03. pump station (lago agrio)

7/23/2019 03. Pump Station (Lago Agrio)

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PUMP STATION


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Contents

1. Specification

2. System diagram & rawings

3. Pumps

1) Outline drawings of Crude oil transfer pump

2) Outline drawings of DO unloading pump

3) Outline drawings of LO unloading pump

4) Outline drawings of LO transfer pump

5) Outline drawings of LO filling pump

6) Maintenance and service instruction (ACE Screw pumps)

7) Maintenance and service instruction (ACG Screw pumps)

8) Installation and start-up commissioning (oil pump)

4. Instruments

Outline drawings of Pressure switch

manual of Pressure switchOutline drawings of Pressure gauge

manual of Pressure gauge

1-1)

1-2)

2-2)

2-1)


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1. Specification


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Pump station

Project Name : PETROAMAZONAS 27.2MW MPU

Customer : Hyundai heavy industries Co., Ltd.

Site : CONONACO / AGRIO in EcuadorPlant owner : PETROAMAZONAS EPManufacturer : MNSI Co.,Ltd

Qty : 1 set / Each site

1. Technical data

Engine Type : HIMSEN ( 9H21/32 * 4sets )Total power max. : 6.8 MW

Crude Oil data

- Viscosity : 30 cSt at 50 deg.C

- Density : 890 kg/m3 at 15 deg.C- Specific heat : 0.45 kcal / kg deg.C

Diesel Fuel data

- D.O viscosity : 4-6 cSt at 50 deg.C

- Density : 860 kg/m3 at 15 deg.C

- Specific heat : 0.45 kcal / kg deg.C

Lub. oil data : SAE 40

Pressure at unit max. : 5 bar

Voltage : 480V / 60Hz / 3Ph

220V / 60Hz / 1ph

Crude oil transfer pump capacity : 10 m3/h, 3bar, 25.8 cSt

Electric Motor : 3.6 kW, 1730 rpm

D.O unloading pump capacity : 10 m3/h, 2.5bar, 5 cSt


L.O unloading pump capacity : 5 m3/h, 3bar, 25.8 cSt


L.O transfer pump capacity : 2 m3/h, 3 bar, 25.8 cSt

Electric Motor : 0.9KW, 1700 rpm

L.O filling pump capacity : 2 m3/h, 2.5 bar, 25.8 cSt

Electric Motor : 0.9KW, 1700 rpm

Certificate : Factory


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2. Main component

ST-105/110-C Suction strainers for crude oil transfer pumps.

2pcs, Basket type filter. Mesh size 0.3mm

PL-102A/B-C Crude oil transfer pumpsIMO ACG052N7 NTBP

2pcs, Rotary self-priming displacement screw pumps, one is stand-by pump

ST-117-C Suction strainers for D.O unloading pump.

1pc, Basket type filter. Mesh size 0.3mm

PL-103-C D.O unloading pumpIMO ACG052N7 NTBP

1pc, Rotary self-priming displacement screw pump.

ST-214-C Suction strainers for L.O unloading pumps.1pc, Basket type filter. Mesh size 0.3mm

PL-201-C L.O unloading pumpIMO ACG045K7 NVBP

1pc, Rotary self-priming displacement screw pump.

ST-218-C Suction strainers for L.O transfer pump.

1pc, Basket type filter. Mesh size 0.3mm

PL-202-C L.O transfer pump

IMO ACE 032N3 NVBP1pc, Rotary self-priming displacement screw pumps.

PL-203-C Portable L.O filling pump ( Loosely supply )

IMO ACE 032N3 NVBP

1pc, Rotary self-priming displacement screw pumps

V General valves

Globe type valve

3. Materials

3.1 Frame is welded of steel plates with bottom for leakage oil, sand blasted

and painted with according to HHIs specification.

3.2 Oil pipes are seam black steel . Flange JIS and ANSICrude oil pipes insulation with mineral wool, which is covered with aluminum plate.

3.3 Instrument pipes are 3/8 inch 316 stainless steel.

3.4 Valves are globe type, nominal pressure class. ANSI 150#.


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4. Instruments

4.1 Pressure switches for high and low press. alarm (PSH 104 / PSL101)

4.2 Pressure gauges diameter 4 inch after and before each pumps.

(PI 102/103/106/107, PI 109/110, PI 203/204, PI 206/207)

4.3 Glycerin bottles for crude oil press. gauges and switches.

5. Control automatic and starters ( Installed safety zone )

5.1 Crude oil transfer pump starter

5.2 D.O unloading pump starter5.3 L.O unloading pump starter

5.4 L.O transfer pump starter5.5 Group alarm starter

6. Enclosure

Size : 20 feet ( L6,058 * W2,438 * H2,896 )

Total weight : Abt. 1,800 kg

Noise level : Under. 80dB @ 1m distance

Lighting : 2pcs, 30W

Flame detector : 1pc

Painting : According to HHI specification.


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2. System diagram &rawings


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PETROAMAZONASLAGOAGR

IO6.8MWP

RO

JECT

COVERSHEET

MAY.2.2013

ISSU

EDFORAPPROVAL

1/1

PETROAMAZO

NASLAGOAGRIO6.8MWM

PU

PUMPSTATION

PAML-TEC-M03-ELE

1/54


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DRAWINGLIST

DRAWINGLIST

MAY.2.2013

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PETROAMAZO

NASLAGOAGRIO6.8MWM

PU

PUMPSTATION

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2/54


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BOMLIST1/2

BOMLIST1/2

MAY.2.2013

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NASLAGOAGRIO6.8MWM

PU

PUMPSTATION

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3/54


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BOMLIST2/2

BOMLIST2/2

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PUMPSTATION

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PANELLAYOUTDIAGRAM

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PETROAMAZO

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PU

PUMPSTATION

PAML-TEC-M03-ELE

600

570

600

265265

570

800

800

1600

5/54

1900

1800

1700

1800


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PANELLAYOUTDIAGRAM

PANELLAYOUTDIAGRAM

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PANE

LINNEARBOARDDETAIL

PANE

LINNEARBOARDDETAIL

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MCCB9

SDPX4

MCCB10

SDPX3

SDPX2

SDPX1

CMPX2

CMPX1

LTPX2

LTPX1

LUPX2

LUPX1

DUPX2

DUPX1

CTPX4

CTPX3

CTPX2

CTPX1

CBX

RCMX3

RCMX2

RCMX1

DCX

ACX

CPX

AX5

AX4

AX3

AX2

AX1

RCMX4

LTX

T1DPX4

T1DPX3

T1DPX2

T1DPX1

SHX

SRX

T3DPX2

T3DPX1

T2DPX2

T2DPX1

T4DPX2

T4DPX1

L-SIDEVIEW

FRONTVIEW

R-SIDEVIEW

MCCB0

MCCB1

MCCB2

MCCB3

MCCB4

MCCB5

MCCB6

MCCB7

88*1

CP-A1

88*2

88*3

88*4

88*5

88*6

88*7

88*8

CP-D4CP-D5C

P-D6CP-D7

CP-D9

49*1

49*2

49*3

49*4

49*5

49*6

49*7

49*8

1700

1700

CP-A2

CP-A3

CP-A4

CP-D1

CP-D2

CP-D3

CP-D13

CP-D10CP-D11

CP-D12

CP-D8

CT

CT

FA

FB

FC

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

TEMP.&HUMIDITY

CONTROLLER

DIODE

MODULE

DO-04

DI-02

D1-04

D

1-03

DO-02

AI-01

AI-02

DUCTW40XH80

DUCTW60XH80

DUCTW

60XH80

DUCTW60XH80

DUCTW

60XH80

DUCTW60XH80

DUCTW60XH80

DUCTW60XH80

DUCTW60XH80

DUCTW80XH80

DUCTW80XH80

DUCTW80XH80

F11

F12

F13

DO-03

DUCTW60XH80

DUCTW60XH80

DI-01

DUCTW60XH80

DO-01

CTSV

SHX2

CDHX2

CDHX1

CSHX2

CSHX1

RCMS

AC/DC

220V/24V

40A

DC/DC

120V/24V

40A

T/R

480V/120.220V

5Kva

PT

PT

DUCTW40XH80

DUCTW60XH80

DUCTW60XH80

DUCTW60XH80

DUCTW60XH80

DUCTW40XH80

DUCTW40XH80

DUCTW40XH80

DUCTW40XH80

DUCTW40XH80

DUCTW40XH80

DUCTW40XH80

DUCTW60XH80

DUCTW60XH80

SHX2

CDHX2

CDHX1

CSHX2

CSHX1

C

SHX2

CSHX1


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ANNUNCIATOR

ANNUNCIATOR

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SINGLELINEDIAGRAM

SINGLELINEDIAGRAM

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T

HREELINEDIAGRAM

T

HREELINEDIAGRAM

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CRUDEOILTRANSFERPUMP

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CRUDEOILTRANSFERPUMP

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D

.OUNLOADINGPUMP

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L.OUNLOADINGPUMP

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L

.OTRANSFERPUMP

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C.W

MAINTENANCEPUMP

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SLU

DGEDISCHARGEPUMP

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SLU

DGEDISCHARGEPUMP

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SOL

SOL

TANKUNITDRAINPUMP

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SOL

TA

NKUNITDRAINPUMP

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MCC

CONTROLPOWERDIST. 2

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PAMO-TEC-M02-ELE

DCCONTROLPOWERDIST.

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MCCCOMMONTRIP

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UM33A-1

UM33A-2

UM33A-3

UM33A-4

PAMO-TEC-M02-ELE

INDICATOR

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UM33

A-5

UM33A-6

UM33A-7

UM33A-8

INDICATOR

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DCIOMODULE

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PETROAMAZONASLAGOAGRIO6.8MWM

PU

PUMPSTATION

PAML-TEC-M03-ELE

"THENUMBEROF

DCIOMODULE

CANBECHANGED

FOLLOWING

ARRANGEMENT"


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27/54

PLC

MAY.2.2013

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PAMO-TEC-M02-ELE

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PLCINPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCOUTPUTDIAGRAM

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PLCANALOGINPUTDIAGRAM

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TERMINALBLOCK

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TERMINALBLOCK

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TERMINALBLOCK

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TERMINALBLOCK

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TERMINALBLOCK

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TERMINALBLOCK

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TERMINALBLOCK

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3. Pumps


2) Outline drawings of DO unloading pump3) Outline drawings of LO unloading pump







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3. Pumps



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ISO G3/8Inlet gauge

ISO G3/8Outlet gauge

Relief valve.Turn clockwiseto increaseopening pressure.

RP

Pump size 045 052 060 070

Main A 367 396 460 490 xxxPDim. A 378 411 474 508 xxxG

A 319 350 397 427 xxxEB 110 122,5 140 150C 50 60 70 70

D 129 140 178,5 196F 16 18 18 13

F F 113 127 153 173CoG 185 200 285 300 xxxP,GCoG 175 190 275 290 xxxE

Flange H 4 4 4 4dim. HG 15 15 20 20

J 145 165 215 215K 175 200 250 250L 120 130 180 180 Tol. ISO h7

LG 11 15 18 18Outlet N 165 185 200 220

O 125 145 160 180P 50 65 80 100Q 4x18 4x18 8x18 8x18 Q-ty x diam

QL 20 20 20 22Inlet R 165 185 200 220S 125 145 160 180T 50 65 80 100U 4x18 4x18 8x18 8x18 Q-ty x diam

UL 20 20 20 22Return RL 18 18 26 30 xxxG

RP G-1 1/4 G-1 1/4 G-1 1/2 G-1 1/2 xxxGDrain W 30 35 45 45Shaft X 19 24 28 28 Tol. ISO j6

Y 21,5 27 31 31Y1 M8x16 M8x16 M8x16 M8x16 Y1 x depthZ 6 8 8 8

Z1 3 3 3 3Z2 22 28 36 36

Weight (kg) 25 33 47 61 xxxP, G

Weight (kg) 22 30 43 57 xxxE

Pump dimensions

E

P

P

G E

Pump ACG (Valve design P, G, E)Dimensions in mm

For UCG models, with ANSI-flangesand for foot mounted models, pleaserefer to IMO AB.

G


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DQL

Q

HD N O P

MKJ

L

T S R

U

ULB B Z

a

AZ

A1

FM

GH

D1

V1V

A

D D2

C

Y

aSpace fordismantling

Space fordismantling

Grease nipple

Drain ISO G1/4

Deaeration

Control forsafety valve

ISO G3/8Inlet gauge


Pump dimensions

P

EG

E

Pump IEC xxx P xxxG xxxE xxxP xxxG xxxE xxxG xxxG *)Weightsize No Frame A A A B D D1 D2 D2 D2 N O P Q QL R S T U UL RL RP V V1 Y Z ca.kg

80F165

679 690 631173

18 G-1 1/4124 74 75 7 5 27

045 90 713 724 665 4 x 4 x 18 G-1 1/4100

F215 760 771 712 110 129

165 188 199 140 1 65 125 50 18 20 165 125 50 18 20 18 G -1 1/4

135 85 75 8 5 28112 773 784 725 18 G-1 1/4

132 F265 843 854 795 164 18 G-1 1/4 155 105 80 105 30

80F165

698 713 652184

18 G-1 1/4124 64

85 6541

052 90 732 747 686 4 x 4 x 18 G-1 1/4 80 70100

F215 779 794 733 122,5 140

174 196 211 150 1 85 145 65 18 20 185 145 65 18 20 18 G-1 1/4

135 75 85 8 0 36112 792 807 746 18 G-1 1/4

132 F265 875 890 829 188 18 G-1 1/4 168 108 90 110 38

160 F300 1035 1050 989 189 18 G-1 1/4 204 144 100 140 40

100F215

846 860 783227,5

26 G-1 1/2148 78 95 8 5 55

060 112 859 873 796 8 x 8 x 26 G-1 1/2132 F265 957 971 894 140 178 ,5 254 ,5 211,5 225,5 148 ,5 200 160 80 18 20 200 160 80 18 20 26 G-1 1/2 196 126 95 130 59

160 1089 1103 1026 227,5 26 G-1 1/2 204 134 100 140 54

180 F300

1175 1189 1112 251,5 26 G-1 1/2 228 158 105 160 59

100F215

876 894 813245

30 G-1 1/2148 78 95 8 5 69

070 112 889 907 826 8 x 8 x 30 G-1 1/2132 F265 987 1005 924 150 1 96 272 224 242 161 220 180 1 00 18 22 220 180 1 00 18 22 30 G-1 1/2 196 126 9 5 130 73

160 1119 1137 1056 245 30 G 1 1/2 204 134 100 140 68

Pump IEC xxx P xxxG xxxEsize No Frame A1 AC A1 AC A1 AC C F G H HD J K L M

80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252

100F215

308 199 308 199 308 199132 110

6029

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252100

F215 308 199 308 199 308 199

132 110 60

29 286

250 220 15112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 F300 495 314 495 314 495 314 180 150 110 20 420 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18

Pump unit ACG (Valve design P, G, E)Dimensions in mm(With standard electric motor)

G

RL045

052

060

070


70/163

3. Pumps

2) Outline drawings of DO unloading pump


71/163

ISO G3/8Inlet gauge



RP

Pump size 045 052 060 070


A 319 350 397 427 xxxEB 110 122,5 140 150C 50 60 70 70

D 129 140 178,5 196F 16 18 18 13


Flange H 4 4 4 4dim. HG 15 15 20 20

J 145 165 215 215K 175 200 250 250L 120 130 180 180 Tol. ISO h7

LG 11 15 18 18Outlet N 165 185 200 220



UL 20 20 20 22Return RL 18 18 26 30 xxxG



Z1 3 3 3 3Z2 22 28 36 36



Pump dimensions

E

P

P

G E



G


72/163

DQL

Q

HD N O P

MKJ

L

T S R

U

ULB B Z

a

AZ

A1

FM

GH

D1

V1V

A

D D2

C

Y



Grease nipple

Drain ISO G1/4

Deaeration


ISO G3/8Inlet gauge


Pump dimensions

P

EG

E


80F165

679 690 631173

18 G-1 1/4124 74 75 7 5 27

045 90 713 724 665 4 x 4 x 18 G-1 1/4100

F215 760 771 712 110 129

165 188 199 140 1 65 125 50 18 20 165 125 50 18 20 18 G -1 1/4

135 85 75 8 5 28112 773 784 725 18 G-1 1/4

132 F265 843 854 795 164 18 G-1 1/4 155 105 80 105 30

80F165

698 713 652184

18 G-1 1/4124 64

85 6541

052 90 732 747 686 4 x 4 x 18 G-1 1/4 80 70100

F215 779 794 733 122,5 140

174 196 211 150 1 85 145 65 18 20 185 145 65 18 20 18 G-1 1/4

135 75 85 8 0 36112 792 807 746 18 G-1 1/4

132 F265 875 890 829 188 18 G-1 1/4 168 108 90 110 38

160 F300 1035 1050 989 189 18 G-1 1/4 204 144 100 140 40

100F215

846 860 783227,5

26 G-1 1/2148 78 95 8 5 55

060 112 859 873 796 8 x 8 x 26 G-1 1/2132 F265 957 971 894 140 178 ,5 254 ,5 211,5 225,5 148 ,5 200 160 80 18 20 200 160 80 18 20 26 G-1 1/2 196 126 95 130 59

160 1089 1103 1026 227,5 26 G-1 1/2 204 134 100 140 54

180 F300

1175 1189 1112 251,5 26 G-1 1/2 228 158 105 160 59

100F215

876 894 813245

30 G-1 1/2148 78 95 8 5 69

070 112 889 907 826 8 x 8 x 30 G-1 1/2132 F265 987 1005 924 150 1 96 272 224 242 161 220 180 1 00 18 22 220 180 1 00 18 22 30 G-1 1/2 196 126 9 5 130 73

160 1119 1137 1056 245 30 G 1 1/2 204 134 100 140 68


80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252

100F215

308 199 308 199 308 199132 110

6029

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252100

F215 308 199 308 199 308 199

132 110 60

29 286

250 220 15112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 F300 495 314 495 314 495 314 180 150 110 20 420 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18


G

RL045

052

060

070


73/163

3. Pumps

3) Outline drawings of LO unloading pump


74/163

ISO G3/8Inlet gauge



RP

Pump size 045 052 060 070


A 319 350 397 427 xxxEB 110 122,5 140 150C 50 60 70 70

D 129 140 178,5 196F 16 18 18 13


Flange H 4 4 4 4dim. HG 15 15 20 20

J 145 165 215 215K 175 200 250 250L 120 130 180 180 Tol. ISO h7

LG 11 15 18 18Outlet N 165 185 200 220



UL 20 20 20 22Return RL 18 18 26 30 xxxG



Z1 3 3 3 3Z2 22 28 36 36



Pump dimensions

E

P

P

G E



G


75/163

DQL

Q

HD N O P

MKJ

L

T S R

U

ULB B Z

a

AZ

A1

FM

GH

D1

V1V

A

D D2

C

Y



Grease nipple

Drain ISO G1/4

Deaeration


ISO G3/8Inlet gauge


Pump dimensions

P

EG

E


80F165

679 690 631173

18 G-1 1/4124 74 75 7 5 27

045 90 713 724 665 4 x 4 x 18 G-1 1/4100

F215 760 771 712 110 129

165 188 199 140 1 65 125 50 18 20 165 125 50 18 20 18 G -1 1/4

135 85 75 8 5 28112 773 784 725 18 G-1 1/4

132 F265 843 854 795 164 18 G-1 1/4 155 105 80 105 30

80F165

698 713 652184

18 G-1 1/4124 64

85 6541

052 90 732 747 686 4 x 4 x 18 G-1 1/4 80 70100

F215 779 794 733 122,5 140

174 196 211 150 1 85 145 65 18 20 185 145 65 18 20 18 G-1 1/4

135 75 85 8 0 36112 792 807 746 18 G-1 1/4

132 F265 875 890 829 188 18 G-1 1/4 168 108 90 110 38

160 F300 1035 1050 989 189 18 G-1 1/4 204 144 100 140 40

100F215

846 860 783227,5

26 G-1 1/2148 78 95 8 5 55

060 112 859 873 796 8 x 8 x 26 G-1 1/2132 F265 957 971 894 140 178 ,5 254 ,5 211,5 225,5 148 ,5 200 160 80 18 20 200 160 80 18 20 26 G-1 1/2 196 126 95 130 59

160 1089 1103 1026 227,5 26 G-1 1/2 204 134 100 140 54

180 F300

1175 1189 1112 251,5 26 G-1 1/2 228 158 105 160 59

100F215

876 894 813245

30 G-1 1/2148 78 95 8 5 69

070 112 889 907 826 8 x 8 x 30 G-1 1/2132 F265 987 1005 924 150 1 96 272 224 242 161 220 180 1 00 18 22 220 180 1 00 18 22 30 G-1 1/2 196 126 9 5 130 73

160 1119 1137 1056 245 30 G 1 1/2 204 134 100 140 68


80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252

100F215

308 199 308 199 308 199132 110

6029

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

80F165

238 158 238 158 238 158112 90 15

244210 180 12 11

90 272 178 272 178 272 178 252100

F215 308 199 308 199 308 199

132 110 60

29 286

250 220 15112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 F300 495 314 495 314 495 314 180 150 110 20 420 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18

100F215

308 199 308 199 308 199132 110 60 29

286250 220 15

112 321 215 321 215 321 215 299 14

132 F265 371 255 371 255 371 2 55 160 116 80 16 348 290 260 18

160 495 314 495 314 495 314 420

180 F300

557 358 557 358 557 358 180 150 110 20

440 340 300 22 18


G

RL045

052

060

070


76/163

3. Pumps



77/163


78/163

3. Pumps



79/163


80/163

3. Pumps


- LO transfer pump

- LO filling pump


81/163

This instruction is valid for all ACE pump models shown on page 2

Contents Page

List of components 2Exploded view 3Ordering code/Service intervals 4Sectional view 5

Useful tools/Shaft seal-assembly drawing 6Dismantling/reassembly 7

Screw pumps

ACE3

Maintenance and ServiceInstruction


82/163

Before commencing any work, read this instruction carefully! Failure to comply withthese instructions may cause damage and personal injury!!

Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: L3/K3/N3

With version codes: N V B P Also valid for pump options: A101T The version code is composed of the letters in the 4 columns.Q Example of pump designations std: ACE 025L3 NTBP;

option: ACE 038N3 NVBP A101

List of components

For more information about the pumps identification code, technical data and performance we refer to theACE Product description. For more information about the pumps installation, Start-up and trouble shootingwe refer to the IMO Installation and Start-up instruction for Low Pressure Pumps.

Components included in spare parts sets:

Pos Denomination Q-ty G011 G012 G050 G053 G054 G057 G070 G082 Notes Explanations:no1010 Power rotor 1 x (x)1020 Power rotor 1 x x G011: Rotor set

113 Key 1 x x x122 Ball bearing 1 x x x G012: Rotor set125 Secondary seal 1 x x x x 1201 Idler rotor 2 x (x) G050: Shaft seal202 Idler rotor 2 x x351 Balancing bush 1 x x x G053: Minor kit401 Pump body 1416 Suction flange 1 G054: Major kit417 Screw 8418 Gasket to 1 x x x G057: Joint kit

suction flange423 Gasket to 1 x x x G070: Valve element

discharge flange

427 Discharge flange 1 G082: Seal Guard kit440 Return valve 1451 Screw 4453 Screw 4462 Plug 1462A Sealing washer 1 x x x463 Plug 1463A Sealing washer 1 x x x501 Front cover 1506 Gasket 1 x x x509 Shaft seal 1 x x x537 Deaeration plug 2537A Washer 2 x x x551 Rear cover 1

556 Gasket 1 x x x557 Plug 1557A Washer 1 x x x605 O-ring 1 x x x x608 Valve spindle 1 x x608A Tension pin 1 x x6120 Set screw 1 x x613 Pin 1 x x614 Valve piston 1 x x615 Valve spring 1 x x7310 Compl. Seal 1 x 2,3

Guard732 Gas generator 1 x 2

Notes:1) Version NTBP

and NQBP

2) Version NQBPonly

3) IncludingGasgenerator


83/163

Exploded view

Fig. 1

All work carried out on the pump has to beperformed in such a manner that risks forpersonal injury are observed!

When handling liquids that may harm skinuse gloves and/or protective clothing.

!

!

!

!

When handling liquids which may involvefire hazards appropriate precautions toavoid danger are to be taken.

In case of failure for a system with elevat-ing pressure fluid jets may cause injuryand/or damage.

Oil leakage may make the floor slipperyand cause personal injury.

Connecting and disconnecting of electriccables must be done only by personnel

!Before any maintenance work, ensure thatthe driver is deenergized and the pumphydraulically isolated.

!

451

501125

463 463A

537A 537

557A 557

537A537

506440

401

556

551

453

(608A)

(614)(615)

(613)(6120)

(608)(605)

462A 462

122351

1131020

202

509

418416417

423

427xVxx

xTxx

7327310

xQxx

xTxx, xQxx xQxxxQxx


84/163

Recommendation:For maintenance the following sparepart sets are recommended:

Set: To be used:G057 Joint kitFor dismantling the pump.

G053 Minor kitFor service.

G054 Major kitFor repair after damage or greaterwear.

Ordering example:For IMO-pump ACE 032N3 NVBP,

serial number 456789:Shaft seal pos G050 p/n 189964Valve element pos G070 p/n 189873

Item Spare Parts sets 025 032 038

G012 Rotor set CW-rotation (std)Low lead-L3 190486 190485 Low lead-K3 190482Normal lead-N3 190487 190484 190483

G011 Rotor set CCW-rotationNormal lead-N3 190492 190491 190488

G050 Shaft seal-xVxx 189964 189964 189964Shaft seal-xTxx 190495 190495 190497Shaft seal-xQxx 190495 190495 190497

G053 Minor kit-xVxx 190501 190710 190500Minor kit-xTxx 190503 190712 190499Minor kit-xQxx 190503 190712 190499

G054 Major kit=G012(G011)+G053+G070

G057 Joint kit-xVxx 190525 190714 190522

Joint kit-xTxx 190524 190713 190523Joint kit-xQxx 190524 190713 190523

G070 Valve element 189873 189873 189873

G082 Sealguard-kit xQxx 190526 190526 190527

125 Secondary seal xTxx, xQxx 190469 190469 190468

732 Gas generator xQxx 190530 190530 190530

Part numbers for pump size

Ordering code

Inspection of shaft seal

Excessively leaking shaft seals (more than 10 dropsper hour) should be changed without delay, as theleakage normally will grow worse and cause addi-tional damage.In installations where unplanned shut downs mustbe avoided, it is advisable to dismantle the pump fora thorough inspection and thereby change out shaftseal and ball bearing, every three years as a maxperiod.It is recommended always to have the spares in-cluded in minor spare part kit available.

Inspection of rotorsA quick inspection of the idler rotors can be madesimply by removing the rear cover. Note that thedriver must be deenergized and the pump hydrauli-cally isolated before the rear cover is removed.If a more thorough investigation is needed, proceedas under Dismantling/Reassembly.

Service intervals

The intervals for inspection and replacement of wearparts vary greatly with the properties of the pumpedliquid and can only be determined by experience.Pumping liquid which contains abrasive materials,or liquid that is corrosive, will significantly reduceservice life and call for shorter service intervals.Wear will normally show as unnormal:

Vibration

Noise

Loss of capacity

Reduction in flow/pressure

Leakage

!If the pumps operating temperature exceeds60C let the pump cool off before any service,maintenance or dismantling work is com-menced to avoid burn injury.


85/163

Sectional view

732

537A537

7310

(xQxx)

125 (xTxx, xQxx)

C - C E - E463 463A


86/163

d

L

D

Fineemery

Puller

Screwspanner16 mm

Plasticmallet

Sliding calliper

Oil can

Screwdriver

Mounting tool kit

Shaft seal - assembly drawing

Fig. 4

Useful tools

Fig. 3

Allen key5 mm and3 mm

Shaft seal G050 (509)

Version code xTxx

S1 SeatS2 O-ringS3 RetainerS4 Seal ringS5 CarrierS6 O-ringS7 Spring unitS8 Stop screw

+ Secondary seal 125

Version code xQxx

xTxx + CompleteSealGuard 7310

Version code xVxx

S1 SeatS2 O-ringS4 Seal ringS6 O-ring

S7 Spring unitS8 Stop screw

Stationary member Rotating member

Frontcoverretainingtab

Seat slotS8

Seat retaining lug

S4S6S1S2S7

S8S5S6S1S2S3 S7S4

S4, S7 is one unit

Stationary member Rotating member

Tool 2Tool 1

D= 25,5 mm

For dimension and material,please contact IMO AB Service.

Retainer lug

Seat slot


87/163

F.

B.

E.

Remove the shaftcoupling.

Remove the key 113.

Dismantling

Turn the electricity OFF.

Close the valves.

Remove the pumpfrom the system.

ATTENTION

Use appropriate vessels to collect oil spill-age when removing and opening the pump.

Note the position of the shaft coupling.

Release the stop screw.

A.

C.

Fig. 8Fig. 7

ONOFF

Fig. 5

D.

Remove the front cover 501 and powerrotor 1020.

Fig. 6

451

113

1020

Remove thescrews 451.

501


88/163

501

1020

G.

L.

Fig. 13 Fig. 14

Fig. 11 Fig. 12

Separate the frontcover 501 and thepower rotor 1020.

K. xTxx and xQxx

Place the front cover 501 on a pair ofwooden pieces.

Press out the shaft seal, stationary memberwith a suitable tool.

Loosen the shaft seal rotating member.

Remove and inspect theidler rotors 202.

I.

202

Remove the secondary seal 125 with asuitable screw driver.

H. xTxx and xQxx

501

501

125

Insert two suitablescrew drivers in thecarrier S5 slots andgently push therotating memberS4, S7 off the rotorshaft.

Loosen the twostop screws S8(3 mm Allen key)

on the carrier S5and pull it off.

xVxx

xTxxxQxx

J. xVxx

Rotating

Member

S5S8


89/163

Reassembly

A.

Fig. 19 Fig. 20

Fig. 17 Fig. 18

C. xVxx

E.

Lubricatethe idler rotors 202and fit them into the pump body 401.

B.

Un-pack a new shaft seal 509.

Check that the O-ring S6 is in place.

xVxx xTxx, xQxx

Polish the power rotor shaft1020 with a fine emery and oil.

Fit the rotating member abovethe ball bearing 122 and lock itwith its stop screws S8.

122

D. xTxx and xQxx

Polish the power rotor shaft1020 with a fine emery and oil.

Fit the carrier S5 tight against theball bearing. Make sure the carrieris not fitted upside down.

Firmly tight the two stop screws S8.

Lubricate the O-ring S6 in the rotat-ing member with oil.

Press the rotating member S4, S7gently on to the rotor shaft and makesure the driving lugs enters the slotsin the carrier S5.

401

1020

Insert the Power rotor 1020 into the pumpbody 401.

F. xTxx and xQxx

501

125

1 2

Press the Secondaryseal 125 in place witha suitable tool in twosteps as shown. Use acolumn drill machineas a press tool.

NOTE!Tool nr 2 hasone end for sizes

025, 032 and oneend for size 038

202

401

Oil can

Emery

S6 S6

S4

S8S8

S5

S4,S7

Tool 1 Tool 2

S5

Rotatingmember


90/163

Fig. 26

Fig. 23

Fig. 25

Fig. 24

G. xVxx

Fit the spring unit S7 in place.Note the position for the Seatslots and lugs.

(See fig 4.)

Lubricate the O-ringS2 and put it on theseat S1. Fit the seatS1 on top of thespring unit. Watchposition of the Seatslots and lugs.(See fig 4.)

Press the seat gently into the recess in thefront cover 501 with a suitable tool asshown.

Turn the front cover 501 up-side down. Theseat shall now remain in the cover.

Fit the retainer S3in place. Note theposition for the

retainer lugs andcover slots.(See fig 4.)

Lubricate theO-ring S2 andput it on theseat S1. Fit the seat S1on top of the retainer.Watch the position of the seatslots and lugs. (See fig 4.)

Press the seat gently into the recess in thefront cover 501 with a suitable tool as shown.

Turn the front cover 501 up-side down. Theseat shall now remain in the cover.

H. xTxx and xQxx

501

I.

506

Replace the gasket506.

Carefully fit theFront cover 501 onthe pump.

501

506

J.451

Fit the screws451.

Tight them crosswise,step by step to avoiddeformation on bearingouter ring and sealdamages.

Turn the shaft to checkthat it moves withouttoo much force.

K.

113

Fit the key 113 back in place.

Press on the shaft couplingto its original position.

Tighten the stop screw.

Install the pumpback into thesystem and proceedaccording to in-structions under

Start-up in theInstallation manual

L.

501

S1

S2S7

501

S1

S2

S3

Tool 1Tool 1


91/163

1

2

5

7

6

9

8

10

4

3

Gas generator

Note!Must be open

6

9

12

310

Fig. 29

Pressure relief valveATTENTION

Spring tension.

Release spring tension by turning set screw 6120CCW as much as possible.

Loosen and remove the screws 453.

Separate the valve element from the rear cover551.

If necessary, replace the gasket 556 and theO-ring 605.

Reassemble the parts in reverse order. Be carefulto tighten the screws 453 crosswise.

Readjust the valve pressure according to theInstallation and Start-up Instruction for IMOLow pressure pumps.

453

612

551

605

556

Recharging1) Disconnect the pipe connector (4) from thedispenser (2). Remove the check valve (3).

2) Remove the cover disk (10). Remove the gasgenerator (9) from the dispenser (2) with a 21mm socket. Dispose the generator in the recyc-ling system for batteries, where available. Pushthe piston to its filled position, and fill thedispenser with high-temperature resistant engineoil. Fit the check valve (3) and the connector (4)to the dispenser.

3) Feed oil into the hose (5) and seal compartment,for example with an oil-filled grease gun. Recon-

nect the hose (5) to the connector (4).4) Fit a new gas generator (9) to the dispenser (2).

Tighten with approx. 2 Nm. Clip on the coverdisk (10).

5) Turn the gas generator set knob (3 mm Allenkey) to no. 6 which will make the oil last forabout 3 months.

K f fi h

SealGuard

For more information about

SealGuard, read the Installa-tion and start-up Instructionfor SealGuard.

ATTENTION

The SealGuard can bereadjusted or switched offduring operation.Depending on temperatureand setting, it can take fromhours to a couple of daysafter starting, until oil isbeing dispensed.

NOTE!

For longer periods of stand-by, the gas gene-rator set-knob could be set to zero to avoidunnecessary oil consumption.

6120

Version code N Q B P


92/163


93/163

3. Pumps


- Crude oil transfer pump

- DO unloading pump

- LO unloading pump


94/163

Screw pumps

ACG/UCG 7

Maintenance and ServiceInstruction

This instruction is valid for all ACG/UCG pump models shown on page 2

Contents Page

List of components 2Exploded view/Ordering code 3Service intervals 4Shaft seal/Service for ball bearing 4Lubricating intervals/Useful tools 5Inspection of rotors 5Sectional view 6

Dismantling 7Reassembly 9

ACG1'IMOA

B


95/163

Qty Components included in Spare parts sets:

PosNo Denomination G011 G012 G050 G053 G054 G057 G070 Note

1010 Power rotor CCW-rot. 1 x (x)

1020 Power rotor CW-rot. 1 x x106 Balancing piston 1 x x x 5113 Shaft key 1 x x x120 Distance sleeve 1122 Ball bearing 1 x x124 Retaining ring 1 x x x124A Support ring 1 x x x201 Idler rotor CCW-rot. 2 x (x)202 Idler rotor CW-rot. 2 x x359 Distance washer 1359A Support ring 1 x x x401 Pump body 1424 Sleeve 1 4424A Washer 1 4429 Spindle 1 4437 O-ring 1 4

440 Return valve 1451 Screw 4/6453 Screw 4462 Plug 2 1462A Sealing washer 2 x x x 1473 Grease nipple 1473A Grease nipple cover 1480 Valve housing 1 25010 Front cover 1502 Tension pin 1 6502A Plug 1 6506 Gasket 1 x x x509 Shaft seal 1 x x x514 Retaining ring 1 x x x537 Plug 2

537A Sealing washer 2 x x x551 Rear cover 1 3556 Gasket 1 x x x601 Valve cover 1 x 2,7602 Sealing washer 1 x x x x 2605 O-ring 1 x x x x 2608 Valve spindle 1 x 2,7608A Retaining ring 1 x x x x 2612 Set screw 1 x 2,7614 Valve piston 1 x 2,7615 Valve spring 1 x 2

Before commencing any work, read this instruction carefully! Failure to complywith these instructions may cause damage and personal injury!

Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K7/N7

With version codes: Also valid for pump options: A101, A327, A385Example of pump designationsstd: ACG 045N7 NVBP; option ACG 070N7 NVBP A101

List of components

For more information about the pumps identification code, technical data and performance we refer to theACG/UCG Product description. Fore more information about the pumps installation, Start-up and troubleshooting we refer to the IMO Installation and Start-up instruction for low pressure pumps.

Explanations:G011: Rotor setCCW-rotation option

G012: Rotor set

CW-rotation (std)

G050: Shaft seal

G053: Minor kit(G050 + G057) + 122

G054: Major kit consistingof: G053+G012 (G011)

G057: Joint kit

G070: Valve element

ACG Pump with DINflanges

UCG Pump with ANSIflanges

A101: CCW

A327: With Tuning

A385: CCW and Tuning

IMOAB

ACG2'IMOA

B

N T

V

B

F

E

P

G

!

Notes:1) Excluded in xxxG2) Excluded in xxxE3) Valid for xxxE

4) Valid for pump optionA3275) Included in item 1020

or 10106) Included in item 50107) Only sold as G070


96/163

ACG/UCG xxBE/BP/BG

Fig. 1

Exploded view

Version

xVxx

Versionx

Txx

xxxE

CCW rotation (non-standard)

xxxP

xxxG

CW rotation

Ordering codeRecommendation:For maintenance thefollowing spare partsets are recommen-ded:Set: To be used:G057 Joint kitFor dismantling ofthe pump

G053 Minor kitFor service

G054 Major kitFor repair afterdamage or greaterwear.

Pos Spare parts sets Part numbers, sizesNo 045 052 060 070

Rotor set CW-rotation (std):G012 Normal lead - pump version N7 178913 179507 179515 179523 " Low lead - pump version K7 187542 187559 187567 187575

Rotor set CCW-rotation (non-std):G011 Normal lead - version N7 186478 186486 186494 186502

Low lead - version K7 189641 189642 189643 189644

G050 Complete shaft seal - version code xVxx 190335 190336 190338 190340 - version code xTxx 174094 174102 174110 174128

G053 Minor kit - version code xVxx 191241 191243 191245 191247 - version code xTxx 191242 191244 191246 191248

G054 Major kit=G012(G011)+G053 - - - -

G057 Joint kit 191237 191238 191239 191240

G070 Valve element - version code xxxP/G 191250 191250 191251 191251

122 Ballbearing x x x x

ACG3'IMOA

B

473

537

537A

506

401556 480

551 453

462

462A

462

537

537A

473A

1010

201

608A

601

602

605

608

612

615

614

453

480

1020 202

113

113

509

359

359A

514

202

124A

124

1 22 1 20

451

5010 453

462

462A

462

Details in pump option A327See the sectional view p. 6

Version

xTxx

VersionxV

xx

Ordering example:For IMO-pump ACG 045N7

NVBP, serial number 456789

Shaft sealpos G050 p/n 190335


97/163

Service intervalsThe intervals for inspection and replacement of wearparts vary greatly with the properties of the pumpedliquid and can only be determined by experience.All internal parts of the ACG-pump are lubricatedby the pumped liquid. Pumping liquid whichcontains abrasive materials, or liquid that is corro-

sive, will significantly reduce service lifeand call for shorter service intervals.Wear in the pump may be indicated by:

Vibration Noise Loss of capacity Reduction in flow/pressure Leakage

In installations where unplanned shut downs mustbe avoided, it is advisable to have a complete pumpavailable for replacement, should any malfunctionoccur. Furthermore we recommend planned inspec-

tion and overhaul at regular intervals, not exceeding3 years.It is recommended always to have the spares in-cluded in minor spare part kit available.

Service for ball bearingThe ACG-pump is fitted with an external greaselubricated ball bearing.When delivered from IMO AB, the ball bearings inpump version xVxx are filled with grease of type B.For version xTxx, type C is used.Whenever the ball bearing is removed, it is recom-mended to exchange it for a new one.

Fit the new ball bearing properly greased andregrease it after one hour of running, while the

Inspection of shaft sealAs the seal faces of a mechanical shaft seal arelubricated by the fluid a certain leakage will alwaysbe present. Ten drops per hour can be considered asacceptable.An external visual inspection of the pump is advis-able at least every two days to assure that the shaft

seal is not leaking too much.Excessively leaking shaft seals should be changedwithout delay, as the leakage normally will growworse and cause additional damage.Follow the instructions in the dismantling/reassem-bly session.When working with a shaft seal, cleanliness is ofutmost importance. Avoid touching the seal faces. Ifnecessary, the seal faces should be cleaned immedi-ately prior to assembly, using a dustfree cloth andclean solvent.Never use grease on the seal faces.

Shaft seal-assembly drawing

Shaft seal G050 (pos 509)

Version code xVxx

Version code xTxx

S2 S1 S5

S2 S1 S4 S6 S9 S7 S5

S1 SeatS2 O-ringS4 Seal ringS5 Seal ring carrierS6 O-ringS7 SpringS9 Stop washer

S1 SeatS2 O-ringS5 Bellows unit

Fig. 3

ATTENTION

Be careful to mountthese parts in rightorder and in rightdirection.

If the pumps operating temperature exceeds60C let the pump cool off before anyservice, maintenance or dismantling work iscommenced to avoid burn injury.

All work carried out on the pump has to beperformed in such a manner that risks forpersonal injury are observed!

Use an appropriate type of grease, as per table and agrease gun suitable for grease nipple (pos 473)according to DIN 71 412 (ISO 6392).On vertical mounted units the greasing intervals arereduced to half.Installed in dusty or dirty premises or in a corrosiveenvironment it should be lubricated at more fre-

quent intervals.If using others than these recommended greases

Connecting and disconnecting of electriccables must be done only by personnelauthorized to do such work.

ACG8

IMOA

B

!

!

!


98/163

Useful tools

ACG7

IMOA

B

Slide calliperPuller

Allenkeys

Mounting sleeve dimensionsPump size D d L Part No

ACG/UCG 045 25.0 21.0 100 188887

ACG/UCG 052 31.0 26.0 100 188888ACG/UCG 060 35.0 31.0 100 188889ACG/ CG

Fineemery

Oil can Grease

Moun-tingsleeve

2 pcs ofscrewdriver

Plasticmallet

Pair ofpliers

Lubricating intervals in working hours

Temp Pump sizes 045 and 052 Pump sizes 060 and 070

max Grease Speed, r/min Speed, r/min

C type 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950

70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 1000090 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750

110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1300

*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.

Recommended greases (the availability of the greases can differ locally):Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak EP2, SKF LGMT2,

Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3, FINA MARSON L3.Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL RETINAX LX,

SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS, CASTROL LMX,INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.

Type C: Mobilith SHC 460

Before any maintenance work, ensurethat the driver is deenergized and thepump hydraulically isolated.

!

!

!

Oil leakage may make the floor slipperyd l i j

When handling liquids that may harmskin use gloves and/or protective clothing.

!

!

Pump size 045 052 060 070

Grease amount (g) 4 6 7 9

d

D

GREASEL

Inspection of rotorsIf an indication of a worn pump is noticed (see serviceintervals above), a brief inspection of the idler rotorsis recommended.A quick inspection of the idler rotors can be madesimply by removing the rear cover or valve cover.Note that the driver must be deenergized and thepump hydraulically isolated before the rear cover isremoved. Provisions to handle the fluid are to bemade. If a more thorough investigation is needed,proceed as under Dismantling.Internal clearances in the pump, which are vital for itsproper function, may have been affected by wear.Acceptable wear can be determined only by experi-

ence of the actual application. As a rule of thumb thefollowing max clearance values may apply:

Between rotor and bores or bushings: 0.2 mm Between rotor flanks: 0.4 mm

For light duties (low pressure, medium viscosity)even bigger clearances may be acceptable but for lowvisc./high pressure duties the limit will be lower.Also check if there are major scratches on these parts.

When handling liquids which may involvefire hazards appropriate precautions toavoid danger are to be taken.

In case of failure for a system with elevatedpressure, fluid jets may cause injury and/ordamage.


99/163

Sectional view

Version xxxE Version xxxG

Version xxBP

424A

424

437

429

Option A327


100/163

ACG14'IMOA

B

Dismantling

Note the axial position of the shaft coupling.

Release the stop screw.

A. B.

C. D.

ACG11'IMOA

B

Remove the key113.

Remove the shaftcoupling.

F.E.

451

Remove the screws 451

124

124A

514

ACG12'IMOA

B

ACG13'IMOA

B

Remove the retaining rings 124 and 514.R th t i 124A

Fig. 8 Fig. 9

Fig. 7Fig. 6

ACG10

IMOA

B

Turn theelectricity OFF.

Close the valves.

Remove the pumpfrom the system.

ATTENTION

Use appropriate vessels to collect oil spill-age when removing and opening the pump.

ACG9

IMOA

B

113


101/163

ACG17

IMOA

B

MOA

B

JxTxx.

K.

Shaft sealVersion xTxx

S4

S6

S5

Take out theidler rotors.

Clean all partsthat are goingto be usedagain.

ACG

20

IMOA

B

202

Unscrew theseal ring

carrier S5screws andtake off theseal ringcarrier S5together withthe seal ring S4and the o-ringS6.

ACG18

IMOA

B

ACG15

IMOA

B

122

120

359

359A

Fig. 12

Fig. 13

G. H.

5010

Push out the ballbearing 122 togetherwith the distancesleeve 120. If there istight fit use a mount-ing sleeve and amallet.

Remove the distancewasher 359 and thesupport ring 359A.

Remove thefront cover5010 with apuller.

I.

J xVxx.

Fig. 15

Fig. 14

Turn the front cover 5010 upside down.

Push out the seat from the front cover 5010.

Remove the o-ring S2.

Remove the gasket 506.

Pull the power rotor 1020 out of the pumpbody and place it into the jaws of a jaw vicewith softjaws or a column drilling machine.

Push with two drivers as shown on thesketch, to remove the shaft seal.

S1

S2

506

5010S4

S5

S4

S5

1020

No toolsfrom thisside

Shaft sealVersion xVxx

ACG16'IMOA

B

5010

!The sealingsurfaces of theshaft seatshould not betouched withthe fingers.

Mountingsleeve


102/163

ACG22

IMOA

B

S4

S5

Balancepiston

Lubricate theidler rotors and

fit them into thepump.Lubricationgroove turneddownwards.

202A.

Fig. 18

Fig. 20

BxTxx.Version xTxx

Reassembly

Open a packagewith a new shaftseal 509 versionxTxx.

Place the seal ringcarrier S5 on theshaft of the powerrotor 1020 flushagainst the bal-ance piston andlock it with itsstop screws. Fitthe o-ring S6 and

the seal ring S4.

ACG21

IMOA

B

S6

ACG23

IMOA

B

Carefully place thepower rotor 1020into the jaw vicewith soft jaws.

Lubricate allsurfaces of thepower rotor 1020.

Open a packagewith a new sealing509, version xVxx.

Place the bellowsunit S5 on the shaftof the power rotorand press it downagainst the balancepiston (106) See fig5.

S4

S5

BxVxx.Version xVxx

1020

Fig. 19

C.

Fig. 21

Lubricate the O-ring S2 and therecess of the frontcover 5010.

Clean the sealingfaces and fit theseat S1 into thefront cover 5010.Mind the position

of the retainingpin if applicable.

S1

S2

ACG2

4I

MOA

B

5010

D. Lubricate the balance piston 106 with a thick oil (ISO VG 460).

Fit the front cover onto the power rotor 1020 untill it rests onthe bellows unit S5.

Fit the support ring 359A and the distance washer 359 into thefront cover. Mind the position of the distance washer 359.

Fit the distance sleeve 120 into the front cover 5010.

Fill the ball bearing with appropriate grease. See page 5 forgrease selection.

Fit the ball bearing 122 onto the shaft.

359

359A

5010

Grease

120

1020

122

Mounting kit

106 ATTENTION

The open side of the bearing towards the cover.

Fit the mounting sleeve and push the bearing toits final position in the front cover. To do thissome force is required. Use Your column drillingmachine or similar press tool (See Fig ?).

!Do not use a hammer etc. as this mightdamage the shaft seal and ball bearing


103/163

F. Fit the key back in position, see fig. 9.

Fit the shaft coupling back into place (see fig. 7and 8) in the same way used when fitting theball bearing.

Fig. 24

!

Fig. 25

G.

Remove the plug 537 and washer 537A.

Hold the rotor unit horizontally with thebore for 537 upwards. Carefully fill thespace completely with thin oil(f. ex. ISO VG 46).

When the oil is flooding, reassemble theabove parts in reverse order.

Slowly turn the shaft a few turns to makesure it moves freely (a certain resistancefrom the shaft seal is normal but it must bethe same during the turns).

Fit the support ring 124A and the retain-ing ring 124 on the shaft.

Fit the retaining ring 514 back in place.

26'IMOA

B

124

124A

514

E.

Fig. 23

5010

1020

537537A

Do not use a hammer etc. as this mightdamage the shaft seal and ball bearing.


104/163

ACG29'IMOA

B

H.

Fig. 26

Pressure relief valve

Replacement of O-ring 605

To avoid changing the setting of the valve, use anAllen key to prevent spindle 608 to turn.Unscrew cover 601 and pull up unit 601/608.

Remove retaining ring 608A and pull the spindle608 out of cover 601. Replace O-ring 605 andassemble the unit 601/608 in reverse order.Replace retaining ring 608A if necessary andwasher 602.

Fit the unit 601/608 in the valve. Make sure the608 enters the set screw 612 and use the Allenkey to prevent 608 to turn when cover 601 istightened.

Replacement of Valve Element G070

Release the spring tension by turning the spindle608 CCW with an Allen key. Use the Allen key toprevent spindle 608 to turn and unscrew cover601 but do not remove it yet.

Remove the set screw 612 by turning the spindle608 CCW. Pull out the valve piston/spring unit614/615.

Fit the valve element in reverse order with a newwasher 602. Turn the spindle 608 CW until theset screw leave enough room for cover 601. Usethe Allen key to prevent 608 to turn further when

cover 601 is tightened. Adj t th l tti di t th "I t l

451

5010

1020

506

Place the gasket 506 on the pump body 401.

Lubricate the power rotor 1020 and fit thefront cover 5010 together with the rotor setinto the pump body. Mind the position of

the tension pin 545. Fit the screws 451 and tighten them cross-

wise.

Version G

Version P

ACG30'IMOA

B

480

608A

601

602

605

608

612

615

614

453

480

453

462

462A

462

401

Fig. 27

I. Put the pump back into the system and

proceed according to instructions underStart-up in the installation manual.


105/163


106/163

3. Pumps



107/163

This instruction is valid for all standard low pressure pumps:LPD, ACD, ACE, ACG/UCG, ACF/UCF, LPQ and ABQ

Contents Page

Pump identification 2Installation 3Start-up 8Trouble shooting 10

!

Before commencing any work, read this instruction carefully! Failure to comply

with these instructions may cause damage and personal injury!

Low pressure pumps

Installation and Start-up Instruction

Screw pumps


108/163

These instructions are valid for all low pressure pumps as specified in the Pump identification chart below.

Pump identification

ABQ

LPQ

ACF/UCF

ACG/UCG

ACE

ACD

LPD 015020

025

025032038

045052060070

080

090100110125

100110125140

160

180

N

LN

KLN

KN

K

LN

LNP

B

LN

1

6

3

6

4

1

5

I

IN

N

IN

I

N

I

I

V

VT

V

T

VT

R

V

R

R

B

B

B

BF

B

F

Y

Y

P

P

EGOP

E

OP

P

O

P

A101

A101A327A020A385

A020

A084A087A101

A328

P

J

Q

Pump name Rotorlead(1)

Shaft-seal

design(1)

Mounting(2)

Valve(3)

Alsovalid foroption

Comments

Pumpunitwithout shaftcoupling

O = max 5 bar

(1) See Product description or Service instruction for specifiedpump model

(2) B = Flange mountingF = Foot mountingY = Vertical foot mounting

(3) E = Without valveG = Valve with external return

OptionA020 Pump with surface treated casing(s)A084 Pump with lifetime greased ball bearingA087 Pump with CCW-rotation and lifetime greased ballbearingA101 Pump with CCW-rotation, when not standardA327 Pump with Tuning

A328 Pump with TuningA385 A101 + A327

Materialpump-body(1)

Size(1)

O = max 6 bar

O = max 10 bar

Designmodification

Pumpunitwithout shaftcoupling


109/163

max 90

min 60

max 90

min 60

!Failure to comply with these instructionsmay cause damage and personal injury!

Transport and storageAlways protect the pump against ingress of waterand other impurities. Store the pump in a clean, dryand warm environment. The pump is delivered withthe internals oiled and with protective covers overthe pipe connections and drain openings. Thesecovers should remain in place for as long as possibleduring the mounting and installation procedure butmust be removed before start up.

!All work carried out on the pump has to beperformed in such a manner that risks forpersonal injury are observed!

Lifting of pump

!All pumps should be lifted with strapssecurely attached to the pump or pump unit,

so that the center of gravity is located be-tween the straps in order to avoid tipping ofthe pump.

Use two eye bolts (M 20) securely fastened to thefront cover for pumps LPQ and ABQ. Pump andconnecting frame are lifted together using two eyebolts securely fastened to the top of the connectingframe. (Thread dimension is M 16, except for framesize 600, where it is M 20).

Identification of safety instructions

Non compliance of safety instructionsidentified by the following symbol -could affect safety for persons.

Safety instructions whereelectrical safety is involved,are identified by:

Safety instructions which shall be considered forreasons of safe operation of the pump or pumpunit and/or protection of the pump or pump unititself are marked by the sign:

ATTENTION

max 90

min 60

Fig. 1 Clean and dry environment.

InstallationBEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!

Design limitations and technical data for each pump are found in the Product description.Installation of IMO AB low pressure pumps does not require special skills. However, these instructionspresume that the work is carried out by experienced fitters.Maintenance and service instructions, which are specific for each pump are presented in a separate docu-ment.


110/163

Lifting of the complete pump unit with the liftingdevice attached to the motor, should be avoided asthe motors lifting provisions may not be able tocarry the combined weight of the pump and motor.

!Lifting a complete pump unit, using slingsor hooks attached to the pump or connecting

frame may be dangerous since the centre ofgravity of the pump unit may be higher thanthe points of attachments.

MountingThe pump must be securely mounted on a firmstable foundation and positioned so that it is easilyaccessible for inspection and servicing.Provisions for collecting oil spillage when servicingthe pump should be considered.

ATTENTION

The installation must always be designed tominimise damage. Should an operational orfunctional failure occur. E.g. precautionsshould be considered to collect oil spillagedue to a broken pipe or pump housing, tostop pump operation if overheating shouldoccur or if the oil volume is below a mini-mum tank level.

Alignment and shaft couplings

The pump shall be connected to its driver via aflexible shaft coupling. Pumps of type ACG/UCGand ACF/UCF may also be driven via gears orpulleys as specified in the Product Description,provided the radial forces are kept within thespecified range.

An angular misalignment of 0.1 corresponds toapprox. 0.2 mm deviation/100 mm.The coupling and alignment shall be selected not totransmit any axial or radial loads on the shaft ends.IMO AB standard couplings shall have a distancebetween the coupling halves as per table, fig 4. thecoupling halves shall be secured by lock screws.

For other types of couplings, please refer to respec-tive makers manual.

When fitting the shaft coupling, do not use ahammer or similar as this may damage theball bearing and shaft seal.Use some kind of press tool.

!

When handling liquids that may harm skinuse gloves and/or protective clothing.

When handling liquids which may involve!

!

Outer diameter Distance between Outer diameter Distance between

of coupling coupling halves of coupling coupling halves

(D mm) (t mm) (D mm) (t mm)

A B A B

50 26 2.0 8 148 3.567 40 2.5 16 168 3.582 55 3.0 18 194 3.597 65 3.0 20 214 4.0

112 80 3.5 24 240 4.0128 95 3.5 26

Fig. 3 Alignment of the IMO AB standard coupling

t

D4 max 0.3 mm

D6 max 0.4 mm

E4 max 0.4 mm

max

0.1

D

See table below An angular

misalignment of0.1 corresponds toapprox. 0.2 mmdeviation/100 mm.

Angularalignment

Distancebetweencoupling halves

Circularrun-out

A

XY

x = y - t

D

t

B


111/163

!Measures shall be provided to avoid acci-dental contact with the rotating shaft cou-pling. Any installed coupling guardshall permit easy access to the pump shaftfor maintenance and inspection of thepump bearing and seal housing.

Pipe connectionsThe pipe work shall be installed and supported sothat no pipe stresses are transfered to the pumpbody.The pipe work should be tight in order to avoidleakage and infiltration of foreign particles and/orair.Shut off valves should be installed in both suctionand discharge pipes, so that the pump can be hy-draulically isolated.

Suction lineThe suction pipe should be designed so that the totalpressure drop, measured at the pump inlet flange,does not exceed the suction capability of the pump.Make a proper calculation of the suction line includ-ing components such as valves, strainer, pipe bendsetc. Generally, the pressure drop in the suction lineshould be as low as possible, which is achieved if thesuction pipe is short, straight and has a suitablediameter.

The velocity in the suction line should be kept in therange 0.5 - 1.2 m/s. For L.O. circulating systems, werecommend to keep it as low as possible.The suction line must be equipped with a port thatallows filling the pump before start.

Discharge lineThe discharge line should be dimensioned to keepthe velocity in the range 1 - 3 m/s.

DeaerationIn installations with negative suction head, wherethe pump might be started against a pressurizedsystem, a deaeration pipe with an orifice (2-3 mmrecommended) has to be installed. The deaerationpipe should be connected to the outlet pipes highestpoint.This must also be installed when the pump is usedas an stand-by pump.

Fig.7 Suction line

Fig. 6 Pipe connections

For direct driven pumps the alignment betweenpump and motor shafts must be kept within thefollowing limits:

Max run-out Max angularmisalignment

(mm) (degrees)

Type LPDand ACD (n/a short coupled)Other types 0.3 0.1

Fig 5.


112/163

Fig. 9 Strainer

StrainerThe pump has to be protected from foreign matter,such as weld slag, pipe scale, etc., that could enterthe pump via the suction line. If the cleanliness ofthe system cannot be guaranteed, a strainer must beinstalled in the inlet pipe near the pump. For practi-cal reasons a suction strainer with 0.5 - 2 mm meshopenings is recommended:Small pumps (LPD, ACD, ACE) 0.5-0.8 mmLarge pumps (ACG/UCG, ACF/UCF, LPQ,/ABQ)0.8-2.0 mmThe size of the strainer should be selected so that itis large enough to allow adequate pressure at thepump inlet. The pressure drop across the strainershould preferably not exceed 0.1 bar at max. flowrate and normal operating viscosity. A vacuumgauge between the strainer and the pump inlet isrecommended to indicate when the strainer needscleaning.

Shaft seal drainThe pump should be installed so that any leakagefrom the shaft seal does not become a hazard. As theshaft seal has to be lubricated a small amount of oildripping cannot be avoided.Provisions to collect the leakage from the shaft sealmust be made.A drain pipe can be connected to the drain connec-tion on the pump, (not applicable to pump seriesLPD). However, when pumping heavy fuel oil orany other liquid that is likely to become very viscousat ambient temperature, we recommend that the

liquid is allowed to drop freely from the drainopening.

SealGuardFor heavy fuel oil high temperature applications, aSealGuard should be applied to the pump. Furtherinformation about SealGuard, read the Installationand Start-up Instruction for SealGuard.

Liquid trapIn some mounting arrangements the pump may notretain the liquid at stand still. In such installationsthe suction pipe should be arranged so it forms aliquid trap together with the pump, keeping thepump half filled with liquid. See fig. 11.

Fig. 10 Shaft seal drain


113/163

bar

Fig. 12 Gauges

GaugesGauges for monitoring the pumps working condi-tions are recommended. These gauges should beplaced readable as close to the pumps in- and outletflanges as possible. On standard pumps, series ACE,ACG/UCG, ACF/UCF and LPQ, there are gaugeconnections for both in- and outlet.

Pressure relief valveAll systems with screw pumps must be equipped

with a pressure relief valve installed immediatelyadjacent to the pump.In the standard versions of IMO AB low pressurepumps, this pressure relief valve is an integral partof the pump to protect the system against excesspressure.When liquid is circulated through the valve it heatsup in proportion to the set pressure level and thepercentage of by-passed liquid. 100% by-pass canonly be tolerated for less than about 3 minutes, 50 %by-pass generally for unlimited periods of time.If more than 50% recirculation is anticipated, a valuespecific to each application should be determined byclosely monitoring the pump body temperature.

If the pump is operating in line with a separatepressure control valve (see fig. 13), the setting of therelief valve should be high enough so as not tointerfere with the control valve. Likewise, if twopumps are operating in parallel, the setting shouldbe such that interference between the two valves isavoided.

Pressure testing and flushingThe system must be flushed and pressure tested

before connecting the pump. If corrosive liquid, suchas water is used, the system must be thoroughlydrained, dried and protected against corrosion afterhaving been flushed.

!Oil leakage may make the floor slippery andcause personal injury.

Fig. 13 Pressure relief valve

Fig. 14 External control with pressure relief valve


114/163

Start-up

Before startingAfter installation and whenever it can be assumedthat the pump has been emptied, the pump must be

thoroughly filled with liquid. See fig 15.For ACE Generation 3, ACG Generation 6 and ACFGeneration 4 delivered after 1997, the pumps hasbeen fitted with deaeration plugs making venting ofthe shaft seal compartment easy before start-up.In installations with positive suction pressure: Afteropening the inlet and outlet valves, simply open thedeaeration plug a few turns until oil sips out.Tighten the plug.In installation with negative suction pressure: Afteropening the inlet and outlet valves, remove thedeaeration plug and fill the shaft seal compartmentwith oil. Fit and tighten the plug. See fig. 16.Note! Not applicable on LPQ/ABQ.

!Make sure the prime mover is locked outand can not be started accidentally.

Rotate the shaft by hand while filling the pump, toensure that the rotor bores and the shaft seal cavityis filled. On the smaller pumps: (LPD, ACD, ACE,ACG/UCG), this is done by rotating the fan on theelectric motor after removing the fan cover.

!Do not forget to fit the motor fan cover againbefore making start of motor possible.

On the ACF/UCF, LPQ and ABQ pumps, the pumpcan be turned using the shaft coupling. If the suctionpipe cannot be completely filled, it is important toensure that the trapped air is evacuated without anypressure build up. (See fig. 8 Deaeration).

ATTENTION

Starting a dry pump is likely to causedamage, especially to the shaft seal.

Direction of rotationWhen the pump is ready to be started, switch themotor briefly on and off and check that the drivemotor rotates in the correct direction as indicated bythe rotation arrow.

The arrow is placed on different spots depending onthe pump series.

ATTENTION

Fig. 15 Filling the pump

Fig. 16 Deaeration plugs

ACG

ACF

ACE

Deaerationplug

Deaeration plug

Deaerationplug

Deaerationplug


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Fig. 18 Adjusting

03. pump station (lago agrio)

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