operating manual for centrifugal pumps at
Contents
1. WHERE LINE SHUT OFF Bre IS POSSIBLE FT STRAINER FLOW CONTROL VALVE FLOODED H SUCTION NON RETURN VALVE dL EY rud ISOLATING VALVE PRESSURE GAUGE H gt MINIMUM FLOW ORIFICE BY PASS FOR INSTALLATIONS WHERE LINE SHUT OFF IS POSSIBLE ISOLATING VALVE SUCTION LIFT FOOT VALVE FILTER Pumps series TMA FLOW CONTROL Jl VALVE FLOODED STRAINER SUCTION TE NON RETURN VALVE PRESSURE GAUGE SUCTION M HET SOLATING VALVE E FOOT VALVE FILTER Pump series TBA BTA FLOW CONTROL VALVE FLOW CONTROL VALVE U NON RETURN VALVE NON RETURN VALVE 7 STRAINER FLOW METER OR FLOW SWITCH PRESSURE GAUGE m SUCTION ACCELOROMETER SENSOR 7 SUCTION G LIFT I2. 92 2 Pumps series TBH KC 2T AT KC 2T Connections for mech seals cooling or heating Pumps series TBA C 2T Connections for mechanical seals cooling or heating Q L3 d6 Pumps series TMA 31 and 32 C and R Standard hook ups and connections d2 2 E EE A RI EE m d ur ay AS em a Si H Sof ANAS d2 d6 93 1 91 1 96 915 916 918 d6 Pumps series TMA 40 and 50 B R RR R2 Standard hook ups and connections Pumps series TCD Standard hook ups and connections Operating manual for centrifugal pumps 10 CHECK LIST PRIOR TO START UP All questions listed below must have POSITIVE answers prior to proceeding to the pump start up The following list may not be complete for special installations which may require further precautions as the cases dictate This manual has been completely read including the following chapters and has been fully understood The piping system has been flushed of any fore
3. 92 2 92 2 pet TIO m gt f d4 2 c mAn ESEJ E He E y dpompetraveint l E 1 LA j co T Wf 07 010 SES EE d2 1 DNM e ju Pumps series MC TC Connections for designs U2 d5 E 1 95 An Tok d7 2 1712 dpempetrevetin o 5 2 7 99 d2 1 Pumps series TC Connections for designs C R RR R2 1 Pumps series MCU CH 5 gr 3 and 4 Standard hook ups and connections TT N da 46 A ay 7 du z Pumps series TBH C TBH KC AT KC TBA C Standard hook ups and conn 18 Operating manual for centrifugal pumps 4r amp p 43 1 d2 2 Pumps series TBH CT AT CT Connections for cooling or heating Fig 22 CONNECTIONS AND HOOK UPS FOR FLUSHING
4. pompetravaini OPERATING MANUAL FOR CENTRIFUGAL PUMPS AT TMA OPERATING MANUAL INSTALLATION START UP AND MAINTENANCE FOR CENTRIFUGAL AND SELF PRIMING PUMPS This manual applies to the listed below centrifugal pump series and or affiliated series AT TBH TBA TBK TBAK TCA TCT TCD TMA All pumps are manufactured by POMPETRAVAINI Via per Turbigo 44 Zona Industriale 20022 CASTANO PRIMO Milano ITALIA Tel 0331 889000 Fax 0331 889090 http www pompetravaini com Distributor WARRANTY products manufactured by POMPETRAVAINI are guaranteed to meet the conditions listed on the general terms and conditions of sale and or conditions listed on the Order Confirmations Failure to strictly adhere to the instructions and recommendations listed in this manual will void the manufacturer s warranty NOTE This manual is valid only for the listed pump series This manual IS NOT for the total installation Instruction and maintenance manual for the installation must be obtained from the engineer that designed the installation Furthermore the installation manual will take precedence over the pump manual In preparing this manual every possible effort has been made to help the customer and operator with the proper installation and operation of the pump Should you find errors misunderstandings or discrepancies please do not he
5. mechanical seal flushing liquid inlet from outside Grease nipple Plugged connection air hole mechanical seal chamber Plugged connection sludge discharge from mechanical seal chamber Plugged connection tank liquid discharge only for TCD 2 SP Threaded connection for tank only for TCD 2 SP Threaded connection to check oil leaks from bearing Threaded connection thermometric probe Plugged connection filling Plug to be removed in case of use Before connecting remove the plastic protection plug Fig 20 CONNECTIONS AND HOOK UPS FOR FLUSHING d5 d5 t 919 pe PL it H d 5 RE dd 46 46 45 98 d5 t d14 d10 x h BASS i i co ns 17 amp p Ed pompetreveini d NJS NIIH ege amp TAN 4900 0 9 dti Pump series Standard connections and hook ups NOTE d19 on both side for gr 2 Operating manual for centrifugal pumps 17 Fig 21 CONNECTIONS AND HOOK UPS FOR FLUSHING
6. 14 7 4 COUPLING PUMP SERIES AND These pumps do not require a coupling between the pump and the motor shaft they have been engineered with a supporting flange and shaft having bore and keyway ready to engage the motor shaft and key Check the tolerances of pump shaft bore with its and motor shaft with key The motor shaft must engage the pump shaft perfectly without iF interference In the event there is interference even if minimal it is required to rework the motor shaft because a forced fitting would be detrimental to the pump operation E Attach the electric motor to the pump flange making L 22 sure that the two shafts lineup and the key engages M the keyway Bolt the assembly with the supplied fasteners and install the supporting foot if it applies to the specific pump see fig 14A 8 ELECTRICAL CONNECTIONS Electrical connections must be made exclusively by qualified personnel in accordance with the instructions from the manufacturer of the motor or other electrical components and must adhere to the local National Electrical Code FOLLOW ALL SAFETY PRECAUTIONS AS LISTED IN CHAPTER 2 BEFORE DOING ANY WORK TO THE INSTALLATION DISCONNECT ALL POWER SUPPLIES It is recommended that electric motors and eventual connected accessories be protected against overloading by means of circuit breakers and or fuses Circuit breaker
7. 9000040 5 D 27220 5 6 REN KR RK e 0600090 KEK KERR KKH 256 SEEKER KKK RE 505 lt lt 5 XX 2505 22 5 0090 2255 255 225 BRS RRS 5 5 5 25 et Where mm mechanical seal diameter pumping pressure NOTE flushing liquid pressure must be higher than pumping pressure 1 liquid flow required NOTE for double mechanical seals double the quantity 2550 525 525 5250 2550 552 RK 555 POLS 222 PERE SERS lt 1 54 50 5 50 5255 9909 505 55 lt 2555 NUN Tote 50 5 lt 5 555552 d 5 0000000 5 bo Y XX 5 lt 525252525 0O 2 4 6 8 10 12 14 16 18 bar Tab 4 LIQUID FLOW REQUIRED TO MINIMUM MAXIMUM SEAL CHAMBERS COOLING PUMPS SERIES QUANTITY QUANTITY group 1 amp 2 group 1 amp 2 MC group 3 amp 4 Operating manual for centrifugal pumps 25 16 TROUBLE SHOOTING CHART PROBLEMS CAUSES AND SOLUTIONS Consult the following table when problems are experienced if solutions are not found in this chart tab 5 or should there be any doubts do not hesitate to contact POMPETRAVAINI or your local representative Ta
8. _ 005 US Gal Litres US Ga 0 02641 USGa Ft Litres ImpGa 0219 US ImpGa m Lies 001 2 2 353 m m USQGa 26417 Ft m 21996 US Ga FU 283 c Fr usea 78 P 628 Toconvert Toobtain Multipyby Toconvert To obtain cm inches 03937 inches cm em m 01 f f t m m 3804 Ni eine 00 SS 1 Operating manual for centrifugal pumps NPSH TMA Multiply by 0 2778 16 67 0 589 0 4719 28 32 1 698 Multiply by 3 785 0 003785 0 0133 0 0832 4 545 0 004545 0 16 1 2 Multiply by 2 54 0 3048 PUMP model Serial Number Computer Number Year of manuf LIQUID handled Lethal Toxic Noxious Corrosive Irritant Malodorous MAXIMUM DIMENSIONS Y INSTALLATION SERVICE Inside Outside Continuous Intermittent Explosive area mw ug TM MOTOR type Frame No Poles No Revolutions Absorbed power Installed Power COMMENTS Operating manual for centrifugal pumps 31 JOUR PRODUCTION MONOSTAGE CENTRIFUGAL PUMPS MAGNETIC DRIVE MONOSTAGE CENTRIFUGAL PUMPS SELF PRIMING CENTRIFUGAL PUMPS MAGNETIC DRIVE SELF PRIMING CENTRIFUGAL PUMPS MULTISTAGE CENTRIFUGA
9. are disassembled users of pace maker 2 meters floppy disk magnetic cards etc 1 meter When the magnetic rotor is mounted in the pump users of pace maker 1 meter floppy disk magnetic cards etc 0 5 meter NOTE There are certain components in the pump which may be dangerous to people coming in their contact even during normal operation procedures and or maintenance See table 1 Tab 1 MATERIAL MAJOR RISKS Oil and grease General lubrication ball bearings Skin and eye rash Plastic amp elastomer components O Ring V Ring splash ring Smoke amp vapours in case of overheating Teflon amp Kevlar fibbers Packing rings Release of dangerous powder release of smoke if overheated Paints amp varnishes Pump outside surface Release of powder and smoke if working the painted areas Flammable 3 IN CASE OF EMERGENCY In the event of pump break down and or loss of pumped fluid immediately disconnect the electrical power to the motor see chapter 11 and contact the responsible personnel in charge of the installation which should intervene with at least two people paying particular attention to the fact that the pump may be handling dangerous fluids hazardous to the health and environmentally unsafe After the causes for the emergency have been addressed and resolved it will be necessary to follow the starting procedures see chapter 10 for the start up of the pump motor assembly 3 1 BASIC FIRST AID In the e
10. listed in the tab 2 for the given coupling size it will be required to correct the alignment by using decimal shims under the pump or motor feet NOTE the optimal values have to be considered half of the reported data When the measured values fall within the tolerances the pump and motor anchoring bolts can be tightened 10 Angular misalignment can be measured with a Calliper Measure the outside coupling dimension at several points see fig 13 Find the minimum and maximum width of the coupling the difference between these two readings Y Y1 Y2 should no exceed the value listed in tab 2 for the given coupling size NOTE the optimal values have to be considered half of the reported data Should this value be greater it will be necessary to correct the alignment by re shimming the pump and or motor Following this operation it is recommended to check once more the value X to make sure that both values are within the allowed tolerance see point 9 Make sure that both set screws on the coupling halves are properly secured Tab 2 COUPLING GAP PARALLEL ANGULAR mm S mm X mm Y mm 0 10 0 20 100 2 to 2 50 130 L 19 3 to 3 75 300 11 Install the coupling guard and its extension if applicable on the pump secure the two locking bolts The gap between motor and guard should not be greater than 2 to 3 mm see fig 14 Operating manual for centrifugal pumps 11 2to3 mm Fig
11. mechanical seals leakages can be piped to a container located nearby on the floor or if available to the drain catch basin for the total installation The pump draining piping should be fitted with an isolating valve and both should be suitable for the pumps maximum operating pressure Fig 19 Cooling heating flushing of mechanical seals and other piping must be connected only to the designated connections located on the pump see fig 20 and 21 All tubing and connections must be a minimum of same size as the connection on the pump Insulation if required must be limited to the pump body leaving all other components such as bearing frame and motor uncovered for heat dissipation Fig 18 Controlling the minimum capacity When the pump operates near the shut off with almost no flow almost all the motor power is transformed into thermal energy which is absorbed by the pumped liquid If the capacity is less than the minimum recommended 10 15 of pump capacity at its best efficiency point not only will there be excessive load on the pump support and bearings but the liquid could evaporate resulting in damage to the impellers and wear rings with possibility of the pump seizing To prevent these problems it is recommended the installation of a minimum flow valve in the discharge piping right after the pump but before the flow regulating valve In the event the flow regulating valve being excessiv
12. seal there should not be any leakage see chapter 15 the bearing support temperature at full operation is less than approx 85 C NEVER OPERATE THE PUMP DRY If at start up there are suspicions of abnormal operation it is recommended to stop the unit and investigate the causes see chapter 16 Operating manual for centrifugal pumps 21 11 3 SHUT DOWN The centrifugal pumps can be shut down by switching off the power to the motor with open or closed flow regulating valve however if there are no provisions against liquid hammer it is recommended to close the flow regulating valve at pump discharge prior to stopping the pump Avoid the use of instantaneous shut off valves such as solenoid valves These can cause severe pump damage If the piping has not been fitted with non return valves it is required to close the shut off valves in sequence to prevent emptying the piping Close first the isolating valve at discharge and then at suction side If the non return valve is not fitted or the isolating valve at the discharge side is not completely closed it may happen that during the shut down the pump shaft will rotate in the opposite direction than is normal in such cases absolutely avoid restarting the pump until the pump shaft has stopped rotating Following pump shut down it is required to close any auxiliary lines such as flushing heating etc After the first start stop and if necessary check pump motor alignment and make sure
13. the PUMP NOT RUNNING following the safety measures given in chapter 2 After completion of the work ALWAYS re install the safety guards previously removed At first start up loosen the nuts of the packing gland allowing a steady flow of liquid to drain out see fig 25 After obtaining a steady flow of leakage gradually tighten the gland nuts until attaining a steady dripping within the limit of the above recommended temperature A few hours time span may be required to establish a steady dripping at low temperatures Packing adjustment is required when the liquid leakage increases When adjustment is no longer possible the packing material should be replaced with new one Follow the Disassembly and Assembly Instructions to replace the packing materials In the event the pump remains out of service for more than 2 months it is recommended to replace the packing LANTERN PACKING GLAND PACKING rings prior to start up is PACKED BOX FLUSHING ADJUSTING BOLTS amp NUTS Fig 25 24 Operating manual for centrifugal pumps 15 MECHANICAL SEALS MECHANICAL SEALS Mechanical seals can be of different materials designs and arrangements see fig 25 The proper selection has been made by POMPETRAVAINI considering the liquid to be handled by the pump and the operating conditions If flushing from an external source is required the proper set up must be provided for a good operation Figures 20
14. the baseplate for base mounted assembly or the bolts on the adapter flange in the case of monoblock design remove the pump anchor bolts on the baseplate remove the pump from installation without damaging other system components When the pump has been repaired re install following the steps from Assembly and Alignment procedures and after see the applicable chapters starting from chapter 7 Operating manual for centrifugal pumps 27 118 SPARE PARTS SPARE PARTS When ordering the pump it is good practice to also order the necessary spare parts especially when there are no stand by pumps in the installation This will minimise unnecessary down times in the event of pump failure or routine maintenance For better parts management the VDMA 24296 standards suggest to stock the number of parts in function of the number of pumps being used by the plant see following table Spare parts Identical pumps number stand by pumps included 6 8 10 2 3 4 5 and and and 7 9 more Components Number of spare parts Suction and discharge elements 1 1 2 2 2 3 30 Impellers a rss d Lie ee Radial seal rings 2 2 3 3 4 50 Ball or roller bearings Shaft complete with keys nuts shoulder rings etc 1 1 2 2 3 3096 Bushes 3 4 50 Shaft protection sleeves 2 2 3 Neck rings 1 1 2 2 3 30 Packing rings 16 16 24 24 24 32 40 Gaskets for pump cas
15. 21 22 indicate the location of connections for proper seal flushing For the proper flow and pressure of flushing liquid see tab 3 and or consult with POMPETRAVAINI and or the seal manufacturer For the liquid flow required to seal chambers cooling see tab 4 The mechanical seals fitted in our standard pumps are to DIN 24960 and or ISO 3069 standards The main seal dimensions can be found in the pump Disassembly and Assembly Instructions Usually mechanical seals do not require maintenance until leakage is visible see Disassembly and Assembly Instructions for mechanical seals replacement Mechanical seals must NEVER RUN DRY the absence or lack of flushing liquid will cause seal faces and elastomers damage greatly reducing their operating life It is suggested to check the conditions of the seal faces every 4000 hours of service Fig 26 SPRING GASKET RUBBER BOOT ROTATING FACE Sw ISS Z 7 SWAY i ERR TN s GELT nbi STATIONARY 4 So gt A Her S SY A QQ WT RING ROTATING FACE Typical example of Typical example of Typical example of single mechanical seal double back to back mechanical seal double tandem mechanical seal Be Tab 3 LIQUID FLOW REQUIRED TO SINGLE MECHANICAL SEALS FLUSHING FROM OUTSIDE 525 550 525 2 505 505
16. Fig 6 PREPARATION TO ASSEMBLY ON MONOBLOCK DESIGN tooo Oo COCO o o COUPLING GUARD FLEXIBLE COUPLIG S S 0000000 Fig 7 CHECKING ALIGNMENT ON MONOBLOCK DESIGN 3 Applying slight hand pressure to the coupling guard rotate it so that one opening of the lantern is accessible see fig 7 4 Rotate by hand the coupling through the lateral opening of the lantern to make sure the pump is free 5 With a proper spacer check the distance between the two coupling halves The gap value COUPLING GUARD S should be as listed on table 2 or as given by 1 the coupling manufacturer In the event adjustment is necessary loosen the set screws Ne on the coupling half and with a screw driver Wi move the coupling half to attain the gap S see fig 11 Then tighten the set screw and rotate EN A the rotor by hand to make sure once more that there is no obstruction 6 Rotate back the coupling guard by hand through EXTENSION the two openings of the lantern so that both openings are completely covered This will complete the alignment verification of the Fig 8 CHECKING ALIGNMENT ON BASE MOUNTED PUMP MONOBLOCK design DESIGN 7 Remove the couplin
17. L PUMPS LIQUID RING VACUUM PUMPS LIQUID RING COMPRESSORS PACKAGE VACUUM UNITS WITH PARTIAL OR TOTAL SERVICE LIQUID RECIRCULATION NA5 IS CENT GBOO UD ZT PRINTED IN ITALY MCENTRGB Continuing research of POMPETRAVAINI results in product improvements therefore any specifications may be subject to change without notice pompetravaini _ 20022 CASTANO PRIMO Milano ITALY Via per Turbigo 44 Zona Industriale Tel 0331 889000 Fax 0331 889090 http www pompetravaini com N Member of CISQ Federation CN AN RINA D 150 9001 2000 Certified Quality System 32 Operating manual for centrifugal pumps
18. Mechanical seals 16 Trouble shooting chart problems causes and solutions 17 Pumprepair and removal from installation 18 Spare parts 19 Engineering data 19 1 Starting torque 19 2 Typical performance curves 19 3 Units convertion table Operating manual for centrifugal pumps 1 GENERAL INSTRUCTIONS This manual is intended to provide reference to pump safe application and operation pump installation and maintenance instructions pump start up operation and stopping procedures The pump user must complete the section at the end of this manual where the design conditions for the pump are recorded The manual must be filed in a safe place and be accessible to the operator and to the maintenance personnel The qualified personnel responsible for the operation or maintenance of the pump should read CAREFULLY the whole manual before operating or working on the pump Qualified personnel are those with experience knowledge and have a good familiarity with the working safety regulations They usually have a knowledge of basic first aid The pump is to be used only for the applications specified on the confirming order for which POMPETRAVAINI has selected the design materials of construction and tested the pump to meet the order specifications Therefore the pump CANNOT be used for applications other than those specified on the order confirmation In the event the pump is to be used for different applications please contact th
19. SOLATING POWER SUPPLY 2 VALVE X RECORDER A E FOOT VALVE HEAT SENSOR 7 Jm 1 224 S SS A FILTER Y m Pump series TCK Fig 17 FILTER 200 00 209 000 492019004 89001090 55 Pump series TC VERTICAL construction Operating manual for centrifugal pumps 1 9 3 ACCESSORIES AND AUXILIARY CONNECTIONS Depending on the application accessories may be installed to test the pump performance instrumentation to measure pressure temperature capacity etc and or for necessary operations cooling heating flushing of seals etc When accessories are required the following should be considered a b d e f 9 h 16 Pressure and vacuum gauges must be properly anchored and connected at the measuring points located at pump flanges or near the flanges using approx 8 mm diameter tubing with pig tail configuration to alleviate pressure fluctuations For safety purposes isolating and vent valves should be fitted before these instruments see fig 18 Temperature gauges should be installed with thermowells selected for the specific purpose and fitted in strategic locations where the reading is required see fig 19 Every pump is fitted with draining connections at the pump casing If required pump drain and
20. ar safety equipment hard hat safety glasses safety shoes etc adequate for the work to be done Be ALWAYS informed on locations of first aid sites inside the company and carefully read safety and medical first aid prescriptions in force ALWAYS stop the pump prior to touching it for whatever the reason ALWAYS disconnect the power to the motor prior to working or removing the pump from the installation NEVER work on the pump when it is hot DONOT attempt to remove the safety guards when the pump is operating After completion of the work ALWAYS re install the safety guards previously removed NEVER touch pump or piping with temperatures higher than 80 C ALWAYS be careful when handling pumps that convey acids or hazardous fluids ALWAYS have fire extinguisher in the vicinity of the pump installation DONOT operate the pump in the wrong direction of rotation NEVER put hands or fingers in the pump openings or holes NEVER step on pump and or piping connected to the pump Pump and piping connected to the pump must NEVER be under pressure when maintenance or repair is carried out 4 Operating manual for centrifugal pumps CAUTION Pumps type TCK TBK and TBAK create a high magnetic field Personnel should take proper precautions if they are wearing pace makers or if they are using instrumentation sensitive to magnetic fields The listed below minimum distances must be kept When the magnetic rotor parts
21. aragraph 19 1 of chapter 19 Operating manual for centrifugal pumps LEGEND for figures 20 and 21 d1 1 d1 2 42 1 02 2 d3 1 010 011 012 013 014 015 016 017 018 019 020 Plugged connection Threaded connection Pump series TCK Standard connections and hook ups Threaded connection double tandem mechanical seal flushing inlet from outside Threaded connection double tandem mechanical seal flushing outlet Plugged connection mechanical seal chamber cooling liquid inlet Plugged connection mechanical seal chamber cooling liquid outlet Threaded connection flushing liquid inlet from outside for double back to back mechanical seal or for single mechanical seal construction Threaded connection double back to back mechanical seal flushing liquid outlet Threaded connection casing heating chamber liquid inlet Threaded connection casing heating chamber liquid outlet Plugged connection casing heating chamber liquid drain Plugged connection for manometer Plugged connection for pump casing drain Threaded connection packing seal flushing liquid inlet from outside Threaded connection packing seal flushing liquid outlet from outside Threaded connection for seal leakages recovery Plugged connection bearings oil drain from housing Plug with dipstick for bearings oil filling into housing Constant level oil filler on request only or Oil level gauge standard Threaded connection
22. ating speed RPM nominal g 250 1000 kW gt ine ERES According to the centrifugal pump starting there could be three principal T p cases each with his characteristic curve of starting see examples below qe 2 40 6 80 00 Motor speed 7 OT Qn lo 3 1 Starting with open valve on discharge Qn 5 E 5 During this starting it can be assumed the curve of T N E i Operating Torque in function of the round number H similar to a parable that starts from about the 20 of 25 the value of Operating Torque to Qn P Ld _ Capacity d Zn Motor speed 2 Starting with partially closed valve on discharge BTE Motor speed i Capacity This type of starting requires a particular observation first the pump must reach a value of a 100 A n oe um minimum capacity Qm correspondent to the d partialized capacity of the valve such to guarantee B 7 4 correct operation without problems of liquid Ee Qm evaporation or excessive radial loads on the shaft 8 v then the pump by totally opening the valve will z reach the value of nominal capacity Qn and 9 therefore the value of maximum operating torque n NOTE In this case it is esteemed an absorbed Capacity 2 Uh santet power at the value of Qm corresponding to M owe 2 e about 6095 of Qn Minimum capacity 9 39 100 Hy OT 3 Starting with completely open valve and with f non
23. b 5 LIST OF PROBLEMS PROBLEM LIST OF POSSIBLE CAUSES Lack of or no flow and or pressure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 25 40 Excessive flow and or pressure 15 16 17 18 High power consumption 10 15 16 18 19 20 21 22 23 Excessive vibration and noise Bearing overheating Sealing malfunction CAUSES SOLUTIONS 1 Pump is not primed Repeat the priming procedure is notad duate Increase the motor speed in relation to the working conditions q Replace impeller with one having larger diameter Increase operating speed if possible see point 2 or replace Installation requires higher pressure than impeller with one of larger diameter Change the pump or expected increase the number of stages in case of multistage pumps Reduce the system pressure 4 Wrong direction of rotation Change the motor direction of rotation 5 There are air pockets in the suction line Modify the layout of suction piping Air enters the suction line Check the piping sealing areas 7 pumped liquid is emulsified with air Install a reservoir or tank before the pump to de aerate th liquid Reset the suction lift to the original value Increase the piping diameter Check the suction piping the foot valve or non return valve the filter Open completely the isolating valve in the suction piping Decrease the friction losses The suction lift or and suction pressure is more than anticipated and therefo
24. cedure Operating manual for centrifugal pumps 7 Fig 1 Fig 2 Fig 3 8 Operating manual for centrifugal pumps 7 MOUNTING AND ALIGNMENT INSTRUCTIONS 7 1 MONOBLOCK PUMP MOTOR AND PUMP MOTOR ASSEMBLY MOUNTED ON A BASEPLATE If the pump has been furnished with bare shaft end i e without motor it is required to procure a proper baseplate on which to mount the pump motor assembly The baseplate must be properly designed for maximum rigidity to prevent vibrations and distortions It is recommended the use of a fabricated baseplate manufactured with rigid U shaped channel fig 15 illustrates an example When the pump has been purchased without the electric motor it is then required to select the proper motor before proceeding to the installation of the unit Selection of motor must consider the following data at running condition maximum power absorbed by the pump over the total operating range pump operating speed RPM available power Hertz voltage poles etc motor enclosure type CVE AD PE ODP TEFC EX PR etc motor mount B3 5 horizontal vertical C flange D flange etc Flexible couplings are selected considering nominal motor horse power motor operating speed coupling guard must meet safety standards as dictated by EN 294 OSHA etc Flexible couplings must be properly aligned Bad alignments will resu
25. ction lift installation and toward the pump in the case of the flooded suction installation Isolating valve should only be on the fully open or fully closed positions and NEVER as a flow regulator The valve should be installed with the stem in the horizontal position relative to the flow in the piping and at a distance from the pump suction flange of at least 10 times the pipe size Depending upon the application a non return valve or a foot valve should be fitted in the suction piping a strainer or filter will prevent solids from entering the pump and a pressure or vacuum gauge will enable reading the pump inlet pressure All components listed above will create pressure drops which must be taken into consideration in the design stage Where more than one pump is installed every pump should have its own separate suction piping if a stand by pump is installed the two inlets can be connected to a common manifold with a single suction piping 9 2 2 Discharge piping see fig 17 Right after the pump discharge flange install a non return valve will stop dangerous water hammer which could seriously damage the pump discharge casing a flow regulating valve Globe or Needle valve a pressure gauge can be connected to the threaded connection under the pump discharge flange a vent valve should be fitted in this piping to fill pump and piping for initial start up 9 2 3 Piping cleaning Before installation start up clean piping and any reservoirs re
26. d or bearing wear It is recommended to periodically check the oil pH which will indicate the oil stability and the oxidation grade consult the supplier for the acceptable values Satisfactory oils are those with a viscosity at 40 C between 46 and 100 centistokes Oils with high viscosity 100 centistokes are recommended for applications with high operating temperatures Pumps of series TCD can use oils with viscosity up to 220 centistokes Some oil types are AGIP OTE 55 EP AGIP BLASIA 68 CASTROL HY SPIN VG 46 CASTROL HY SPIN AWS 68 ESSO TERESSO 68 ESSO NURAY 100 SHELL TELLUS OIL T68 IP HIDRUS 68 NOTE Avoid mixing different oil brands and with different characteristics Operating manual for centrifugal pumps 23 VENT PLUG PLUG WITH DIPSTICK OIL LEVEL GAUGE Fig 24 14 PACKED STUFFING BOXES PACKED STUFFING BOXES Pumps fitted with packed stuffing boxes require packing flushing either from an external source or directly from the pumped media through pump internal passages This liquid is necessary to remove the friction heat generated between the shaft and the packing The dripping quantity is a function of the pump size and of the pressure in the stuffing box housing In any event the liquid drops coming out of the stuffing box should not exceed a temperature of 60 70 C in relation to handling a liquid at ambient temperature 14 1 ADJUSTING THE PACKING All adjustment operations must be performed with
27. e sales office or representative of the manufacturer POMPETRAVAINI declines to assume any responsibility if the pump is used for different applications without prior written consent The user is responsible for the verification of the ambient conditions where the pump will be stored or installed Extreme low or high temperatures may severely damage the pump unless proper precautions are taken POMPETRAVAINI does not guarantee repairs or alterations done by user or other unauthorised personnel Special designs and constructions may vary from the information given in this manual Please contact POMPETRAVAINI should you have any difficulty NOTE Drawings appearing in this manual are only schematics and not to be used for construction For more specific information contact the Engineering Department of POMPETRAVAINI or the authorised local representative 2 SAFETY INSTRUCTIONS CAUTION CAREFULLY READ FOLLOWING INSTRUCTIONS Strictly adhere to the instructions listed below to prevent personal injuries and or equipment damage ALWAYS apply the pump for the conditions outlined on the confirming order Electrical connections on the motor or accessories must ALWAYS be carried out by authorised personnel and in accordance to the local codes Any work on the pump should be carried out by at least 2 people When approaching the pump ALWAYS be properly dressed avoid use of clothes with wide sleeves neckties necklaces etc and or we
28. ee of vibrations do not store in areas with less than 5 C temperature for lower temperature it is necessary to completely drain the pump of any liquids which are subject to freezing FREEZING DANGER Where the ambient temperature is less than 5 C it is recommended to drain the pump piping separator heat exchanger etc or add an anti freeze solution to prevent damage to the equipment fill the pump with a rust preventative liquid that is compatible with the pump gaskets and elastomers Rotate the shaft by hand to impregnate all internal surfaces Drain the excessive liquid from the pump and associated piping see chapter 11 Please note that the pumps with cast iron internal parts have been treated at the factory prior to shipment with a rust preventative liquid this liquid is capable of protecting the pump against rust for a period of 3 to 6 months A further solution for long term storage is to fill the pump with the rust inhibitor rotate the pump shaft by hand to eliminate any air pockets the liquid must be suitable with gasket elastomers and pump materials plug all openings that connect the pump internals to the atmosphere protect all machined external surfaces with an anti rust material grease oils etc cover the unit with plastic sheet or similar protective material rotate pump shaft at least every three months to avoid possible rust build up or seizing any pump accessories should be subjected to similar pro
29. ely throttled or even completely closed there will always be the required minimum liquid flow recirculated from the pump discharge to the suction piping of the pump The other device which may be fitted in this by pass line from pump discharge before flow regulating valve to pump suction is a calibrated orifice sized for the minimum liquid flow required by the pump Pumps with magnetic drives series TBK TBAK TCK should be fitted with a temperature sensor to monitor and register the temperature in the area of the magnetic coupling Pumps are fitted with a threaded connection for this purpose To prevent pumps running dry it is recommended to install in the pump discharge line a flow meter to check that there is a constant liquid circulation in the piping Fitting of a power meter will help analyzing the operation of the pumps Knowing the minimum and maximum power absorbed by the operating pumps will help identifying problems that may be caused by dry running siphoning etc Accelerometers fitted on the bearing housing near the bearings will help with the reading of the vibrations An analysis of the vibration diagram direct or indirect would provide a diagnostic to prevent mechanical breakdowns such as hydraulic cavitation It is recommended to start the magnetic pumps over 3 KW and all other pumps with more than 7 5 KW motor drive with Soft Starters or Delta Star connections Further information may be found in chapter 8 and in p
30. g should be approximately 3 to 5 C above the temperature of the product being pumped in standard conditions water at ambient temperature Higher values could indicate operation at low flow obstruction of internal flushing connections or mechanical damage of the magnetic coupling Please contact POMPETRAVAINI if there are doubts regarding abnormal temperature rises 13 LUBRICATION INSTRUCTIONS Pumps often operate in severe conditions and the bearings are subject to relevant radial and axial forces For a good pump operation it is therefore very important to keep the pump bearings well lubricated and clean WARNING The maintenance must be carried out with the pump turned off and the electrical power or other driving mechanism must be disconnected The power should only be turned back on by the same person doing the maintenance It is however recommended to have at least a team of two workers doing the maintenance and the supervisors should be fully aware of the work in progress CAREFULLY FOLLOW THE SAFETY PROCEDURES LISTED IN CHAPTER 2 Bearings and lubricants must be free of any foreign particles such as dirt dust etc which could cause the bearings to seize See Disassembly and assembly instructions for bearing sizes quantity and type of lubricants 22 Operating manual for centrifugal pumps 13 1 GREASE LUBRICATED BALL BEARINGS TMA pump series are fitted with regreasable bearings and grease type EP 3 The grea
31. g guard and its extension if there is one attached to the pump by removing the two locking screws see fig 8 and 9 p E 1 COUPLING GUARD L EXTENSION COUPLING GUARD Ve EXTENSION Fig 9 MOUNTING THE UNITS ON THE BASEPLATE 10 Operating manual for centrifugal pumps 8 the electric motor on the baseplate and bring the two coupling halves together with approx 2 mm between them keeping the motor axially aligned with the pump shaft In the event the two shaft heights do not align proper shimming under the pump or motor feet will be required Mark the motor and or pump anchoring bolt holes Remove motor and or pump drill and tap the holes clean and mount pump and or motor in place and lightly tighten the bolts see fig 10 BOLTS MOTOR BOLTS PUMP Fig 10 9 With a straight edge ruler check the parallelism of the two coupling halves at several points 90 from each other see fig 12 NOTE Easier and more accurate readings can be attained with instruments such as Dial Indicators if readily available HALF COUPLING ji HALF COUPLING 1 oe ip A x 1 EE CI LO Lt E H EHH SET SCREW S SET SCREW HO Fig 11 Fig 13 Y2 If the maximum value of X is higher than that
32. gal pumps for large flows of clean and dirty liquids Design with open impeller Capacity to 2100 m h Max pressure 4 bar Flanges PN 10 Magnetic drive single stage centrifugal pumps for toxic and contaminated liquids Designed to DIN TCK 24256 1SO 2858 standards Design with closed impeller Capacity to 85 m h Max pressure 7 Flanges PN 16 Self priming multistage centrifugal pumps with dual lateral channel Low NPSH requirements Capacity to 30 m h Max pressure 7 bar Flanges PN 40 Self priming multistage centrifugal pumps with single lateral channel Capacity to 70 m h Max pressure 34 bar Flanges PN 40 Magnetic drive self priming multistage centrifugal pumps with single lateral channel Capacity to 70 m h Max pressure 34 bar Flanges PN 40 Operating manual for centrifugal pumps 5 Self priming multistage centrifugal pumps with centrifugal pre stage with very low NPSH requirements Capacity to 35 m Max pressure 31 bar Flanges PN 40 Magnetic drive self priming multistage centrifugal pumps with centrifugal pre stage with very low NPSH requirements Capacity to 35 m Max pressure 31 bar Flanges PN 40 Multistage centrifugal pumps for clean liquids medium and high pressures Capacity to 45 m h Max pressure 40 bar Flange inlet PN 16 flange outlet PN 40 4 1 PUMP MODEL NUMBERS AND MATERIALS OF CONSTRUCTION TABLES Pump nameplate affixed to each pump contains model number serial numbe
33. ift the liquid as soon as it starts operating If the pump is not self priming but the suction piping is fitted with a foot valve the suction piping and the pump can be filled with liquid by opening the valve at the discharge side provided the discharge piping is full of liquid or fill the pump body as well as suction piping with the liquid to be pumped through the vent valve For non self priming pumps with the suction piping not having a foot valve the suction piping and the pump can be filled with liquid by hooking up the vent valve to a vacuum pump or vacuum source and keeping closed the valve at the discharge side of the pump when the liquid exits the vent valve it means that the pump and suction piping are completely full of liquid At this point the vent valve should be closed and the vacuum pump or source can be turned off Check the position and or control the opening of the minimum flow valve flushing lines and or auxiliary supply lines After the pump and its suction line is full of liquid the pump should be started In this regard there are two possible cases 11 1 4 Starting a pump without back pressure at discharge side For centrifugal pumps type MC TC TMA motor must be started with discharge valve closed When the motor has reached full speed the discharge valve can be opened until the required differential pressure is reached CAUTION do not operate the pump with closed discharge piping for an extended period
34. ign particles welding impurities etc Have all piping and pump obstruction been removed All connections and piping are leak proof and there are no external forces or moments applied to the piping or pump flanges Pump and motor are properly lubricated if required Pump motor alignment has been checked f mechanical seal requires flushing has this been connected All valves in the installation are in the correct position All safety guards are in place Hasthis pump s direction of rotation been checked by jogging the motor The pump Stop switch is clear and visible Are pump and installation ready for start up 11 STARTING OPERATING AND STOPPING PROCEDURES Upon receipt and or completion of installation before turning on the power to the electric motor rotate the pump shaft by hand to make sure that the pump rotor is free In the event the shaft does not turn try to free it up by applying a torque to the pump coupling with a pipe wrench To free the rotor of a monoblock style pump without coupling introduce a bolt or similar tool at the motor shaft end that has a threaded connection and apply the torque by hand In the event the pump does not become free with the above procedures fill up the pump with a suitable solvent or lubricating liquid let it rest for several hours to allow softening of the rust build up inside the pump drain the pump and apply torque to the pump shaft as described above to finall
35. ing Set 4 6 8 8 9 12 15096 Other gaskets Set 10 10096 ua Rotating part a 2 stationary part 2 3 4 292 co otating part gasket 9 Stationary part gasket 3 8 is 1250 Springs 1 1 1 1 2 2 20 Bearing housing groups complete with shaft u a VE Wt 22 1 2 bearings covers seal rings etc Coupling inserts Set 2 3 4 5 6 7 75 On the pump nameplate there are printed pump model year of manufacture and pump serial number When ordering spare parts always provide this information Pump type parts item number VDMA and description per the pump sectional drawing and parts list is useful information which helps to supply correct spare parts for your pump We recommend the use of original spares in case this is not respected POMPETRAVAINI declines any responsibility for eventual damages and not correct running caused by not original spare parts 28 Operating manual for centrifugal pumps 19 ENGINEERING DATA 19 1 STARTING TORQUE OT Starting torque of a centrifugal pump is very low Usually standard electric 9 P motors may be safely used to drive this pump Pump operational speed 9 any speed is reached only if motor torque is greater than pump Small motors operating torque See side figure E 5 40 kW Operating Torque Nm is given by gt 2 e Large motors Operating Torque 9549 x kW absorbed at oper
36. ith the motor installation and alignment 9 2 SUCTION AND DISCHARGE PIPING see fig 16 Identify first locations and dimensions of all connections required to interconnect the pump with the installation then proceed with the actual piping connect the pump suction and discharge flanges the service liquid line and all other service connections BE SURE TO PIPE THE CORRECT CONNECTION FROM THE INSTALLATION TO THE RESPECTIVE PUMP CONNECTION To prevent foreign matters from entering the pump during installation do not remove protection cap from flanges or cover from openings until the piping is ready for hook up Inlet and discharge piping should be of same size as the pump flanges where possible increase the pipe size but NEVER decrease the size In general the liquid velocity in the suction piping should not exceed 2 m s and in the discharge piping should be less than 3 m s Higher liquid velocities will result in higher pressure drops which could create cavitation in the suction piping and excessive pressure losses in the discharge piping which would negatively affect the system performance and the pump Where possible avoid using piping turns and especially short radius elbows Operating manual for centrifugal pumps 13 When using larger pipe sizes than the nominal the reduction from a larger diameter to a small diameter should be gradual and with conical configuration the length of the conical area should be 5 to 7 times the differe
37. lt in coupling failures and damage to pump and motor bearings Assembly instructions for MONOBLOCK design are listed on paragraph 7 3 steps 1 2 4 5 6 Assembly instructions for PUMP MOTOR ON BASEPLATE are listed on paragraph 7 3 steps 7 1 8 5 9 10 11 For pump driven with V BELT please consult POMPETRAVAINI for eventual information 7 2 ALIGNMENT PROCEDURE FOR MONOBLOCK AND FOR PUMP MOTOR ASSEMBLY ON BASEPLATE The pump motor assembly is properly aligned by POMPETRAVAINI prior to shipment It is however required to verify the alignment prior to the start up Misalignment can occur during handling transportation grouting of assembly etc For alignment procedures of MONOBLOCK DESIGN see paragraph 7 3 steps 3 4 5 6 For alignment procedure of BASEPLATE DESIGN see paragraph 7 3 steps 7 5 9 10 11 PLEASE NOTE Coupling sizes and permissible coupling tolerances listed in this manual are applicable to the particular coupling brand installed by POMPETRAVAINI as a standard For sizes and tolerances of other type of couplings follow the instructions given by their respective manufacturer 7 3 ALIGNMENT INSTRUCTIONS NOTICE Alignment should be done at ambient temperature obviously with power to the motor disconnected and following the safety procedures to avoid accidental starting see chapter 2 Should the pump operate at high temperatures which could upset the coupling alignment it is necessary to check the alignment to sec
38. moving loose materials and foreign particles Particular attention for cleaning should be for installations where welding of piping and components has taken place 9 2 4 Pressure testing When the installation has been completed it is necessary to test the piping for both static pressure and vacuum Testing should be carried out in accordance to the applicable standards for the piping function and the operating pressures 14 Operating manual for centrifugal pumps 1 FLOW CONTROL VALVE NON RETURN VALVE PRESSURE GAUGE FLOODED SUCTION SUCTION LIFT E d boon FLOW CONTROL VALVE 1 Pump series STRAINER NON RETURN VALVE ISOLATING VALVE FLOODED SUCTION PRESSURE GAUGE 29 FOOT VALVE BS ISOLATING VALVE v IFT FILTER MINIMUM FLOW ORIFICE BY PASS LINE FOR INSTALLATIONS
39. nce in size of the two diameters Piping should always be supported to neutralise any forces moments piping weights thermal expansions etc which could create pump motor misalignment deflections and overloading to foundation bolts Pipe joints should be by means of flanges with flange gaskets of proper size and material Flange gaskets should be properly centred between the flange bolts so that there is no interference with the flow of the liquid There should not be any tensions deformations or misalignment of the piping when loosening the bolts holding the flanges together Any thermal shocks and or excessive vibrations should be controlled by means of expansion joints flexibles etc having same size as the piping PUMP gt 2 1 SUCTION PIPING SUPPORT d JOINT 2 JOINT P Y 2 E 0 PUMP 2 PIPING SUPPORT 5 ji een Pd PIPING FROM ABOVE PUMP PIPING FROM BELOW PUMP Fig 16 9 2 1 Suction piping see fig 17 To prevent loosing pump priming absolutely avoid formation of air pockets in the suction piping This piping therefore should have a slope toward the reservoir in the case of su
40. ntact POMPETRAVAINI the seals The shaft sleeve is worn out Replace the sleeve with a new one The pumped flow is less than the Increase the flow Adjust the by pass recirculating valve or line minimum required 37 Baseplate or pump foundation is not Change or reinforce the baseplate and or foundation following adequate the recommended procedures 17 PUMP REPAIR AND REMOVAL FROM INSTALLATION Should the pump require repairs it is recommended to be familiar with the procedures outlined in the Disassembly and Assembly Instructions RESPECT THE SAFETY PRECAUTION MEASURES OUTLINED IN CHAPTER 2 In any case before working on the pump it is important to procure and wear the proper safety equipment hard hat safety glasses gloves safety shoes etc disconnect the electrical power supply and if required disconnect the electrical cables from the motor close the pump inlet and outlet isolating valves let the pump cool down to ambient temperature if is pumping hot liquids adopt safety measures if the pump has been handling dangerous liquids drain the pump body of the pumped liquid through the draining connections if necessary rinse with neutral liquid To remove the pump and the motor from the installation proceed as follows remove bolts from pump suction and discharge flanges remove the coupling guard remove the spacer of the coupling if there is one if required remove motor by removing the bolts on
41. o ventilate the areas to help cooling the motor All components used in the installation should comply with the safety codes Select a mounting pad that will minimise vibrations or torsion of the pump baseplate or frame It is generally preferred to have a concrete base or sturdy steel beams It is important to provide adequate anchor bolting for the pump frame or baseplate to be firmly attached to the foundations see fig 15 BASEPLATE SPACER 5t us CONCRETE amp s V DSL ANCHOR BOLT S Fig 15 Concrete pads and other concrete works must be aged dry and clean before the pump assembly can be positioned in place Complete all the work relating to the foundations and grouting of the pump assembly before proceeding with the mechanical and electrical portion of the installation 9 1 INSTALLATION OF PUMP MOTOR ASSEMBLY Place the pump assembly on the foundation pad aligning the anchoring bolts If necessary use metal spacers to level the unit and check the flange connection for good horizontal and vertical planes Tighten the foundation bolts Check again the level of the assembly and proceed with the pump motor alignment verification as discussed in paragraph 7 2 In cases where the pump is installed on a baseplate separated from that of the motor due to expected piping forces moments or as it often is in cases of large units it is recommended to first install the pump and then proceed w
42. of time to avoid overheating problems previously discussed For self priming pumps type AT TBH TBA all valves in suction and discharge piping must be fully open before starting the motor After the motor has been started the discharge valve can be throttled to build up the expected pressure It is possible to start these pumps with the discharge valve at the closed position but in this case there will be maximum power consumption at start up 11 1 5 Starting a pump with back pressure at discharge side In this case a non return valve must always be installed in the discharge piping The unit is started with the discharge valve partially open and after the pump pressure exceeds the back pressure in the discharge line then is time to adjust the discharge flow regulating valve to attain the operating pressure For the Starting Torque of the pump see chapter 19 1 11 2 OPERATION After starting the pump the following should be checked The differential pressure and the capacity are as expected if required adjust the flow regulating valve at the pump discharge side but NEVER throttle the valve at the suction side The motor amperage does not exceed the value shown on the motor nameplate The pump motor assembly does not have unusual vibrations and noises The seal arrangement works as it should if the sealing is by packing there should be continuos dripping from the stuffing box see chapter 14 if the sealing is by mechanical
43. on GS RA A3 HC DU Gasing Ductile iron Cover casin Hastelloy C ASTM CN7M Impeller Cast iron Stainless steel AISI 316 Shaft Stain steel AISI 420 ASTM CF8M Incoloy 825 Bearing frame Cast iron Generic materials for STANDARD CONSTRUCTION pumps AT TB Description GH RA A3 B2 GP Casing Ductile iron Ductile iron Element Cast iron Bronze Cast iron Impeller Brass Stainless steel AISI 316 Brass Shaft Stain steel AISI 420 ASTM CF8M Stain steel AISI 420 Bearing frame Cast iron Generic materials for STANDARD CONSTRUCTION pumps TMA Description Stage casing Impeller Shaft Stainless steel AIST 420 Stainless steel AISI 316 ASTM CF8M For detailed information on materials of construction standard or special for pumps TCD TCK MEC TBK and TBAK please contact POMPETRAVAINI or your local representative 6 Operating manual for centrifugal pumps 5 UNCRATING LIFTING AND MOVING INSTRUCTIONS Upon receipt verify that the material received is in exact compliance with that listed on the packing slip When uncrating follow the instructions listed below Check that no visible damage exists on the crate that could have occurred during transport Carefully remove the packaging material Check that pump or accessories such as tanks piping valves etc are free from visible markings such as dents scratches and damage which may have occurred during transportation In the event of damage report this immedia
44. ply voltage is wrong Motor does operate properly Change the motor Correct the power supply 16 The packing is too tight Loosen the nuts of the packing gland Pump seizing is experienced Stop the pump and look for any rotor obstructions The pump and or piping are loose Torque the bolts as required 25 Pump is worn out or damaged with Overhaul the pump excessive internal clearances The coupling rubber inserts are worn Replace the coupling inserts 27 The impeller is out of balance due to Disassemble clean balance and or replace the impeller Soften wear deposits and encrustation the liquid Forces moments and piping misalignment loading the pump Realign and Support te piping 26 Operating manual for centrifugal pumps quality is inadequate or there is lack of level n bearing frame is low oll Replace oil or grease to the normal level using proper quality grease lubricants The power absorbed is too high Decrease the power consumption by identifying the cause 31 Pump is running dry Reinstate the correct working conditions Pumped liquid or the flushing liquid to e p 32 the seals is dirty and or not adequate Install a filter in the flushing lines Change flushing fluid There are excessive shaft vibrations and Identify the causes and reinstate the correct working conditions deflections refer to more specific points in the table The pumped liquid is not adequate for Co
45. r and year of manufacture Interpretation of pump model number may be attained with the aid of the following table The pump model is such that it gives information pertaining to the pump type and design For information regarding temperature and pressure LIMITATIONS applicable to the varying designs types and materials of construction please contact POMPETRAVAINI or your closest authorised representative The maximum operating pressure is normally the sum of the suction and discharge pressures Listed below are some examples of pump nomenclatures Pumps series MC TC TCH 50 200 A 1 C A3 M V T TCH gt gt Shaft seal type 50 Diameter discharge flange Materials of construction see table 200 Impeller nominal diameter M Monoblock design with flanged motor A Hydraulic project modification V c Vertical mounting 1 c Constructive project number T c Special design Pumps series AT TB TBH 315 1 K C T M V GH Pumps series TMA TMA 322 TAII 7 gt Pump type c Shaft seal type e Bumpers gt Materials of construction see table 55 Number of stages M Monoblock design with flanged motor A Hydraulic project modification V c Vertical mounting 1 c Constructive project number Z c Special design Generic materials for STANDARD CONSTRUCTION pumps MC TC Descripti
46. re the pump cavitates The wear ring and or impeller neck and or the impeller and or the diffusers Overhaul the pump replacing and or repairing the damaged components are worn out or damaged 10 Viscosity density or specific weight of Re establish the characteristics of the liquid as originally liquid have higher values than expected expected if necessary contact POMPETRAVAINI Suction piping is not sufficiently e submersed in the liquid creating vortex Increase the depth of piping or foot valve in the liquid Impeller is plugged with scale deposit Take out the impeller clean it free the vanes and cavities of any and or foreign materials materials Soften the pumped liquid 13 There is entrained air in the system s the packed stuffing box or repair replace the mechanical Piping is plugged Clean piping and valves clean the filters Velocity is too high If possible decrease the pump rotational speed Th teg ired pressure GE systemie lower Adjust the flow regulating valve in discharge piping Decrease than kane gat y the impeller diameter contact POMPETRAVAINI Decrease the number of stages case of multistage pumps Pump is not suitable for the application Contact POMPETRAVAINI Reduce the pressure but without adjusting the isolating valve at 18 Inlet pressure is too high iha s ctian side Pump motor coupling is misaligned Realign the coupling Bearings are defective or worn out Replace bearings The power sup
47. return valve on discharge 37 og During the starting the non return valve will remain E e closed up to the attainment of the pressure value H1 5 correspondent to the pre load pressure of the same o H j gt valve and therefore void capacity This value is 25 reached at speed 1 this example esteemed N dts about 60 of the nominal speed The continuous motor acceleration will reach the attainment of Qn Capacity Q 0 25 75 100 zn after having passed through n2 Q2 H2 Motor speed Operating manual for centrifugal pumps 29 19 2 TYPICAL PERFORMANCE CURVES A A A I H H 2 I a L NPSH Z NPSH Q a a Q Typical performance curves Typical performance curves for pumps series AT TB for pumps series TC MC Where H Head NPSH Net Positive Suction Head P Absorbed power Q Capacity 19 3 UNITS CONVERSION TABLE Discharge and Delivery Capacity Linear measure 30 Toconvert Toobtain Multiply by Toconvert To obtain Litres sec Litres mn 60 Litres sec Liressec 236 Liressc 212 Litres sec 0 01667 Lites sec Liresmn 006 Litres min Liresmn 0053 mh Toconvert Toobtain Multiply by Toconvert _To obtain Lies 001 USQGa Lies
48. s and fuses must be sized in accordance with the full load amperage appearing on the motor nameplate It is advisable to have an electrical switch near the pump for emergency situations Prior to connecting the electrical wiring turn the pump shaft by hand to make sure that it rotates freely Connect the electrical wiring in accordance with local electrical codes and be sure to ground the motor Motor connection should be as indicated on the motor tag frequency voltage poles and max consumption and as discussed in the motor instruction manual It is recommended that motors over 7 5 kW be wired for Star Delta start up to avoid electrical overloads to the motor and mechanical overloads to the pump Pump series TCK TBK and TBAK and all motors over 7 5 kW should always be preferably wired for Star Delta start or soft start Be sure to replace all safety guards before switching on the electrical power If possible check the direction of rotation before the motor is coupled to the pump but protect the motor shaft to prevent any accidents When this is not possible briefly jog the pump to check its direction of rotation see arrow on pump for correct rotation If the direction must be changed two of the three electrical wire leads must be alternated with each other at the terminal box or at the motor starter Please be aware that rotation in the wrong direction and or pump running dry may cause severe pump damage Electrical instrumentation such a
49. s solenoid valves level switches temperature switches flow switches etc which are supplied with the pump or systems must be connected and handled in accordance with the instructions supplied by their respective manufacturers 12 Operating manual for centrifugal pumps 9 INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS Information to determine the piping sizes and floor space requirements can be obtained from dimension drawings and other engineering data The information required is size and location of suction and discharge flanges Size and location of all connections for flushing cooling heating draining etc location and size for mounting bolts for monoblock pump and or baseplate and or frame In the event additional accessories are required to complete the installation such as separators piping valves etc refer to following chapters 9 1 9 2 9 3 Proper lifting devices should be available for installation and repair operations Pump assembly should be installed in an accessible location with adequate clear and clean space all around for maintenance so that an efficient and proper installation can be made It is important to have proper room around the unit for ventilation of motor Avoid installing the unit in hidden locations dusty and lacking of ventilation Pump motor assembly should not be installed in narrow areas dusty toxic and explosive ambient In the event this is not possible it is recommended t
50. se applied at time of pump assembly is usually suitable for approx 1500 to 2500 hours of operation It is important to remember not to overlubricate the bearings excessive grease will lead to overheating of bearings It is preferred that every 1500 to 2500 hours of operation the bearings be cleaned of old grease and the bearing gage be refilled with new suitable grease AT TBH TBA TCK TBK TBAK pump series are fitted with self lubricated ball bearings which do not require re grease in normal operating conditions series TCK TBK e TBAK may also be fitted with oil lubrication as described in the paragraph listed below It is necessary to carry out the greasing and maintenance operations as per the above description for the pumps with roller bearing fitted on the drive end Bearing temperature should not exceed 85 C in normal conditions and ambient temperatures Overheating could be caused by excessive grease coupling misalignment excessive vibrations and or bearing wear see chapter 16 13 2 OIL LUBRICATED BALL BEARINGS Pump series TC MC are fitted with oil lubricated ball bearings The series TCK TBK and TBAK can also be with grease lubricated bearings It is good practice to replace the lubricating oil used at time of testing Oil should also be changed after the first 50 to 100 hours of operation NO we The lubricating oil poured through the hole which is also the dipstick seat or vent plug located at the
51. sitate to bring them to our attention 2 Operating manual for centrifugal pumps INDEX 1 General instructions 2 Safety instructions 3 Incase of emergency 3 1 Basic first aid 4 Pump outlines 41 Pump model numbers and materials of construction tables 5 Uncrating lifting and moving instructions 6 Storage instructions 7 Mounting and alignment instructions 7 1 Monoblock pump motor and pump motor assembly mounted on a baseplate 7 2 Alignment procedure for monoblock and for pump motor assembly on baseplate 73 Alignment instructions 74 Coupling pump series TCHM and TCTM 8 Electrical connections 9 Installation instructions 9 1 Installation of pump motor assembly 9 2 Suction and discharge piping 9 2 1 Suction piping 9 2 2 Discharge piping 9 2 3 Piping cleaning 9 2 4 Pressure testing 9 3 Accessories and auxiliary connections 10 Check list prior to start up 11 Starting operating and stopping procedures 11 1 Start up 11 1 1 Submersed pump vertical design 11 1 2 Pump with flooded suction 11 1 3 Pump with suction lift from well 11 1 4 Starting a pump without back pressure at discharge side 11 1 5 Starting a pump with back pressure at discharge side 11 2 Operation 11 8 Shutdown 12 Operation check list 13 Lubrication instructions 13 1 Grease lubricated ball bearings 13 2 Oil lubricated ball bearing 14 Packed stuffing boxes 14 1 Adjusting the packing 15
52. sulation preheating etc Prior to starting the suction piping and the pump must be filled with the liquid to be lifted for this purpose there are three types of installations to be identified WARNING During the following operations it is particularly important to avoid contact and or inhale of eventual spilled liquid vapour therefore all safety precautions must be taken For this purpose there are three types of installations to be identified 11 1 1 Submersed pump vertical design Pump filling is not applicable 20 Operating manual for centrifugal pumps 11 1 2 Pump with flooded suction Close the valve at pump discharge side fully open the valve at pump suction side and the vent valve including any breather valve on the stuffing box NOTE Pump series TCD are fitted with a vent cock see fig 21 which should be open to prevent forming air pockets in the mechanical seal chamber Be sure to do this only when the spilled thermal oil is at ambient temperature When the thermal fluid exits the air cock without any air or gas bubbles even after turning the pump rotor it means that the whole pump is full of liquid therefore close the air cock 11 1 3 Pump with suction lift from well In this case the pump must be primed fully open the isolating valve in suction piping If the pump is self priming and it has been previously filled with liquid there will be no problems because the pump will be able to prime itself and l
53. tely to the transport company and to POMPETRAVAINI s customer service department Discard through controlled disposals all packaging materials which may constitute personal injury sharp objects nails The pump must ALWAYS be moved and transported in the horizontal position Prior to moving the unit find the following total weight centre of gravity maximum outside dimensions lifting points location For a safe lifting it is recommended to use ropes or belts properly positioned on the pump and or lifting eyebolts with correct movements to prevent material damages and or personal injuries Lifting eyebolts fitted on single components of the assembly pump or motor should not be used to lift the total assembly The fig 1 shows several additional examples of lifting Avoid lifts whereby the ropes or straps form a triangle with the top angle over 90 see fig 2 The fig 3 shows several additional examples of lifting to be avoided Prior to moving the unit from an installation always drain any pumped fluid from the pump piping and accessories rinse and plug all openings to prevent spillage For instructions to remove the unit from installation see chapter 17 6 STORAGE INSTRUCTIONS After receipt and inspection the unit if not immediately installed the unit must be repackaged and stored in the best way For a proper storage proceed as follows store the pump a location which is closed clean dry and fr
54. that no external forces or moment rest on pump or piping In the event the pump is shut down for an extended period of time it is recommended to completely drain the pump to prevent the possibility of freezing in the winter time and or the possibility of corrosion due to stagnant liquid left in the pump see chapter 6 12 OPERATING CHECK LIST OPERATING CHECK LIST Periodically check the good working condition of the pump by reading the instruments such as gauges amp meters flow meters etc the pump should constantly be performing as the installation requires The operation of the pump should be without abnormal vibrations or noises if any of these problems is noticed the pump should be stopped immediately search for the cause and make the necessary corrections It is good practice to check the pump motor alignment the running conditions of the bearings and of the mechanical seals see chapters 13 14 15 16 at least once a year even if no abnormalities have been noticed If there is a deterioration of the pump performance which is not attributable to changes in system demands the pump must be stopped and proceed with necessary repairs or replacement When the pump is fitted with auxiliary supply lines such as cooling heating or flushing it is recommended to periodically check their flow temperature and pressure If the magnetic driven pump is fitted with a temperature sensor the temperature in the area of the magnetic couplin
55. top of the bearing frame should as a maximum cover the bearing balls of the lower crown the oil dipstick or the oil level gauge show the correct quantity see fig 24 EX The installation of a constant level oil filler as option consents a correct GAS lubricating oil level in the avoiding recurrent fillings For the first filling proceed as follows remove vent plug of the bearing frame upset the oil cruet pour oil into the bearing frame through the hole of plug till you can see oil in the oil filler eloow the oil filler pouring oil directly into the oil cruet and NOT into the elbow see fig 23 Fig 23 replace the cruet in normal position let oil flow into bearing frame repeat operation till the oil level in the cruet cease to decrease The following fillings should be done pouring oil directly into the cruet and NOT into the elbow of the oil filler or bearing frame plug see fig 23 If there are no particular dangers of oil contamination dust water and the temperature in the bearing frame oil bath does not exceed 60 C oil should be changed every 4000 to 6000 hours of service For higher operating temperatures and contaminated oil the frequency of oil changes should be increased Bearing temperature should not exceed 85 C in normal conditions of operations and ambient temperatures Overheating could be caused by too much oil coupling misalignment excessive vibrations an
56. ure proper working operation at such operating temperatures It is recommended the use of proper hand protections such as gloves when effecting the operations listed below schematics for various assemblies are shown NOTE The following points must be followed with the sequence stated above and depending upon the type of operation alignment assembly or alignment verification 1 Thoroughly clean motor pump shaft ends and shaft keys place the shaft keys in the proper keyway slots and fit the coupling halves in line with the shaft ends The use of a rubber hammer and even pre heating of the metal half couplings may be required see fig 4 Lightly tighten the set screws Verify that both pump and motor shafts rotate freely LANTERN SET SCREW ALIGNMENT LINES HALF COUPLING h SHAFT 4 MOTOR PUMP n J HALF COUPLING SUPPORTING FOOT Fig 4 Fig 5 Operating manual for centrifugal pumps 9 2 Insert the perforated metal sheet coupling guard inside the lantern so that the coupling is accessible from one of the lateral openings Couple the electric motor to the pump lantern engaging the two coupling halves hands may reach the coupling halves through the lateral opening see fig 6 tighten the assembly with bolts supplied with the unit and install the supporting foot when applicable see fig 5 SAFETY GUARD OPENING LANTERN E
57. vent dangerous substances have been inhaled and or come in contact with the human body immediately follow the instructions given in the company s internal medical safety procedures 4 PUMP OUTLINES PUMP OUTLINES The instructions given in this manual refer to the listed below single stage and multistage centrifugal pumps horizontal or vertical mounted NOTE Capacities and pressures are approximated and refer to the maximum attainable values for pumps applied in standard conditions at room temperature TCH MCU CH Single stage centrifugal pumps for clean liquids designed to DIN 24256 ISO 2858 standards Design with closed impeller Capacity to 1200 m h Max pressure 16 bar Flanges 16 Single stage centrifugal pumps for abrasive liquids to DIN 24256 ISO 2858 standards Design with fully open impeller Capacity to 100 m h Max pressure 10 bar Flanges PN 16 Single stage centrifugal pumps for very dirty liquids derived from DIN 24256 ISO 2858 standards Design with open vortex impeller Capacity to 250 m h Max pressure 10 bar Flanges PN 16 Single stage centrifugal pumps for Thermal fluids Oils to DIN 24256 ISO 2858 standards Design with closed impeller Capacity to 350 m h Max pressure 10 bar Flanges PN 16 Single stage centrifugal pumps with inspection opening for clean and dirty liquids Design with closed and open impeller Capacity to 550 m h pressure 4 bar Flanges PN 10 Semi axial centrifu
58. y free the rotor NOTE The selected solvent or lubricating fluid must be compatible with the pump seals and gasketing materials New pumps from the factory and pumps coming from long term storage are likely impregnated with a rust preventative liquid before the start up these pumps should be subjected to fresh water rinsing for approximately 15 minutes The liquid mixture coming out of the pumps should be collected to safeguard the environment this liquid should be send for treatment as a special liquid CHECK PUMP MOTOR COUPLING ALIGNMENT This must be done prior to the first start up and before every start up if pump or motor has been removed from the installation for maintenance or other reasons See chapter 7 2 11 1 START UP Never run the pump when it is dry Before starting up verify that all auxiliary supplies are in place ready to be used and where necessary they have been correctly opened Example seal or packing flushing pressurising buffer liquid to back to back double mechanical seals etc Make sure the pump and motor bearings have been properly lubricated and oil levels are correct If necessary oil topping should be done through the proper connections see fig 20 and 21 and with recommended lubricants see chapter 13 If the liquid to be handled is at dangerous high temperatures it is required to insulate the pump and the piping to prevent direct contact the pump should also be protected against thermal shocks by in
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