finding Guide in Section 7 5.4 Stopping Procedure Stop the engine or motor, and then close any valves in the discharge pipes. Section 6 Maintenance and Service 6.1 General Introduction ACME Dynamics DYNAPRIME equipment will provide many years of trouble free service when maintained in accordance with these instructions. In the event of failure it is recommended that ACME Dynamics, Inc. Service Department be called to investigate and carry out repairs. The following instructions are given to cover the main elements of strip and rebuild but do T include instructions for work that MUST be done by an ACME Dynamics, Inc. Service Engineer. The following hazards may arise during maintenance work: Page 3
Manual No/Rev Operators Handbook for Fluid Pressure Jet Hazards Check and ensure that the pump operates at below the Maximum Working Pressure specified on the pump nameplate and before maintenance, ensure that the pump is drained down. Hazardous Materials Wear a suitable mask or respirator when working with Packing and Gasket components, which contain fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautious, if other supplier's components have been substituted for genuine ACME Dynamics parts, these may then contain hazardous materials. Hazardous Gases, Mists, Sprays and Leaks Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious and toxic gases, skin understand the hazardous substance data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures. BEFORE ATTEMPTING ANY MAINTENANCE ON A PUMP, PARTICULARLY IF IT HAS BEEN HANDLING ANY FORM OF HAZARDOUS LIQUID, ENSURE THAT THE UNIT IS SAFE TO WORK ON. THE PUMP MUST BE FLUSHED THOROUGHLY WITH A SUITABLE CLEANSER TO PURGE AWAY ANY OF THE PRODUCT LEFT IN THE PUMP COMPONENTS. THIS SHOULD BE CARRIED OUT BY THE PLANT OPERATOR AND A CERTIFICATE OF CLEANLINESS OBTAINED BEFORE STARTING WORK. TO AVOID ANY RISK TO HEALTH IT IS ALSO ADVISABLE TO WEAR PROTECTIVE CLOTHING AS RECOMMENDED BY THE SITE SAFETY OFFICER, ESPECIALLY WHEN REMOVING OLD PACKING WHICH MAY BE CONTAMINATED. Recommended Maintenance Schedule For pump, motor or engine maintenance refer to the separate operators handbooks included within the pump documentation pack. PERIOD Daily Weekly or 100 hours Monthly or 500 hours 6 monthly or 3000 hours Annually or 6000 hours TASK - (Priming equipment only) Drain any water from the coalescer. Check and top up the oil in the Coalescer. Check the tension of the vacuum pump belts. Change the coalescer sump oil. Clean the coalescer sump oil filter mesh Check the valve gear. Clean or renew filter element. Check high capacity filter element. Check the non-return valve ball is seating correctly. Check and if needed renew the vacuum pump drive belt(s). Strip and clean priming tank and valve gear. Check condition of the vacuum pump blades, renew if necessary. Replace the coalescer filter mesh. The above schedule is given for guidance but site-operating conditions may override the suggested maintenance intervals. Adjustments to time scales will also have to be made if the pump is idle for long periods. Page 4
Operators Handbook for Manual No/Rev 6.1 Preparation for Maintenance 6.3 Drive Belt Adjustment Electric Shock & Accidental Starting Hazard ISOLATE the equipment before any maintenance work is done. Switch off the main supply, remove fuses, apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent reconnection. For diesel driven pumps disconnect the negative battery lead to prevent inadvertent starting. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapours. It is recommended that maintenance work be carried out away from the pump location by removal of the pump unit to a suitable maintenance area. No special tools are required for dismantling and re-assembling, however, it is important to ensure the suitable lifting equipment is available and that the work is carried out in a clean area. 6.2 Coalescer Maintenance Check the oil level in the coalescer tank and drain any water daily. The top of the oil should be level with the underside of the filler cap. Water is removed by means of the drain tap fitted to the side of the coalescer sump. The filter mesh is accessed by removing the coalescer lid and must be cleaned regularly by washing in petrol or a similar spirit. When refitting ensure filter mesh is below exhaust port. The oil feed pipe should be cleaned in a similar manner and blown through with an airline. Belt type Timing belt (toothed) PowerTwist A section link belt Deflection X Force producing deflection X ) 4 mm 1.5 kg 1.6 mm 1.5-2.0 kg To adjust belt tension, loosen the vacuum pump holding nuts and slide the vacuum pump outward. When the correct belt tension is obtained re-tighten holding nuts. Ensure that the pump drive is in line after tightening. Link belt drives can be further adjusted by removing links. ATTENTION DO T OVERTIGHTEN BELTS UNDER ANY CIRCUMSTANCES. For pumps fitted with V belts, it is necessary to disconnect the coupling to replace the belts. For pumps fitted with PowerTwist link belts, the belts can be replaced by slackening the vacuum pump holding down bolts. 6.4 Non-Return Valve The ball should be regularly checked for freedom of movement and absence of debris by inspection through the delivery flange of the valve body. The valve body should be removed to check the seat for damage or wear. 6.5 Vacuum Pump Air Filter 6.5.1 Standard Air Filters Air filters are located in the valve cover of the primary tank and should be checked regularly for cleanliness, distortion or damage. Replace if distorted or damaged Air Filter for SY25 Priming Tanks Page 5
Manual No/Rev AIR FILTER Operators Handbook for 25PTFLTA Undo the central nut holding the air filter cover and remove to expose the filter element. Air Filter for SY60 Priming Tanks AIR FILTER 60PTFLTA Undo the six nuts holding the top cover and remove the top cover complete to expose the air filter element. 6.5.2 High Capacity Air Filter SY25 & SY60 vacuum pumps have the option of a high capacity air filter, which is located externally as shown. The high capacity filter is fitted in lieu of the standard element. 60PTVLVA.PCX 25 & 60cfm main valve assembly 6.6 Surge Control Valve On SY25 and SY60 priming tanks a surge control valve is fitted. This should be checked regularly for signs of wear or damage. Components arrowed below are vulnerable to wear and should be replaced if worn excessively. The valve seat should be greased to prevent seizure. 60AFELEA 2 1 Undo the screws holding the retaining cover and remove (1) the cover to inspect the filter. The element pulls out (2). Note that the orientation of the unit should be as shown so that any debris from the filter falls away from the outlet connection when the unit is opened. It can then be easily swept out with little chance of it entering the outlet. Replace the cover O ring when the filter is changed. 6.5 Valve Gear Surge control valve --- --- SURGAS1A.PCX Typical main valve assemblies are shown below. The areas arrowed should be checked regularly for wear or damage. Worn parts should be replaced. The main valve is located on the underside of the top cover. Page 6
Operators Handbook for Manual No/Rev Section 7 Fault Finding Guide Pump Fails to Prime Disconnect suction hose Blank off suction entry Fit vacuum gauge Are all plugs tight? Reading between 85-89.5 kpa (28.5 0 30 ft H20)? Check vertical suction lift Type of unit? OTHERS AC 50/75 Is the mini ball valve open? Lift< or = 6.1m (20ft) for AC50/75 8.53m (28ft) for AC80/100 9.75m (32ft) for others? Test the Vacuum Pump directly Fit Vacuum Gauge Move Pump Reading between 85-89.5 kpa (28.5 0 30 ft H20)? Is reflux ball seating properly? Are hoses leaking, collapsed or blocked? Is vacuum pressure seal leaking? Is intake blocked? Is oil level correct? Is Vacuum Pump filter blocked? Is impeller blocked? Is belt drive tension OK? Is float gear free and intact? Excessive wear. Remove pump & either overhaul or fit new or exchange Vacuum Pump Is pump casing free from holes? Are all joints sound & leak free? Check impeller wear plate clearances and rectify Is the pump or NRV blocked or damaged? Page 7
Manual No/Rev Operators Handbook for Section 8 Supplementary Documents 8.1 General Arrangement Drawing Dimensions are given on ACME Dynamics Drawing No.380/3289, available on request. 8.2 Principles of Operation SUCTION FROM PUMP AIR DRAWN FROM ATMOSPHERE SUCTION FROM PUMP AIR FILTER ANTI-SURGE AIR FILTER ANTI-SURGE N RETURN BALL BACK PRIMING LINE CONTROL BACK FLUSH N RETURN BALL BACK PRIMING LINE CONTROL BACK FLUSH N RETURN DELIVERY N RETURN PRIMARY FLOAT SECONDARY AUTO SECONDARY DUMP AND PIPE PRIMARY FLOAT SECONDARY AUTO SECONDARY DUMP AND PIPE AIR FLOW SUCTION FLOW PACKING IMPELLER PACKING IMPELLER VOLUTE VOLUTE ON INITIAL START - PRIMING SUCTION FROM PUMP AIR FROM PRIMING AIR FILTER ANTI-SURGE N RETURN BALL BACK PRIMING LINE CONTROL PUSH BACK FLUSH OIL FEED TO PUMP AIR VENTED TO ATMOSPHERE N RETURN MESH RETAINING BRACKET PRIMARY FLOAT SECONDARY AUTO SECONDARY DUMP AND PIPE AIR AND OIL RETURN FROM PUMP COALESCER FILTER MESH OIL FILLER CAP BACKFLUSH FLOW PACKING SY-Prime4.cdr IMPELLER VOLUTE BACK FLUSH OPERATION SYCoas1.CDR RESTRICTED ORIFICE (3/32") PUMP & COALESCER WATER DRAIN TAP OIL FEED FILTER Page 8
Operators Handbook for Manual No/Rev 8.4 Spare Parts Spare parts information is available from the Spare Parts Book No. W77-004E ACME Dynamics, Inc. operate a comprehensive Spares and Service support network throughout the world, and can be contacted as follows: SPARES & SERVICE Telephone: (800) 622-9355 For spare parts, supply only. For breakdowns, spare parts and, on-site fitting, pump installation and, commissioning, and service contracts. Ask for - Parts Dept. ask for - Service Dept. Spares & Service Office ACME Dynamics, Inc. General Fax line: (813) 752-4580 P. O. Box 1780 Plant City, FL 33564-1780 Copies of this manual are available from the ACME Dynamics, Inc. Parts & Service Department by quoting the manual reference number. W78-001E Page 9