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  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

    Rev.0, Printed: 2010.08

    Erection Work, Operating and Maintenance Instructions

    Machine: Centrifugal Pump, ACP series

    Issued: Revision: Checked: Checked:

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

    Rev.0, Printed: 2010.08

    The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or partly reproduced without authorization by Andritz AG. Contraventions shall entail damage claims and may have penal consequences. All rights shall also be reserved for any patents granted, registration of trade marks and technical modifications without prior notification. 2010 Andritz

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    TABLE OF CONTENTS

    1 INTRODUCTION ....................................................................................................... 6 1.1 Use ..................................................................................................................................................... 6 1.2 Standards and guidelines ................................................................................................................... 6 1.3 How to use the manual ...................................................................................................................... 7 1.4 Warranty and guarantee .................................................................................................................... 8 1.5 Manufacturers name and address .................................................................................................... 9 1.6 Copyright ............................................................................................................................................ 9

    2 SAFETY .................................................................................................................. 10 2.1 General safety regulations ............................................................................................................... 10 2.2 Danger and warning signs ............................................................................................................... 10 2.3 Designated use ................................................................................................................................ 11 2.4 General remarks on machine/plant safety ....................................................................................... 11 2.5 Users obligations ............................................................................................................................. 12 2.6 General obligations of personnel ..................................................................................................... 14 2.7 Safety devices .................................................................................................................................. 15 2.8 Personal protective apparel ............................................................................................................. 17 2.9 Safety at the machine installation site ............................................................................................. 18 2.10 Temperature ..................................................................................................................................... 18 2.11 Noise ................................................................................................................................................ 18

    2.11.1 Noise levels (dB(A)) ............................................................................................................................... 19 2.12 Electrical equipment ......................................................................................................................... 20 2.13 Fluids (liquids, gases, vapor or smoke) ........................................................................................... 20 2.14 Oils and greases and cleaning agents ............................................................................................. 21 2.15 Chemicals ........................................................................................................................................ 21

    3 TECHNICAL DESCRIPTION .................................................................................. 23 3.1 General description .......................................................................................................................... 23

    3.1.1 Field of application ................................................................................................................................. 23 3.1.2 Design ..................................................................................................................................................... 24

    3.2 Main components of the centrifugal pump ....................................................................................... 25 3.2.1 Centrifugal pump with base frame ......................................................................................................... 25 3.2.2 Centrifugal pump .................................................................................................................................... 26 3.2.3 Bearing support ...................................................................................................................................... 27

    3.3 Type of seal ...................................................................................................................................... 29 3.3.1 Andritz cartridge mechanical seal - single .............................................................................................. 31 3.3.2 Andritz cartridge mechanical seal - double ............................................................................................ 32 3.3.3 Standard cartridge mechanical seal - single ............................................................................................ 34 3.3.4 Standard cartridge mechanical seal - double .......................................................................................... 36 3.3.5 Single standard mechanical seal ............................................................................................................. 38 3.3.6 Tandem standard mechanical seal........................................................... Error! Bookmark not defined. 3.3.7 Stuffing box packing............................................................................................................................... 40

    3.4 Type specification ............................................................................................................................ 42 3.4.1 Applicable standards............................................................................................................................... 42 3.4.2 Model designation .................................................................................................................................. 42

    3.5 Application limiting values ................................................................................................................ 43 3.6 Performance limits for bearing supports for different shaft material ................................................ 48 3.7 Technological description ................................................................................................................. 49

    4 ERECTION AND TRANSPORT .............................................................................. 50 4.1 General ............................................................................................................................................ 50 4.2 Safety regulations ............................................................................................................................ 50 4.3 Haulage ............................................................................................................................................ 51

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    4.4 Storage ............................................................................................................................................ 55 4.5 Installation ....................................................................................................................................... 56

    4.5.1 Erection of the centrifugal pump ............................................................................................................ 57 4.5.2 Pipework ................................................................................................................................................. 60 4.5.3 Aligning the coupling ............................................................................................................................. 61

    4.6 Instruments ...................................................................................................................................... 62 4.7 Electrical equipment ........................................................................................................................ 63 4.8 Cold test .......................................................................................................................................... 64

    5 START-UP .............................................................................................................. 66 5.1 General ............................................................................................................................................ 66 5.2 Safety regulations ............................................................................................................................ 66 5.3 Prerequisites for start-up ................................................................................................................. 67 5.4 Start-up ............................................................................................................................................ 69 5.5 Certificates....................................................................................................................................... 70

    6 OPERATION ........................................................................................................... 71 6.1 General ............................................................................................................................................ 71 6.2 Safety regulations ............................................................................................................................ 71 6.3 Control via DCS ............................................................................................................................... 72 6.4 Starting ............................................................................................................................................ 72 6.5 Checks after initial start-up .............................................................................................................. 73 6.6 Normal operation ............................................................................................................................. 74 6.7 Centrifugal pump requirements (delivery head and flow rate) ........................................................ 75 6.8 Shutdown ......................................................................................................................................... 76 6.9 Operating malfunctions and troubleshooting ................................................................................... 77

    7 MAINTENANCE ..................................................................................................... 81 7.1 General ............................................................................................................................................ 81 7.2 Safety regulations ............................................................................................................................ 81 7.3 Regular maintenance ...................................................................................................................... 82 7.4 Maintenance schedule .................................................................................................................... 84 7.5 Fasteners......................................................................................................................................... 85 7.6 Lubrication ....................................................................................................................................... 87

    7.6.1 Oil lubrication......................................................................................................................................... 87 7.6.2 Grease lubrication ................................................................................................................................... 90

    7.7 Aligning the coupling ....................................................................................................................... 92 7.8 Installing and removing the pull-out unit .......................................................................................... 93

    7.8.1 Removing the pull-out unit ..................................................................................................................... 94 7.8.2 Mounting the pull-out unit...................................................................................................................... 95

    7.9 Changing the impeller and the front lining ....................................................................................... 96 7.10 Trimming the impeller ...................................................................................................................... 99 7.11 Changing the shaft seals ............................................................................................................... 100

    7.11.1 Changing the Andritz cartridge mechanical seal-single and double ..................................................... 100 7.11.2 Changing the standard cartridge mechanical seal-single and double ................................................... 102 7.11.3 Changing the single standard mechanical seal ..................................................................................... 104 7.11.4 Changing the tandem standard mechanical seal ................................................................................... 106 7.11.5 Changing the stuffing box packing and the shaft protection sleeve ..................................................... 108

    7.12 Changing the anti-friction bearings ............................................................................................... 112 7.13 Disassembly and disposal ............................................................................................................. 114

    8 TECHNICAL DATA ............................................................................................... 116 8.1 Data sheet ..................................................................................................................................... 116 8.2 Characteristic curve ....................................................................................................................... 116 8.3 Dimensional drawing ..................................................................................................................... 116 8.4 Coupling ........................................................................................................................................ 117 8.5 Shaft seal ....................................................................................................................................... 117

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    1 INTRODUCTION This manual is part of the ANDRITZ AG technical documentation for the pump. It is intended to provide the operator with the basic knowledge required for proper, safe and economical use of the equipment delivered by ANDRITZ AG. Observing these instructions helps avoid hazards and reduce repair and downtime costs, as well as increasing the reliability and useful life of the machines.

    1.1 Use

    Target group This operating manual is intended for users with a knowledge of mechanical engineering and is for the exclusive use of the operator of the mill and his personnel.

    Personnel entrusted with work on the machine must have read and understood these operating instructions and comply with them. This refers in particular to the following tasks:

    Handling, starting and stopping

    Troubleshooting

    Maintenance and upkeep

    Haulage

    Maintenance and disposal of process materials, cleaning of machine and area around the machine.

    The following sections are especially important:

    The Chapter on SAFETY,

    The safety instructions contained in various other chapters

    Supplementary instructions

    The mill operator shall complete this manual by adding national regulations on safety at work, health protection and environmental protection.

    Instructions on any special operational conditions concerning work organization, sequence of work/operations and the personnel assigned to the job shall also be added. This also includes instructions on supervising and reporting obligations.

    Safekeeping Keep the entire operating manual near the place where the machine is installed and within easy reach.

    1.2 Standards and guidelines

    The pump is delivered together with a CE declaration of conformity according to Machinery Directive 2006/42/EC Annex II, 1.A. It is confirmed that European standards (harmonized) EN 809 and EN ISO 12100, Parts1 and 2, have been observed. Auxiliary electrical equipment supplied, such as motors, measuring instruments, ... carry a CE marking (if they fall within the scope of a guideline, for example the low-voltage or EMV guideline).

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    1.3 How to use the manual

    Presentation Chapter and paragraph headings are printed in capitals in the continuous test

    SAFETY

    Designations of indicating and handling elements are written in inverted commas in the continuous text.

    Operate switch xxx

    Lists without numbering do not require operations to be carried out in a certain order.

    Pictograms The following pictograms are used in the manual:

    Warning signs.

    Warning signs are shown with an explanation of the type of the hazard.

    The meaning of the different graduations of hazards is described in the Chapter on SAFETY.

    Marks an instruction on handling of the machine of system.

    Marks a useful piece of information

    Marks a cross-reference to another Chapter with absolute path indication.

    e.g. /ACP-Pump/SAFETY

    Work steps (operations)

    Work steps are presented in tables. Work steps are numbered and must be carried out in the order specified.

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    Item numbers 411.2 The item numbers shown in this format refer to the assembly drawing and the parts list.

    Numbering of pages, tables and figures

    Pages

    Tables

    Figures

    consecutive numbering of Chapters 2-1

    Tab. + Continuous numbering of Chapters Tab.2-1

    Fig. + Consecutive numbering of Chapters Fig.2-1

    Abbreviations Tab.

    Fig.

    Table

    Figure

    1.4 Warranty and guarantee

    Andritz AGs general terms of delivery and sale shall apply.

    Guarantee and liability claims on Andritz AG shall become void if personal injury or material damage is caused by one or several of the following:

    Use of the machine/system for any purpose other than its designated use.

    Non-conformity of erection work, start-up and handling of the machine/system.

    Non-observance of the safety instructions in the manual.

    Non-authorized structural changes to the machine/system.

    Non-observance of the maintenance and upkeep instructions.

    In the event of a claim for repair under guarantee, ANDRITZ AG reserves the right to assess the damage to the machine/system.

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    1.5 Manufacturers name and address

    Andritz AG

    Stattegger Strasse 18

    A-8045 Graz

    Our service department will be pleased to help you and can be contacted at:

    Andritz AG

    Stattegger Strasse 18

    A-8045 Graz

    Service department for pumps

    Tel.: +43/316-6902-2706

    Fax: +43/316-6902-413

    Email: [email protected]

    In case of emergency outside working hours

    Tel.: +43 316 6902-0

    1.6 Copyright

    The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or partly reproduced without authorization by Andritz. All rights shall also be reserved for any patents granted, registration of trade marks and technical modifications without prior notification.

    2010 Andritz AG

    mailto:[email protected]

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    2 SAFETY 2.1 General safety regulations

    The chapter on safety contains general safety regulations which must be observed when working on the machine/plant.

    In addition, the chapters in the operating manual contain further safety regulations. These are marked by DANGER SIGNS.

    Safety instructions on components not supplied by Andritz AG are contained in the descriptions of the components ( /ACP-PUMP/SUPPLIER DOCUMENTATION). The safety instructions supplement ANDRITZ AGs operating instructions.

    All safety instructions must be observed. Disregarding the safety instructions may cause a risk to life and limb, environmental pollution hazards and damage to property.

    2.2 Danger and warning signs

    The entire SAFETY chapter is of extreme importance and relevant to safety. The information in this chapter, therefore, is not marked with special danger symbols.

    The Chapters on ERECTION WORK, START-UP, OPERATION and MAINTENANCE in this Manual are marked by a pictogram. The following warning signs are used:

    DANGER

    This symbol indicates there may be a risk to life and limb.

    Non-compliance with the warning signs may lead to serious health problems or even fatal injuries, and can cause extensive damage to property.

    WARNING

    This symbol points to an imminent health risk, as well as a risk of environmental pollution and of damage to property.

    Non-compliance with the warning sign may cause moderate health problems and/or extensive environmental pollution and damage to property.

    CAUTION

    This symbol points to a dangerous situation.

    Non-observance of these signs may cause environmental pollution and damage to property.

    Further symbols and pictograms used are described under INTRODUCTION.

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    2.3 Designated use

    The centrifugal pump should only be used according to the specifications forming part of the purchase order.

    Any change in the application must be checked by the operator and, if necessary, approved by Andritz AG.

    Non-observance of the application can lead to environmental or property damage, or to personal injury.

    Any modifications to the scope of supply made without the agreement of Andritz AG are considered contrary to the designated use.

    The term designated use shall also include adherence to the operating instructions, observance of the operating, inspection and maintenance conditions and of the regulations on cleaning and upkeep.

    Please also observe the type specification ( /TECHNICAL DESCRIPTION/TYPE SPECIFICATION Chapter 3.5), and the operating limits ( /TECHNICAL DESCRIPTION/OPERATING LIMITS Chapter 3.6)

    2.4 General remarks on machine/plant safety

    The centrifugal pump has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user of third parties, of cause damage to the machine/plant and to other material property.

    The centrifugal pump may only be operated when in perfect condition and with due consideration to safety and the risks involved. All protective devices and the emergency cut-out devices must be in place and fully functional.

    Malfunctions and unforeseen changes in the centrifugal pump must be remedied immediately.

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    2.5 Users obligations

    Designated use The user of the centrifugal pump is responsible for its designated use.

    Work instructions In addition to the operating instructions, applicable legal stipulations and other rules governing the safety at work, health and environmental protection must be observed and personnel instructed in them.

    Qualification of assigned personnel

    The centrifugal pump may only be operated, maintained and serviced by authorized, skilled personnel with hands-on training.

    Personnel must not be below the legal minimum age.

    Any person undergoing training, serving an apprenticeship or being instructed must not work on the centrifugal pump except under the supervision of an experienced person.

    Instructions The users operating and maintenance personnel will be instructed by manufacturer personnel or his contractual distributor upon completion of installation work.

    The user undertakes to have new, additional operating and maintenance personnel instructed in machine and maintenance of the centrifugal pump to the same extent and applying the same care, and with due consideration to the safety instructions.

    Workers entrusted with the transportation, erection work and start-up of the centrifugal pump must have read and understood the operating instructions, especially the chapter on SAFETY, the safety instructions concerning a certain activity, as well as the safety instructions issued by sub-suppliers.

    Definition of areas of responsibility

    The user shall be responsible for:

    definition of the machine operators responsibility and his right to give instructions

    Definition of the contents and responsibility for keeping the records on functioning and any failure of the monitoring equipment (log book)

    Personnel areas of responsibility in terms of operating, Tooling, maintenance and upkeep.

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    Inspections The operator undertakes

    To check at regular interval whether the safety instructions and regulations governing work on the centrifugal pump are observed.

    To carry out regular training to confirm the level of knowledge of the operating and maintenance personnel.

    Attaching safety devices

    The user shall ensure that the following equipment, regulations, symbols and instructions are mounted in the production area;

    Safety devices and regulations (see Chapter 2.7)

    Fire prevention regulations

    Markings on the floor for driveways, protective fencing and danger areas (yellow)

    Fencings and covers

    Railings (foot, center and chest height)

    Emergency lighting

    Emergency-off switch

    Repair switch for drive motors

    Signs on fire-fighting equipment

    Signs for emergency calls

    Direction arrows to exits

    Direction arrows to escape routes

    Signs to first-aid post

    High-voltage protection

    The operator shall provide suitable earthing and high-voltage protection equipment.

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    2.6 General obligations of personnel

    To avoid personal and material damage anybody working on the machine shall

    Observe the safety instructions in the operating regulations and on the centrifugal pump itself.

    Stop and secure the centrifugal pump in case of a safety-relevant functional disorder. Report disorders and have them repaired immediately.

    Do not perform any work in a manner disregarding safety considerations.

    Use only the machine accesses, paths and passages foreseen for this purpose.

    Do not touch moving and rotating parts and/or reach out beyond them.

    Keep the machine and the work place clean. Do not place tools or other objects on the centrifugal pump.

    Do not wear any garments/pieces of jewelry which might get stuck on rotating/moving pump parts; this includes ties, scarves, rings and necklaces.

    Not wear long hair down.

    Familiarize yourself with the function and any failure of machine monitoring equipment (log book) before starting work.

    Refrain from smoking in the vicinity of the centrifugal pump.

    Personal protective apparel must be worn when working on the centrifugal pump. (see Section 2.8)

    Due to the high temperatures, high pressure and humidity, people wearing glasses may find that their glasses steam up, thus exposing the wearer to a risk of injury.

    The operating personnel must be acquainted with the safety data sheets in order to be able to recognize how dangerous the chemicals can be.

    In order to identify the risks of high pressure (up to 25 bar), the personnel must know the technical data of the centrifugal pump, as well as its place of installation.

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    2.7 Safety devices

    The centrifugal pump must not be operated without effective safety equipment.

    Safety equipment must not be circumvented, dismantled or made unserviceable during operations. The safety equipment is there to protect operating personnel.

    Safety equipment and access thereto must be kept free.

    Safety covers The centrifugal pump must not be operated without safety covers mounted.

    Check in particular that the coupling guard does not have any deformations!

    Fig. 2-1 shows the protective covers for the centrifugal pump.

    Fig. 2-1 Safety covers at the ACP pump

    Coupling guard

    Safe guard for sealing chamber

    Earthing

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    Indicative, warning

    and prohibiting signs

    Indicative, warning and prohibiting signs must be observed. They must be

    Checked regularly for legibility and completeness and they must not be removed or obstructed.

    The following indicative, warning and prohibiting signs are attached to the machine.

    Hot surface

    Chemicals:

    If the pump is used in the chemicals sector, the operator must mount appropriate safety instructions on the plant.

    Examples of signs required where chemicals are used:

    Warning against

    toxic substances

    Caustic substances

    Emergency-off switch, safety shutdown

    The pump is usually part of a plant or system.

    The operator is responsible for installation of EMERGENCY OFF/STOP devices so that the plant can be brought to a halt in an emergency.

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    2.8 Personal protective apparel

    General protective

    apparel

    Operating personnel must use and carry personal protective equipment along with them in accordance with the national regulations or as specified by the plant operator.

    It should be compulsory to wear hard-toed boots throughout the entire mill premises.

    In addition to the regulations applying, we recommend using the following safety equipment for certain work:

    Activity Safety equipment

    Time spent in the immediate

    vicinity of the machine while it is

    running

    Taking pulp samples

    Field installation and

    maintenance work for which parts

    of the machine have to be

    removed

    Tab. 2-1 recommended safety equipment for certain work

    Key to symbols

    Protective clothing to prevent the

    pulp from coming into contact with the skin

    Safety shoes as protection against foot injuries

    Gloves to prevent hand injuries

    Ear protection to prevent damage

    to hearing

    Goggles to prevent eye injuries

    Standard hard hat as protection

    against head injuries

    Tab. 2-2 Purpose of the safety equipment

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    2.9 Safety at the machine installation site

    Adequate lighting must be provided (industrial lighting).

    The foundations must be sized to withstand the loads caused by the centrifugal pump. The customer will be provided with a load plan.

    The pump must be easily accessible. The operator must provide safe means of access (e.g. ladders, platforms)

    Area around machine and marked escapes to be kept clear. Area around machine must be marked as danger zone.

    Make sure machine and surrounding area are kept clean. In particular, oil and grease on the floor and on machine elements may cause slipping. Thus, they present a considerable risk of injuries, particularly in combination with tools.

    The floor around the centrifugal pump must be provided with a non-slip finish.

    In order to prevent any falls from or damage to the machine, it is forbidden to climb onto machine elements or on the machine (except for the treading areas provided). Use ladders or similar equipment in accordance with recognized standards.

    Ramps, platforms and lifts must be used to avoid injury or excessive physical effort.

    2.10 Temperature

    As the temperature of the medium can exceed 73C, the housing and covers prevent from direct contact with the medium. Danger symbols mounted on the machine warn against the hot surface. It is compulsory to wear personal safety equipment in the immediate vicinity of the pump.

    The operator is responsible for informing new personnel on the danger of burns and for implementing further safety mwasures, e.g. insulation or access restrictions.

    No maintenance work should be carried out until the hot surface has cooled down.

    The centrifugal pump can be designed for a media temperature of up to180C. If media with temperatures higher than 65C are to be pumped, the operator must take the necessary safety measures (e.g. safety devices, protective gloves, training of operating staff, etc.).

    2.11 Noise

    The total noise emissions from all machines in the production room can restrict spoken communication and impair hearing.

    The machine is designed such that no operator is required in the immediate vicinity of the machine. Appropriate hearing protection should be worn throughout maintenance and adjusting work while the machine is running.

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    2.11.1 Noise levels (dB(A))

    990 u/min 1180 u/min 1450 u/min 1780 u/min 3000 u/min 3560 u/min

    ACP 65-315 70 70 72 75 80 83

    ACP 100-500 70 70 72 76

    ACP 65-250 70 70 71 73 79 83

    ACP 100-315 70 70 71 75 82 84

    ACP 125-400 70 70 73 76

    ACP 150-500 70 72 76 77

    ACP 100-250 70 70 72 76 81 84

    ACP 125-315 70 71 73 77

    ACP 150-400 70 72 75 78

    ACP 200-500 70 73 77 79

    ACP 300-700 70 76

    ACP 125-250 70 71 75 79 82 85

    ACP 150-315 70 70 71 75

    ACP 200-400 70 73 76 79

    ACP 400-700 70 75

    ACP 250-315 70 71 73 77

    ACP 300-400 70 72 75 78

    ACP 450-550 70 73

    ACP 600-700 70 74

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    2.12 Electrical equipment

    All work on the electrical equipment, without exception, must be carried out by skilled electricians.

    Any form of contact with electrical equipment may cause fatal injuries. Before beginning any maintenance or repair work, the operator must disconnect the energy supply to all drives securely. This can be achieved with a maintenance switch, lockable racks in the MCC, or with other suitable measures that comply with the safety regulations.

    Employees performing work on live parts should be accompanied by an assistant who can operate the emergency switch if necessary.

    Users of medical electronic equipment, such as pacemakers, must not enter the electric danger zone.

    Earthing Machine must be earthed to avoid electrostatic loading. Machine, gears and

    motors must be connected to the earthing system.

    Machine must be earthed to avoid electrostatic loading.

    Proper earthing must be restored after conducting maintenance work (e.g. check and set the earthing resistance)

    2.13 Fluids (liquids, gases, vapor or smoke)

    Unintentional chemical reactions may take place in the medium during a prolonged standstill and hazardous fumes may be produced.

    The machine must be thoroughly cleaned after prolonged stoppages. The area must be adequately ventilated.

    Before beginning work on the machine, ensure that no liquids, gases, vapors or smoke can enter the working area from feed pipes, discharge pipes or shafts.

    If it is not possible to reliably exclude the risk of liquids, gases, vapours or smoke flowing in, all persons working in the danger zone must be quipped with a safety harness and a safety rope. Each worker must be monitored by a second person outside the danger zone. It must always be possible to evacuate a worker from the danger zone without delay.

    Any leakage (e.g. at the shaft seal) of hazardous media (e.g. explosive, toxic, hot) must be drained off in such a way that there is no risk to individuals, nor to the environment. Any legal regulations must be observed.

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    2.14 Oils and greases and cleaning agents

    The safety instructions for the products concerned must be observed when handling oil, grease and other chemical substances.

    Suitable skin protection is required when handling aggressive media. See manufacturers information for the type of skin protection required.

    Also observe relevant requirements for disposal

    2.15 Chemicals

    The centrifugal pump can be used in the chemical sector (except in chlorine bleaching and in the chlorine dioxide area) of the pulp and paper industry.

    The following chemicals can be pumped:

    Hydrogen peroxide H2O2

    Caustic soda (sodium hydroxide) (NaOH)

    Silicate

    DTPA

    Hydrogen peroxide (H2O2) and caustic soda (NaOH) can irritate or even burn the skin and mucous membrane, particularly the eyes, and can also lead to inflammations of the respiratory system.

    In addition, please note that hydrogen peroxide (H2O2) is not combustible, but enhances the combustibility of other substances.

    Reactions In reactions with other substances, hydrogen peroxide (H2O2) and caustic soda

    (NaOH) can lead to highly exothermic reactions, heat generation, and danger of ignition or generating of inflammable gases or vapours, even to a risk of explosion.

    Safety data sheets If chemicals are used, the measures prescribed in the safety data sheets for the

    individual chemicals must be observed.

    The user shall be responsible for the following, among other things:

    Staff wearing personal safety attire, particularly adequate eye protection

    Installing water connections and emergency showers in order to rinse the eyes or skin under running water in the event of an emergency and have a source of drinking water if any chemicals are inadvertently swallowed.

    Providing medical treatment in emergencies

    Preventing any chemical reactions that can lead to a risk of fire or explosion

    Regular training on the properties and handling regulations for the chemicals used.

    Mounting of safety signs on the plant (e.g. warning against toxic or corrosive substances)

    Mounting devices for flushing the pump (e.g. the inlet flange) in order to

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    clean the pump from aggressive media.

    Interlocking the chemical feed so that no more chemicals can flow into the pump when pump is shut down.

    Emptying the vent line safely to prevent from possible contact with chemicals.

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    3 Technical Description 3.1 General description

    3.1.1 Field of application

    The centrifugal pump is used in continuous operation to pump specified liquids and various pulps in the paper industry.

    (See chapter headed Technical Data)

    Fig. 3-1 Centrifugal pump

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    3.1.2 Design

    This spiral casing centrifugal pump is carried out in process design. The impeller, the wear lining, the casing cover and the stuffing box body with the shaft seals and the bearing support can be assembled and disassembled without detaching the suction and delivery pipes.

    Impeller(230)) Function: Accelerating the medium by charging it with energy.

    Design: Semi-open impeller with vanes on the back.

    Spiral casing (102) Function: Guiding the medium with a favorable flow pattern, converting speed

    energy into pressure energy.

    Design:

    Pressure-sealed pump casing with delivery and suction channels.

    Suction and delivery flange.

    Holds the bearing housing with bearing assembly, shaft and impeller.

    Standard design . . . . . . . . . . . . . . . . . . . . . . . . . . single spiral casing Special design . . . . . . . . . . . . . . . . . . . . . . . . . . . Double spiral casing

    Pump shaft (211) Function: Holding the impeller, shaft seal, bearing assembly and coupling.

    Transmitting the drive energy to the impeller and thus, to the medium.

    Design: Sturdily dimensioned drive shaft

    Bearings Function: Interface between stationary and rotating parts. Absorption of axial

    and radial forces.

    Design:

    Impeller side: . . . Two angular contact ball bearings (321.1) with steel

    cage.

    Drive side. . . . . One deep groove ball bearings (321.2) with steel cage.

    Shaft seal Depending on operating requirements, there is a choice of eight different

    shaft seals:

    Andritz cartridge mechanical seal - single

    Andritz cartridge mechanical seal - double

    Standard cartridge mechanical seal - single

    Standard cartridge mechanical seal double

    Single standard mechanical seal

    Tandem mechanical seal

    Stuffing box packing

    Dynamic shaft seal

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.2 Main components of the centrifugal pump

    3.2.1 Centrifugal pump with base frame

    Fig. 3-2 Main components of the centrifugal pump

    Item Component Item Component

    A Centrifugal pump, complete F Motor (800)

    B Coupling (840)

    C Coupling guard (681)

    D Base frame (891)

    E Sliding rail (593)

    Tab. 4-1 Main components of the centrifugal pump

    A C B F

    D E

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.2.2 Centrifugal pump

    Fig. 4-3 Main section - centrifugal pump

    Item Component Item Component

    102 Volute casing 330 Bearing support

    135.1 Front lining 680 Safety guard for sealing chamber

    230 Impeller 183 Supporting leg

    430 Shaft seal 161 Casing Cover

    Tab. 4-2 Principal section ACP pump

    135.1 230 430 330

    680

    183

    102

    161

    554.1, 920.1, 902.1

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.2.3 Bearing support

    Fig. 4-4 Grease lubrication

    Item Component Item Component

    350 Bearing housing 421 Rotary shaft seals (421.1, 421.2)

    211 Shaft 672 Vent screw

    321.1 Angular contact ball bearing 642 Oil level indicator

    321.2 Deep groove ball bearing 636.1 Grease lubricating nipple

    550

    Splash ring washer (550.1,550.2) 904 Set screw

    507 Splash ring (507.1,501.2)

    Tab. 3-3 Main components for the bearing support

    350 321.1 321.2

    550.1 421.1

    507.1

    904.1

    550.2 421.2

    507.2

    904.2

    636.1 636.1

    211

    903.2

    672

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    Fig. 3-5 Oil lubrication

    Item Component Item Component

    350 Bearing housing 903 Plug

    211 Shaft 672 Vent screw

    321.1 Angular contact ball bearing 914 Socket head cap screw

    321.2 Deep groove ball bearing 411 Sealing washer

    423

    Bearing isolator (423.1,423.2) 633 Constant level oiler (option)

    642 Oil level indicator (option)

    Tab. 3-4 Main components for the bearing support

    350

    903.3

    321.1

    321.2

    903.4

    211

    423.1

    914.11 411.11

    423.2

    914.10 411.10

    672

    633

    642

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.3 Type of seal

    Fig. 3-6 Andritz cartridge mechanical seal - single Fig. 3-7 Andritz cartridge mechanical seal - double

    Fig. 3-8 Standard cartridge mechanical seal - single Fig. 3-9 Standard cartridge mechanical seal - Double

    Fig. 3-10 Single mechanical seal Fig. 3-11 Single mechanical seal

    Type: A1

    Type: A2

    Type: A3

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    Not available yet

    Fig. 3-14 Stuffing box packing Fig. 3-15 Dynamic shaft seal

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    433.1

    914.1

    3.3.1 Andritz cartridge mechanical seal - single

    Function: Seal between medium and the atmosphere. The mechanical seal

    is lubricated by the medium to be pumped.

    Fig. 3-16 Andritz cartridge mechanical seal - single

    Item Component Item Component

    433.1 Mechanical seal 914.1 Screw

    Tab. 3-5 Andritz cartridge mechanical seal - single

    Application limits:

    T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100C

    p max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar

    n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)

    Bearing suppport size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Tab. 3-6 Sizes - Andritz cartridge mechanical seal single

    Medium Atmosphere

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    3.3.2 Andritz cartridge mechanical seal - double

    Function: Seal between medium and the atmosphere by sealing water

    between the medium-side and the atmosphere-side seal in order to

    guarantee functioning of the mechanical seal within special application

    limits.

    Fig. 3-17 Andritz cartridge mechanical seal - double

    Item Component Item Component

    433.1 Mechanical seal 914.1 Screw

    Tab. 3-4 Andritz cartridge mechanical seal - single

    Application limits:

    T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100C

    p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar

    n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)

    Bearing suppport size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Sealing water pressure [bar] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12

    Sealing water quantity [1/min] 2 3 3 4 4

    Tab. 3-7 Sizes - Andritz cartridge mechanical seal single

    433.1

    914.1

    Medium

    Atmosphere

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    Sealing water data:

    Pressure 0.5 bar min. - 12 bar max.

    Quality Pure water

    Mechanical contamination: 80 microns max.

    Temperature 10C min. - 30C max.

    Solids content 2 mg/l max.

    Tab. 3-8 Sealing water data for Andritz cartridge mechanical seal Monitoring In order to guarantee proper operation the sealing water must be

    monitored with suitable monitoring units according to the diagrams (Fig. 4-18, Fig. 4-19).

    Sealing water connection and monitoring for the tandem mechanical

    seal:

    Fig. 3-18 Unpressurised Fig. 3-19 Pressurised

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    3.3.3 Standard cartridge mechanical seal - single

    Function: Seal between medium and the atmosphere. The mechanical seal

    is lubricated by the medium to be pumped.

    Fig. 3-20 Andritz cartridge mechanical seal - single

    Item Component Item Component

    145 Adapter 412.5 O-ring

    433.1 Mechanical seal 914.1 Screw

    504 Spacer 902.4 Bolt

    Tab. 3-9 Standard cartridge mechanical seal - single

    Application limits:

    T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100C

    p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar

    n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)

    Medium

    Atmosphere

    433.1

    145

    914.1

    412.5

    902.4, 920.4, 554.4

    504 551.2

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    Bearing suppport size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Sealing water pressure [bar] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12

    Sealing water quantity [1/min] 2 3 3 4 4

    Tab. 3-10 Sizes - Standard cartridge mechanical seal single

    Sealing water data:

    Pressure 0.5 bar min. - 12 bar max.

    Quality Pure water

    Mechanical contamination: 80 microns max.

    Temperature 10C min. - 30C max.

    Solids content 2 mg/l max.

    Tab. 3-11 Sealing water data for standard mechanical seal Monitoring In order to guarantee proper operation the sealing water must be monitored

    with suitable monitoring units according to the diagrams (Fig.4-21, Fig. 4-22).

    Sealing water connection and monitoring for the tandem mechanical

    seal:

    Fig. 3-21 Unpressurised Fig. 3-22 Pressurized

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.3.4 Standard cartridge mechanical seal - double

    Function: Seal between medium and the atmosphere by sealing water

    between the medium-side and the atmosphere-side seal in order to

    guarantee functioning of the mechanical seal within special application

    limits.

    Fig. 3-23 Andritz cartridge mechanical seal - double

    Item Component Item Component

    145 Adapter 412.5 O-ring

    433.1 Mechanical seal 914.1 Screw

    504 Spacer 902.4 Bolt

    Tab. 3-12 Andritz cartridge mechanical seal - single

    Application limits:

    T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100C

    p max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar

    n max: . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)

    433.1

    145

    914.1

    Medium

    Atmosphere

    412.5

    902.4,920.4, 554.4

    504 551.2

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    Bearing suppport size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Sealing water pressure [bar] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12

    Sealing water quantity [1/min] 2 3 3 4 4

    Tab. 3-13 Sizes - Andritz cartridge mechanical seal single

    Sealing water data:

    Pressure 0.5 bar min. - 12 bar max.

    Quality Pure water

    Mechanical contamination: 80 microns max.

    Temperature 10C min. - 30C max.

    Solids content 2 mg/l max.

    Tab. 3-14 Sealing water data for tandem mechanical seal Monitoring In order to guarantee proper operation the sealing water must be

    monitored with suitable monitoring units according to the diagrams (Fig. 3-24, Fig. 3-25).

    Sealing water connection and monitoring for the tandem mechanical

    seal:

    Fig. 3-24 Unpressurised Fig. 3-25 Pressurized

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.3.5 Single standard mechanical seal

    Function: Seal between medium and the atmosphere. The mechanical seal

    is lubricated by the medium to be pumped.

    Fig. 3-26 Single mechanical seal

    Medium Atmosphere

    145

    914.1

    412.5

    504 551.2

    433.1

    Type: A1

    Type: A2

    Type: A3

    Medium Atmosphere

    145

    412.5

    914.1

    433.1

    509

    914.12

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    Item Component Item Component

    145 Adapter 412.5 O-ring

    433.1 Mechanical seal (MG12) 914.1 Screw

    504 Spacer

    Tab. 3-15 Single standard mechanical seal type A1-MG12S14

    Item Component Item Component

    145 Adapter 412.5 O-ring

    433.1 Mechanical seal (MG12) 914.1 Screw

    Tab. 3-16 Single standard mechanical seal type A2- 578

    Item Component Item Component

    145 Adapter 412.5 O-ring

    433.1 Mechanical seal (MG12) 914.1 Screw

    509 Fastening ring 914.12 Screw

    Tab. 3-17 Single standard mechanical seal type A3 SR6

    Application limits:

    T max:. . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . 100C

    p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar

    n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)

    Bearing support size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Tab. 3-18 Sizes Single standard mechanical seal

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    3.3.6 Stuffing box packing

    Function: Seal between medium to be conveyed and the atmosphere

    formed by packing rings and sealing water.

    Fig. 3-30 Stuffing box packing

    Item Component Item Component

    451 Stuffing box casing 461 Stuffing box packing

    452 Stuffing box gland 524 Shaft protection sleeve

    458 Sealing water ring 412.5/8 O-ring

    902.4 Bolt 914.1 Screw

    Tab. 3-24 Stuffing box packing

    Bearing suppport size 42 48 60 75 100

    Shaft diameter D[mm] 42 48 60 75 100

    Seal diameter D1[mm] 53 60 70 85 115

    Packing diameter D2[mm] 65 70 80 100 130

    Packing [mm] 10x10 10 x10 10x10 12x12 12x12

    Number 1+3 1+3 2+3 2+3 2+3

    Sealing water pressure [bar] 3-5 3-5 3-5 3-5 3-5

    Sealing water quantity [l/min] 2 3 3 3 4

    Tab. 3-25 Sizes - Stuffing box packing

    452

    412.5

    902.4 920.4

    554.4 458

    524

    451

    412.8

    461

    914.1

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    Sealing water data:

    Sealing water

    pressure

    3 - 5 bar +inlet pressure

    Quality Pure water

    Mechanical contamination: 80 microns max.

    Temperature 10C min. - 30C max.

    Solids content 2 mg/l max.

    Tab. 3-26 Sealing water data for stuffing box packing Monitoring In order to guarantee proper operation the sealing water must be

    monitored with suitable monitoring units according to the diagram (Fig.

    3-22).

    Sealing water connection and monitoring for the stuffing box:

    Fig. 3-31 Unpressurised

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    3.4 Type specification

    3.4.1 Applicable standards

    Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 2858

    Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 5199

    Inspection (Q, H, NPSH) . . . . . . . . . . . . . . . . . . . . . ISO 9906 Class

    Product safety . . . . . . . . . . . . . . . .EN 809, EN 12100-1, ISO 12100-2

    Flanged drilling . . . . . . . . . . ISO 2084, PN 10 (DIN 2501, SFS 2123)

    . . . . . . . . . . . . . . . . . . . . . . . ISO 2084, PN 16 (DIN 2501, SFS 2123)

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 2084, PN 25

    Special flange bore . . . . . . . . . . . . . . . . . . . . . . . . . . . JIS B2210 10K

    Special flange bore . . . . . . . . . . . . . . . . . . . . . . . . . . . JIS B2210 16K

    Special flange bore . . . . . . . . . . . . . . . . . . . . . ANSI B 16.1 Class 125

    Special flange bore . . . . . . . . . . . . . . . . . . . . . ANSI B 16.5 Class 150

    3.4.2 Model designation

    ACP 400 - 700 Impeller diameter in Q and H optimum

    Nominal width of delivery branch (mm)

    Centrifugal pump Series ACP

    Fig. 4-33 Type code

    Type plate Each centrifugal pump has a type plate mounted on the spiral casing showing the main pump data.

    Q Flow rate ( m3/h)

    H Head (m)

    P Motor output (kW)

    n Motor speed (rpm)

    C Consistency (%)

    Spec. gravity (kg/m3)

    pmax Max. permitted pump pressure at 20C

    tmax Max. permitted medium temperature at pmax 20C

    Fig. 3-34 Type plate

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.5 Application limiting values

    CAUTION

    The limit values shown in the present Chapter should not be exceeded under any circumstances!

    The limit values shown for the centrifugal pump Series ACP stated in the present Chapter should not be exceeded under any circumstances.

    Pressure limit value

    The maximum permitted pressure for each pump as stated on the rating plate should not be exceeded.

    Temperature limit value

    The maximum permitted operating temperature for each pump as stated on the rating plate should not be exceeded.

    Spiral casing made of steel casing

    Temperature [0C]

    Spiral casing made of steel casing

    Temperature [0C]

    Fig. 3-35 Application limiting values

    Material 1.4460 Material 1.4460

    Material 1.4408 Material 1.4408

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    Shaft seal

    The application limit for the appropriate shaft seal (Andritz cartridge mechanical seal single / double, Standard cartridge mechanical seal single / double, Single standard mechanical seal, Tandem standard mechanical seal, Stuffing box packing, Dynamic shaft seal) can be obtained in writing from the pump manufacturer and is also shown in the data sheet (see Chapter on Technical Date)

    Material to be conveyed/medium

    The centrifugal pump ACP is used to pump non-combustible liquids and pulps.

    Before planning the use of combustible liquids (solvent, petrol, alcohol etc.), it is essential to consult ANDRITZ AG beforehand!

    Lower flashpoints of combustible liquids can lead to hazards due to fire or explosion.

    Zone allocation The ACP centrifugal pump is not intended for use in a potentially explosive

    environment / atmosphere. The ACP centrifugal pump is intended for use outside a zone, according to guideline 1999/92/EG (gases/vapors and dust).

    A change of zone e.g. to zone 2 or zone 22 must be documented in writing and can entail additional costs as well as delays in delivery.

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    Permitted forces

    and torques

    The permitted forces and torques according to Table (Tab.3-27) should not be exceeded.

    As a general principle, the suction and delivery pipes must be connected up stress-free. We recommend checking this item before initial start-up.

    The values stated apply to the spiral casing made of steel casing with base frame grouted in.

    For other designs, the following figures apply:

    Spiral casing made of grey cast iron with frame grouted in35% of the figures stated

    Spiral casing made of steel casting Frame not grouted in70% of the figures stated

    essu

    re F

    lan

    ge

    Diameter

    DN

    Force N Torque N.m

    Fy Fz Fx Fb My Mz Mx Mb

    25 700 850 750 1 300 600 700 900 1 300

    32 850 1 050 900 1 650 750 850 1 100 1 600

    40 1 000 1 250 1 100 1 950 900 1 050 1 300 1 900

    50 1350 1 650 1 500 2 600 1 000 1 150 1 400 2 050

    65 1 700 2 100 1 850 3 300 1 100 1 200 1 500 2 200

    80 2 050 2 500 2 250 3 950 1 150 1 300 1 600 2 350

    100 2 700 3 350 3 000 5 250 1 250 1 450 1 750 2 600

    125 3 200 3 950 3 550 6 200 1 500 1 900 2 100 3 050

    150 4 050 5 000 4 500 7 850 1 750 2 050 2 500 3 650

    200 5 400 6 700 6 000 10 450 2 300 2 650 3 250 4 800

    250 6 750 8 350 7 450 13 050 3 150 3 650 4 450 6 550

    300 8 050 10 000 8 950 15 650 4 300 4 950 6 050 8 900

    350 9 400 11 650 10 450 18 250 5 500 6 350 7 750 11 400

    400 10 750 13 300 11 950 20 850 6 900 7 950 9 700 14 300

    450 12 100 14 950 13 450 23 450 8 500 9 800 11 950 17 600

    500 13 450 16 600 14 950 26 050 10 250 11 800 14 450 21 300

    550 14 800 18 250 16 450 28 650 12 200 14 050 17 100 25 300

    600 16 150 19 900 17 950 31 250 14 400 16 600 20 200 29 900

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    Diameter

    DN

    Force N Torque N.m

    Fy Fz Fx Fb My Mz Mx Mb

    Su

    cti

    on

    Fla

    ng

    e

    25 750 700 850 1 300 600 700 900 1 300

    32 900 850 1 050 1 650 750 850 1 100 1 600

    40 1 100 1 000 1 250 1 950 900 1 050 1 300 1 900

    50 1 500 1 350 1 650 2 600 1 000 1 150 1 400 2 050

    65 1 850 1 700 2 100 3 300 1 100 1 200 1 500 2 200

    80 2 250 2 050 2 500 3 950 1 150 1 300 1 600 2 350

    100 3 000 2 700 3 350 5 250 1 250 1 450 1 750 2 600

    125 3 550 3 200 3 950 6 200 1 500 1 900 2 100 3 050

    150 4 500 4 050 5 000 7 850 1 750 2 050 2 500 3 650

    200 6 000 5 400 6 700 10 450 2 300 2 650 3 250 4 800

    250 7 450 6 750 8 350 13 050 3 150 3 650 4 450 6 550

    300 8 950 8 050 10 000 15 650 4 300 4 950 6 050 8 900

    350 10 450 9 400 11 650 18 250 5 500 6 350 7 750 11 400

    400 11 950 10 750 13 300 20 850 6 900 7 950 9 700 14 300

    450 13 450 12 100 14 950 23 450 8 500 9 800 11 950 17 600

    500 14 950 13 450 16 600 26 050 10 250 11 800 14 450 21 300

    550 16 450 14 800 18 250 28 650 12 200 14 050 17 100 25 300

    600 17 950 16 150 19 900 31 250 14 400 16 600 20 200 29 900

    Tab. 3-27 Permitted forces and torques at the pump flange

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    *) F ...Vector sum of forces from:

    FX, FY and 0.47 * Fz at the delivery flange and FX, FY and 1.0 * Fz at the suction

    flange

    **) M ...Vector sum of torques:

    MX, MY and Mz

    Fig. 3-36 Coordinates systems for forces and torques at delivery and suction flange

    Pump Type

    Diam. Suction Side Flange [mm]

    Diam. Pressure Side Flange [mm]

    ACP 65-315 100 65

    ACP 100-500 150 100

    ACP 65-250 80 65

    ACP 100-315 125 100

    ACP 125-400 150 125

    ACP 150-500 200 150

    ACP 100-250 125 100

    ACP 125-315 150 125

    ACP 150-400 200 150

    ACP 200-500 250 200

    ACP 300-700 350 300

    ACP 125-250 150 125

    ACP 150-315 200 150

    ACP 200-400 200 200

    ACP 400-700 450 400

    ACP 250-315 250 250

    ACP 300-400 300 300

    ACP 450-550 450 450

    ACP 600-700 600 600

    Fig. 3-37 Diameters of suction and pressure side flanges

    Y Z

    X

    Y Z

    X

  • Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions

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    3.6 Performance limits for bearing supports for different shaft material

    The performance limit shown in the table for different shaft materials

    must be observed!

    Bearing

    support

    Shaft performance limits (kW)

    42 48 60 75 100

    Ma

    teria

    l:1

    .44

    04

    Tm

    ax=

    100

    0C

    n = 1000 rpm 70 85 230 720

    n = 1200 rpm 80 105 270 870

    n = 1500 rpm 100 135 330 1180

    n = 1800 rpm 125 165 420 1300

    n = 3000 rpm 200 - - -

    n = 3600 rpm 240 - - -

    Ma

    teria

    l:1

    .44

    62

    Tm

    ax=

    60

    0C

    n = 1000 rpm 135 175 445 1550

    n = 1200 rpm 155 205 520 1880

    n = 1500 rpm 205 270 650 2300

    n = 1800 rpm 245 340 780 -

    n = 3000 rpm 400 540 - -

    n = 3600 rpm 470 - - -

    Ma

    teria

    l:1

    .44

    04

    Tm

    ax=

    130

    0C

    n = 1000 rpm 115 151 380 1320

    n = 1200 rpm 130 180 450 1580

    n = 1500 rpm 170 235 570 1950

    n = 1800 rpm 195 280 660 -

    n = 3000 rpm 345 450 - -

    n = 3600 rpm 400 - - -

    Ma

    teria

    l:1

    .44

    62

    Tm

    ax=

    180

    0C

    n = 1000 rpm 108 140 350 1250

    n = 1200 rpm 125 165 420 1480

    n = 1500 rpm 160 215 530 1850

    n = 1800 rpm 210 260 660 -

    n = 3000 rpm 325 425 - -

    n = 3600 rpm 380 - - -

    Tab. 3-28 Performance limits for different shaft material

    The shaft material used for each bearing support is shown in the Technical Data Sheet for the individual pump.

    In case the bearing support is to be used under conditions beyond the values

    shown in the table (Tab. 4-30), the manufacturer must be contacted first of all

    and a written response requested.

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    3.7 Technological description

    Definition The centrifugal pump is to be used for an application according to the purchase order specification to convey specified media observing the manufacturers instructions. If any changes are made and the pump is to be used for an application not specified, the manufacturer must be contacted beforehand. (e.g. ATEX sector)

    Fig. 3-38 Centrifugal pump

    Supply of medium The medium reaches the impeller through a suction pipe that connects up to the horizontal axial flange.

    Pressure increase The medium is drawn in by the single-flow impeller in axial direction.

    In the impeller, the medium undergoes radial accelerationthus obtaining speed energy-due to the rotational energy and the shape of the blades (changing from axial to radial).In the spiral casing the speed energy is converted into pressure energy. The medium then enters the delivery pipe, which is converted into pressure energy. The medium then enters the delivery pipe, which is connected to the vertical outlet flange.

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    4 ERECTION and TRANSPORT 4.1 General

    This chapter describes certain steps for transport, storage and installation of the centrifugal pump which may be the responsibility of the user.

    Activities which are carried out by ANDRITZ AG, including works assembly, are not the subject of this description.

    4.2 Safety regulations

    DANGER

    Disregarding the safety regulations may cause a risk to life and limb and damage to the machine or its components.

    All safety instructions in this Chapter must be strictly observed.

    General safety Instructions

    All applicable accident prevention rules must be observed.

    Do not exceed permissible crane loads and weights on lifting gear and ropes/shackles. Secure loads against falling down.

    Do not step or walk below suspended loads. Standing below suspended loads is dangerous and thus forbidden.

    Jerking must be avoided. This refers especially to the handling of pre-assembled machines.

    Qualification of assigned personnel

    Transport and unloading to be carried out by personnel especially skilled with such work.

    Workers entrusted with lifting and conveying equipment must have the required national qualification.

    Start-up may only be carried out by trained, skilled workers.

    Personal Protective apparel

    The following protective equipment must be worn when carrying out start-up and transport work:

    Hard hat

    Protective gloves

    Protective shoes

    Goggles

    Tools Only use tools of a reputable brand and in good condition for any work performed on the centrifugal pump.

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    4.3 Haulage

    DANGER

    During transport of the centrifugal pump or loading/unloading (pump may fall).

    The loading equipment must bear the name of the manufacturer, the type of material and the permitted load!

    Do not lift machine and transport crates except at the points marked for lifting by crane or forklift.

    Do not step or walk below suspended loads.

    Supply The centrifugal pump is supplied pre-assembled. Machine components and auxiliary material are packed in crates.

    Transport sizes and weights are stated in the shipping documents.

    Largest supply weights:

    /CENTRIFUGAL PUMP/TECHNICAL DATA

    Acceptance Check whether supply is complete (against shipping documents and packing list) and in perfect condition.

    In the event of transport damage or short supply, do not accept goods but notify forwarder and ANDRITZ AGs shipping department.

    If there is a hidden defect, notify forwarder and ANDRITZ AGs shipping department within two weeks.

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    Lifting the entire centrifugal pump

    The complete centrifugal pump should only be raised as follows after unpacking:

    The complete centrifugal pump should only be raised if the lifting devices have been attached under the suction and delivery flanges. The lifting devices must be short enough to prevent the centrifugal pump from tilting (Fig. 4-1).

    CAUTION

    Take care to maintain the balance

    DANGER

    Never lift the complete centrifugal pump at the bearing support window only. This could cause a risk to life and limb and damage to the pump.

    Fig. 4-1 Lifting the entire centrifugal pump

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    Lifting the centrifugal pump with free shaft

    The centrifugal pump with free shaft should only be raised as follows:

    The pump should only be lifted if the lifting devices have been mounted under the suction branch and at the shaft end.

    The lifting devices must be short enough to prevent the pump from tilting.

    CAUTION

    Take care to maintain the balance

    Fig. 4-2 Lifting the centrifugal pump

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    Lifting the pull-out unit

    Attach lifting slings at the points marked in Fig.5-3

    Through the bearing support windows

    Between the coupling half and the bearing cover

    Secure sling to lifting hook and tension slightly.

    CAUTION

    Take care to maintain the balance

    Fig. 4-3 Lifting the pull out unit

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    4.4 Storage

    Short-term storage If the pump is to be stored for less than three months before erection work begins, please observe the following storage instructions.

    Store the centrifugal pump in a dry place, with suitable protection against dirt and corrosion.

    Packing should not be removed until erection work begins.

    If there is no oil or grease in the bearing housing, it must be filled with oil or grease to protect the bearing assembly against corrosion.

    Rotate the pump shaft manually every 2 weeks to prevent damage to the shaft bearing assembly.

    Long-term storage If the pump is to be stored for more than three months before erection work begins, please observe the following storage instructions.

    Store the centrifugal pump in a dry place, with suitable protection against dirt and corrosion.

    Incidentals should be protected against damage and unauthorized withdrawal by storing in a lockable room.

    Drain any liquid from the centrifugal pump.

    Rotate the pump shaft manually every 4 weeks to prevent damage to the shaft bearing assembly.

    If the centrifugal pump has a casing of grey cast iron and a stuffing box packing, remove the packing cord and coat the stuffing box body with an anti-rust agent.

    If there is no oil or grease in the bearing housing, it must be filled with oil or grease to protect the bearing assembly against corrosion.

    CAUTION

    The grease or oil in the bearing housing must be renewed before start-up. Anti-rust agents must be removed entirely.

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    4.5 Installation

    General Installation takes place in accordance with the sequence plan defined by ANDRITZ AG.

    WARNING

    Disregarding the sequence plan and the installation instructions may result in hazardous situations causing a danger to life and limb and in machine damage.

    The sequence of erection work is important and must be strictly observed.

    Implementation of the various steps must be documented in the certificate of completion of erection work.

    The sequence of erection work is shown in step-by-step tables. Individual activities are numbered in their order of precedence.

    Preservation Those machine components which are not corrosion-resistant should be protected against corrosion with preserving grease.

    The preservative grease need not be removed.

    Required documentation at installation site

    The following supplementary documentation must be available at the beginning of erection work.

    Foundation and arrangement drawing

    Assembly drawings

    Documentation on electrical, measuring and control equipment

    Parts lists

    Packing lists for each individual delivery

    Space requirement for erection work, operation and maintenance will be defined

    Together with the ANDRITZ AG representative in charge before the beginning of erection work.

    Ambient temperature during erection work should not be less than 10-15 C.

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    4.5.1 Erection of the centrifugal pump

    Foundation The foundation should be made according to ANDRITZ AGs foundation plan.

    The following preparations have to be made prior to placing the centrifugal pump on the foundation:

    Mark axes and levels on the foundation.

    Check the finish of the foundation before beginning erection work.

    Mounting and foundation work

    The foundations are to be laid according to the following table.

    Step Activity

    1 Lift centrifugal pump onto the foundation and place on the support rails. Height of support rails: 50-100mm Raise the pump according to Chapter 4.3,Fig.4-1 Align axes and height of the pump according to the plant requirements.

    2 Transfer the fastening points from the base frame to the foundation. Drill block holes and insert dowels.

    3 Insert the threaded rod (Item 5) from above and screw on 2 washers and 2 hexagon nuts (Items 4, 6) between the foundation and the base frame. Screw threaded rod (Item 5) into the dowel and tighten with the fastening nut (Item 6).

    4 Raise pump unit with the setting nuts (Item 4) and remove the support rails.

    5 Set the pump unit with setting nuts and tighten on the base frame with the fastening nuts (Item 3).

    6 Cut off and debar the threaded rod with 5 mm allowance. (see Fig. 4-4)

    7 Grout base frame in firmly up to the top edge of the special section tube with non-shrinking cast concrete and leave to set (Approx. 2 days). At least concrete strength category according to EN206-1. C16/20

    Tab. 4-1 Foundations

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    Step Activity

    8 Mounting the motor:

    Draw the drilling coupling half flush onto the motor stub and secure on the feather key with a set screw.

    Mount motor on motor base frame (893).

    If there are no fastening threads in the motor base frame, transfer the bore holes from the motor and drill the threads accordingly.

    The axle height of the motor is established by the spacers

    (898.1). If the centrifugal pump is ordered specifying the motor, the correct spacers will be mounted.

    DANGER

    Due to the centrifugal pump or components of the centrifugal pump falling during transport on installation site.

    Raise centrifugal pump according to the transport instructions in Chapter 4.3.

    Do not step or walk below suspended loads.

    DANGER

    Due to parts of the body being jammed or crushed during installation work.

    Wear your personal protective apparel.

    WARNING

    Transport devices that are forgotten may result in risks to life and limb and in damage to the machine.

    Remove all transport devices.

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    Fig. 4-4 Lifting the pull out unit

    Item Component Item Component

    1 Cast concrete according to EN206-1, C16/20

    5 Threaded rod

    2 Foundation 6 Fastening nuts

    3 Fastening nuts 7 Flush anchor

    4 Adjusting nut

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    4.5.2 Pipework

    DANGER

    If pipework is not mounted professionally.

    This can result in risks to life and limb and in damage to the machine.

    Under no circumstances should the centrifugal pump be used to support a pipe!

    WARNING

    If there is risk of dangerous backflow after the pump is shut down, a reflux check device must be installed in the delivery pipe!

    Support When planning the pipework, a supplement must be included for heat expansion.

    Pipes should always be mounted stress-free. During erection work ensure that the pipes are supported in such a way that no forces, vibrations or weight can be transferred to the pump.

    Maximum permitted forces and torques that the pump can absorb can be found in the Chapter headed "Technical Description" under "Permitted

    load on supports".

    The suction and delivery pipes should be supported in such a way that the weight of the pipe is not transferred to the centrifugal pump.

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    4.5.3 Aligning the coupling

    Data on the coupling used (tolerances, application limits, aligning information, etc.) can be found in the manufacturer's operating instructions.

    /CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER DOCUMENTATION/COUPLING)

    Fig. 4-5 Electronic aligning Fig. 4-6 Conventional aligning

    Item Component Item Component

    1 Hub - pump side 4 Flexible part

    2 Hub - motor side 5 Coupling aligning device

    3 Spacer sleeve

    The coupling must be aligned with a suitable device.

    The tolerances observed when aligning the coupling are to be recorded in

    the erection work report on the coupling.

    After the coupling has been set, it must be fitted with a coupling guard according to the regulations issued by the authorities.

    1 5 4 3 2 5

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    Suction pipe The following must be observed at the suction pipe:

    The suction pipe should be kept as short as possible to maintain pipe friction losses at a minimum.

    Run a pressure test to check the pipe for leaks.

    The suction pipe should rise or fall slightly towards the centrifugal pump,

    If a reducing piece is installed directly upstream of the centrifugal pump, the narrowing section thereof should always be at the bottom (Fig. 4-7).

    Inlet points in the suction pipe should be located at a distance from the centrifugal pump suction flange that is equivalent to a minimum of 5 times the diameter of the suction pipe.

    For safety reasons the pump must be prevented from starting up while it is opened. (lockable maintenance switch or main switch)

    Fig. 4-7 suction pipe

    After connecting up the suction and delivery pipes stress-free, check alignment of the unit and rotate the impeller by hand.

    4.6 Instruments

    According to the manufacturers' instructions, the sealing water

    monitoring unit is to be connected to the sealing water system and to the connections provided at the centrifugal pump.

    Special accessories (temperature monitoring, vibration measurements, etc.) are to be connected up to the centrifugal pump according to the manufacturer's instructions. Please contact Andritz AG if you have special requirements.

    Cleaning opening with cover

    Suction branch (Special accessories)

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    4.7 Electrical equipment

    Motor and instruments are to be connected up according to the operating instructions provided by the appropriate supplier.

    /CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER DOCUMENTATION/... The electrical equipment must be installed such that there is no risk of

    injury to personnel, nor of damage to machines. All regulations in this

    respect must be observed.

    Earthing In addition to protective earthing, the following measures must be observed to protect machine components: Shielded power cables (3-core) with separate protective earth cable for

    frequency converter drives. The shield for high frequency is to be applied to the motor and to the frequency converter.

    All machine parts and frequency-inverter fed motors are to be connecte