sunflo pumps - ipp · 2011-09-02 · c. the piping, both suction and discharge, should have no...

02.10.11E, 11/02 Visit our website at www.sundyne.com

Sunflo PumpsTechnical Manual

02.10.11E, 2/00 Visit our website at www.sundyne.com 1

COPYRIGHT

All rights reserved. No part of this publication may bereproduced, stored in a retrieval system or transmitted in anyform or by any means, electronic, mechanical, photocopying,recording or otherwise without the prior permission of SundyneCorporation.

© 2002 Sundyne Corporation

WARRANTYSundyne Corporation warrants to Buyer for a period of twelve (12) months from thedate of being placed in service (but not to exceed eighteen (18) months after thedate of shipment) that the equipment at the time of shipment will be free fromdefects of design, material and workmanship. If any defects or malperformanceoccur during the warranty period, Sundyne’s sole obligation shall be limited toalteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts orequipment, which upon return to Sundyne and upon Sundyne’s examination proveto be defective. Equipment and accessories not manufactured by Sundyne arewarranted only to the extent of and by the original manufacturers’ warranty.Sundyne shall not be liable for damage or wear to equipment caused by abnormalconditions, vibration, failure to properly prime or to operate equipment without flowor caused by corrosives, abrasives or foreign objects. THE FOREGOINGWARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OFMERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In noevent shall Sundyne be liable for consequential or incidental damages.


Icons Used in this Manual

The following icons (symbols) are used to indicate specifictypes of information.

Good ideas to use.

A reminder to do something.

Equipment use alert. Unless you followthese procedures correctly, the equipmentmay be damaged.

Safety alert. Failure to follow theseprocedures can endanger the safety of youor others.

Electrical hazard. Failure to follow theseprocedures can endanger the safety of youor others.


TABLE OF CONTENTSTITLE PAGE

SUGGESTED SAFETY INSTRUCTIONS 4INTRODUCTION 5INSPECTION 5STORAGE 5LONG-TERM STORAGE 5MOUNTING 6FRAME MOUNT DRIVE INSTALLATION 6FINAL ALIGNMENT 6SUCTION AND DISCHARGE PIPING 6SEAL AND ENVIRONMENTAL CONTROL SYSTEM 7SINGLE SEAL FLUSH SYSTEM 7DOUBLE SEAL LIQUID BUFFER SYSTEM 7TANDEM SEAL LIQUID BUFFER SYSTEM 8GEARBOX AND PROCESS SEAL DRAIN 8SEAL CAVITY PRESSURE RISE 8OPERATION 14GEARBOX OIL FILL 14START-UP 14PUMP CONTROL 15RECOMMENDED CONTROL OF CENTRIFUGAL PUMPS 15PARALLEL OPERATION 16TROUBLESHOOTING-GEARBOX, PUMP, MECHANICAL SEALS 18SPARE PARTS 25


Equipment Instruction Manual: Suggested Safety Instructions

During installation, maintenance, or repair operations of Sundyne Corporation pumps orcompressors, systems for safety shall be applied before the commencement of work. Failure totake responsibility for safety may lead to operator injury.

Personal Protective Equipment (PPE) safety glasses with side shields shall be worn by allpersonnel installing or performing maintenance or repair on the equipment. If equipment is to bemanually lifted and the weight is over 15 pounds (7kg), or if pallet jacks or forklifts are to be used,the person shall wear safety toed shoes. When testing the equipment, hearing protectors (eardefenders) are recommended to be worn if noise levels exceed 85 dB over the work day.Chemical resistant gloves shall be used if chemical use is required (see Chemical Use below foradditional information). If chemicals have warnings regarding fumes and/or dust/mists, a dustmask respirator shall be worn.

When selecting one piece of PPE to be used with another, consider the compatibility betweenthem. For example, safety glasses should not interfere with the seal from hearing protectors toprotect hearing. Be sure to clean the PPE after each use.

Use of Forklifts: All forklift drivers must have a current recognized license. If using a forklift, firstensure that the lift is in safe operating condition.

Electrical Safety:

Installation, Service, Repair: Ensure all electrical sources are off and safe to install, service,and/or repair the equipment. A recognized Lockout/Tagout program should be followed - Locksand/or tags should be provided warning employees that the equipment is being installed, serviced,and/or repaired. Once the work is completed, the person installing the lock and/or tag shallremove it and inform others of start-up. Should there be a shift change, the lock and/or tag shallbe removed by the first authorized person and the lock and/or tag shall be installed by the secondshift authorized person.

Testing Equipment: Persons in the immediate area shall be warned when a test is to beperformed.

Tools: Tools shall be insulated from electrical shock. Ensure all tools are clean and free of oiland the insulation is not damaged in any way.

Chemical Use: Any chemicals to be used shall be accompanied by a relevant Hazard Data Sheet,in accordance with your government legislation. If applicable, chemical proof gloves shall beused. An eye wash station (or equivalent) should be available in the event of injury. Should anyhazardous or flammable chemicals have flowed through the equipment a completedecontamination of the equipment is required.

Fall Protection: When working over six feet from the ground, fall protection is required.

Machine Guarding: Guards shall remain in place on all equipment. Only duringmaintenance/repair can the guards be removed, and prior to start-up, the guard must be replaced.


INTRODUCTION

This manual presents installation, servicing, starting, pump control, trouble shooting, maintenance, and spare partsinformation for Sunflo Pumps.

Information that may be required and is not included herein may be obtained from your Sundyne CorporationDistributor, or directly from the factory.

Instructions under the heading of “NOTE” give specific details to ensure satisfactory pump operation and durability ofpump.

Instructions under the heading of “WARNING”, if ignored, can cause pump damage and void the warranty.

COMPLIANCE WITH APPLICABLE SAFETY REGULATIONS AND THE PROVISION OF REQUIRED PROTECTIVEDEVICES ARE THE RESPONSIBILITY OF THE USER.

1.0 INSTALLATION

1.1 INSPECTION

Upon receipt of your Sunflo pump, check visually for any damage which may have occurred during shipment. Notifythe shipping carrier and Sundyne Corporation promptly if damage has occurred. Check packing list to verify receipt ofall items contained in the shipment.

1.2 STORAGE

If pump is not to be installed immediately, it should be stored in a clean, dry area. Care should be taken to protect thepump from exposure to moisture and dust. Shipping covers installed at the factory (for pump and seal ports) shouldbe kept securely in place until just prior to installation. Storage instructions provided by the driver (motor or turbine)manufacturer should be observed.

WARNINGAll shipping covers should be removed prior to operation of the pump. Be sure to remove seal drain shipping plugs.

1.3 LONG-TERM STORAGE

Certain long-term storage considerations should be met for any Sunflo pump which will not be operating for a periodof time exceeding six months from date of factory shipment. This action will ensure minimum corrosion damage tothe gearbox and fluid-end components. Because of storage location and other unknown site factors beyond ourcontrol, Sundyne Corporation will not accept any liability for damage to equipment during the storage period, nor willSundyne Corporation guarantee the quality of the equipment during and after the storage period.

To ensure the original quality of the Sunflo pump (before commissioning the pump) after storage, all componentsmust be inspected by an authorized Sundyne Corporation service engineer. Any required replacement will be at thepurchaser’s expense. Any components not manufactured by Sundyne Corporation (except mechanical seals) mustbe inspected by the particular sub-manufacturer’s authorized service personnel and any component replacement willbe at the purchaser’s expense.

The method employed for long-term storage is to prevent the humidity/temperature and airborne chemicals frommaking contact with the internal components of the equipment.

When the equipment is to be stored in strong chemical environments or near salt water, protection should be initiatedimmediately upon receipt of the equipment.

Following is the Sundyne Corporation preferred list of recommended long-term storage procedures:

1. Indoor climate controlled building (maintain constant temperature and humidity).


2. Inert gas purging of internal components.

3. Oil film on internal components.

4. Desiccant bags in suction and discharge flanges.

1.4 MOUNTING

For both the close coupled and the frame mounted units, the pump, gearbox and driver should be mounted on a rigidfoundation and have minimum deflection freedom from resonant frequencies. The horizontal base or motor feetshould be secured in position using the maximum size bolt accepted by the motor or horizontal base.

Bolts used should have sufficient length to extend at least three threads above the nut after tightening.

When the horizontal base is to be grouted, the horizontal base should be leveled prior to grouting.

1.5 FRAME MOUNT DRIVE INSTALLATION

Alignment of the pump and drive is of extreme importance for trouble-free mechanical operation.

NOTEIf other than Sundyne Corporation supplied couplings are used, they must be a flexible type, vibration dampeningcoupling design. Refer to coupling manufacturer’s recommendations for installation and alignment.

On initial alignment set the motor 0.003-0.004 inches or 0.076 - 0.101 mm higher than the pump.

1.6 FINAL ALIGNMENT

Final alignment can only be accomplished after the unit has been run under actual operating conditions for a sufficientlength of time to bring the unit up to operating temperature.

A. After warm up period has elapsed, stop the unit and immediately disconnect the coupling and check thealignment.

B. Repeat the alignment procedure.

NOTEMotor shaft height should be equal to pump shaft height at operating temperature.

C. Reconnect coupling, check final alignment after approximately one week of operation.

1.7 SUCTION AND DISCHARGE PIPING

A. The suction line should be clean and a strainer (40 mesh is suggested) should be installed to protect the impellerfrom damage by mill scale, welding slag, or other foreign particles during initial startup.

B. All piping must be supported independently of the pump. The piping should always line up with the pump flanges.

WARNINGNever draw the piping into place by the use of force as this will cause “pipe strain” which may impose excessivestress on the unit.

C. The piping, both suction and discharge, should have no unnecessary elbows, bends, and fittings, as they increasefriction losses in the piping. The size of pipe and fittings should be selected carefully and be sufficient to keep thefriction losses as low as practical.


NOTEPiping must not be connected to the pump until after pump hold-down bolts have been tightened.

NOTEWhen frame mount units are being used, coupling alignment should be verified after suction and discharge piping hasbeen connected. If realignment is necessary, pipe strain may be present.

NOTESuction pipe should never be of smaller diameter than the pump suction inlet and should have at least 10 pipediameters of straight pipe leading into the pump suction flange.

D. Block valves (both suction and discharge) are recommended to isolate the pump during shut-down, to minimizefluid leakage during the shut-down condition, and to prevent possible reverse rotation due to back flow throughthe pump.

E. If reverse flow during shutdown is possible, a check valve should be installed in the discharge piping to protectthe pump from possible reverse rotation.

NOTEMaximum solid size for the pump is 400 microns. Maximum solid size for the mechanical seal is 5-10 microns.

1.8 SEAL ENVIRONMENTAL CONTROL SYSTEM

Depending upon the pump seal arrangement and application, a seal environmental control system may be required.The pump seal environment must always be maintained as determined by the seal arrangement. There are three sealarrangements available for Sunflo Pumps: single, double, tandem (not available for the P-1500). Therefore, it’simperative that the seal environmental control system piping be installed properly and that the seal drain port is open.

A. SINGLE SEAL FLUSH SYSTEM

A seal flush system is available for use with the single seal arrangement when the process fluid is contaminated withsolid particles or if the pump fluid temperature dictates the need to flush. A clean, cool fluid from an external source isintroduced into the seal flush port at 15 psi/103.4 kPa above seal cavity pressure and at a controlled flow of:

P-1500 - 1.0 gpm / 0.22 m3/hr.P-2000 - 2.0 gpm / 0.45 m3/hr.P-3000 - 3.0 gpm / 0.68 m3/hr.

See seal cavity pressure, Chart 1.

NOTESeal flush ports must be plugged if not in use.

B. DOUBLE SEAL LIQUID BUFFER SYSTEM

A liquid buffer system is used with double liquid seals to prevent process liquid leakage out of the pump. The buffermust be cool, clean and compatible with the process fluid and pump metallurgy. The buffer liquid is introduced intothe “buffer in” port of the seal housing at a pressure of 15 psi /1.05 kg/cm2 higher than the seal cavity pressure. Seeseal cavity pressure, Chart 1. A small portion of the buffer fluid flows across the front seal into the process fluid and asmall portion flows across the rear seal and is vented from the drain port. A buffer flow of:

P-1500 - 1.0 gpm / 0.22 m3/hr.P-2000 - 2.0 gpm / 0.33 m3/hr.P-3000 - 3.0 gpm / 0.68 m3/hr.

The flow should be regulated by a valve or orifice on the buffer out port.


WARNINGThe buffer system must be in operation prior to flooding the pump casing.

C. TANDEM SEAL LIQUID BUFFER SYSTEM(Not applicable to P-1500 nor P-1000)

A liquid buffer system is used with tandem seal arrangement to cool and lubricate the outboard seal and to containprocess fluid leakage from the inboard seal. The buffer fluid must be cool, clean, and compatible with the processfluid and pump materials of construction. The buffer liquid is introduced into the “buffer in” port of the seal housing atatmospheric pressure and must maintain a flow of 0.5 to 3.0 gpm (0.10 to 0.70 m3/hr) through the buffer cavity toproperly lubricate and cool the outboard (secondary) seal.

D. GEARBOX AND PROCESS SEAL DRAIN

Seal drain must be open, free to drain. Ensure all shipping plugs have been removed.

E. SEAL CAVITY PRESSURE RISE

Whenever a single seal with external flush, double, or tandem seal arrangement is used, the seal cavity pressure risemust be known to determine the seal flush or buffer pressure. The area behind the impeller, near the seal, is referredto as the seal cavity. Suction pressure plus the seal cavity pressure rise plus a safety margin of 15 psi/103.4 kPaequals the required double seal buffer pressure or the single seal flush pressure.

The required seal flush/buffer pressure may be determined for your pump model by using the appropriate values inthe Seal Cavity Pressure Rise Tables (1 through 6) and the method provided below:

1. Find the pump model which is applicable to your pump.2. Determine the seal cavity pressure rise (based on water with a specific gravity of 1.0).3. Multiply this seal cavity pressure rise value by the specific gravity of the process fluid.4. Specify the seal flush/buffer pressure to equal the sum of the suction pressure, the specific gravity corrected seal

cavity pressure rise determined in Step E-3, and 15 psi/103.4 kPa.

EXAMPLE

Model: Sunflo P3-AJGSuction Pressure: 19 psigSeal Cavity Pressure Rise: 20 psig (from the P3 Table)Process Specific Gravity: 0.95Required Seal Flush/Buffer Pressure (RSFBP) = Suction Pressure + Seal Cavity Pressure Rise + 15 psigRSFBP = 19 psig + (20 psig)(0.95) + 15 psigRSFBP = 53 psig

EXAMPLEModel: Sunflo P3-AJGSuction Pressure: 131 kPaSeal Cavity Pressure Rise: 138 kPa (from the P3 Table)Process Specific Gravity: 0.95Required Seal Flush/Buffer Pressure (RSFBP) = Suction Pressure + Seal Cavity Pressure Rise + 103.4 kPaRSFBP = 131 kPa + (138 kPa)(0.95) + 103 kPaRSFBP = 365.1 kPa


P-1500/P-1000 Seal Cavity Pressure Rise(Based on Water: S.G. = 1.0)

60 HZ Pump

Model Pressure Rise(psi / kPa)

P1-Axx 17 / 117P1-Bxx 20 / 138P1-Cxx 40 / 276P1-Dxx 60 / 414P1-Exx 85 / 586

(Table 1)

P-1500/P-1000 Seal Cavity Pressure Rise(Based on Water: S.G. = 1.0)

50 HZ Pump


P1-Lxx 16 / 110P1-Mxx 28 / 193P1-Nxx 47 / 324P1-Pxx 60 / 414P1-Qxx 114 / 786

(Table 2)

P-2000 Seal Cavity Pressure Rise (Based onWater: S.G. = 1.0)

60 HZ Pump


P2-Axx 5 / 35P2-Bxx 10 / 69P2-Cxx 10 / 69P2-Dxx 15 / 103P2-Exx 15 / 103P2-Fxx 20 / 138P2-Gxx 30 / 207(Table 3)

P-2000 Seal Cavity Pressure Rise (Based onWater: S.G. = 1.0)

50 HZ Pump


P2-Hxx 5 / 35P2-Jxx 10 / 69P2-Kxx 10 / 69P2-Lxx 15 / 103P2-Mxx 20 / 138P2-Nxx 30 / 207(Table 4)


P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 60 Hz)MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*P3-AJGP3-AKGP3-ALGP3-AMGP3-ANGP3-APG

20/ 138 P3-AJHP3-AKHP3-ALHP3-AMHP3-ANHP3-APH

20/138 P3-AMJP3-ANJP3-APJ

20/138 P3-AMKP3-ANKP3-APKP3-AQKP3-ARKP3-ASKP3-ATKP3-AVKP3-AWK

20/138 P3-ARLP3-ASLP3-ATLP3-AVL

20/138

P3-ARMP3-ASM

25/172 P3-BNEP3-BPEP3-BQEP3-BREP3-BSEP3-BTEP3-BVEP3-BWE

25/172 P3-BLFP3-BMFP3-BNFP3-BPFP3-BQFP3-BRFP3-BSFP3-BTFP3-BVFP3-BWF

25/172 P3-BMGP3-BNGP3-BPGP3-BQGP3-BRGP3-BSGP3-BTGP3-BVGP3-BWG

25/172 P3-BLHP3-BMHP3-BNHP3-BPHP3-BQHP3-BRHP3-BSHP3-BTHP3-BVHP3-BWH

25/172

P3-BLJP3-BMJP3-BNJP3-BPJP3-BQJP3-BRJP3-BSJP3-BTJP3-BVJP3-BWJ

25/172 P3-BMKP3-MNKP3-BTKP3-BVKP3-BWK

30/207 P3-BRLP3-BSL

30/207 P3-CMDP3-CNDP3-CPDP3-CQDP3-CRDP3-CSDP3-CTDP3-CVDP3-CWD

30/207 P3-CJEP3-CKEP3-CLEP3-CMEP3-CNEP3-CPEP3-CQEP3-CREP3-CSEP3-CTEP3-CVEPE-CWE

35/241

P3-CJFP3-CKFP3-CLFP3-CMFP3-CNFP3-CPFP3-CQFP3-CRFP3-CSFP3-CTFP3-CVFP3-CWF

35/241 P3-CHGP3-CJGP3-CKGP3-CLGP3-CMGP3-CNGP3-CPGP3-CQGP3-CRGP3-CSG

40/276 P3-CJHP3-CKHP3-CLHP3-CMHP3-CNHP3-CPHP3-CQHP3-CRHP3-CSH

40/276 P3-CMJP3-CNJP3-CPJP3-CQJ

45/310 P3-CMKP3-CNK

45/310

P3-DGBP3-DHBP3-DJBP3-DKBP3-DLBP3-DMBP3-DNBP3-DPB

50/345 P3-DFCP3-DGCP3-DHCP3-DJCP3-DKCP3-DLCP3-DMCP3-DNCP3-DPC

50/345 P3-DEDP3-DFDP3-DGDP3-DHDP3-DJDP3-DKDP3-DLDP3-DMDP3-DNDP3-DPD

50/345 P3-DDEP3-DEEP3-DFEP3-DGEP3-DHEP3-DJEP3-DKEP3-DLEP3-DME

50/345 P3-DFFP3-DGFPG-DHFP3-DJFP3-DKFP3-DLFP3-DMF

50/345

P3-DGGP3-DHGP3-DJGP3-DKG

60/414 P3-DJH 60/414 P3-EDBP3-EEBP3-EFBP3-EGBP3-EHBP3-EJBP3-EKBP3-ELBP3-EMBP3-ENB

70/483 P3-ECCP3-EDCP3-EECP3-EFCP3-EGCP3-EHCP3-EJCP3-EKCP3-ELC

70/483 P3-ECDP3-EDDP3-EEDP3-EFDP3-EGDP3-EHDP3-EJDP3-EKD

70/483

* Seal Cavity Pressure Rise (SCPR) in psi / kPa(Table 5)

02.10.11E,2/00 Visit our website at www.sundyne.com 11

P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 60 Hz) (con’t)MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*P3-EEEP3-EFEP3-EGEP3-EHEPE-EJE

70/483 P3-EGFP3-EHF

70/483 P3-FCBPE-FDB

75/517 P3-FEBP3-FFBP3-FGBP3-FHBP3-FJB

80/552 P3-FCCP3-FDCP3-FECP3-FFCP3-FGCP3-FHC

80/552

P3-FCDP3-FDDP3-FEDP3-FGD

80/552 P3-FEEP3-FFE

80/552

* Seal Cavity Pressure Rise (SCPR) in psi / kPa(Table 5 con’t)


P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 50 Hz)MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*P3-HJGP3-HKGP3-HLGP3-HMGP3-HNGP3-HPG

17/117 P3-HJHP3-HKHP3-HLHP3-HMHP3-HNHP3-HPH

17/117 P3-HMJP3-HMJP3-HPJ

17/117 P3-HMKP3-HNKP3-HPKP3-HQKP3-HRKP3-HSKP3-HTKP3-HVKP3-HWK

20/138 P3-HRLP3-HSLP3-HTLP3-HVL

20/138

P3-HRMP3-HSM

20/138 P3-JNEP3-JPEP3-JQEP3-JREP3-JSEP3-JTEP3-JVEP3-JWE

25/172 P3-JLFP3-JMFP3-JNFP3-JPFP3-JQFP3-JRFP3-JSFP3-JTFP3-JVFP3-JWF

25/172 P3-JMGP3-JNGP3-JPGP3-JQRP3-JRGP3-JSGP3-JTGP3-JVGP3-JWG

27/186 P3-JMHP3-JNHP3-JPHP3-JQHP3-JRHP3-JSHP3-JTHP3-JVHP3-JWH

27/186

P3-JLJP3-JMJP3-JNJP3-JPJP3-JQJP3-JRJP3-JSJP3-JTJP3-JVJP3-JWJ

30/207 P3-JLKP3-JMKP3-JTKP3-JVKP3-JWK

30/207 P3-JRLP3-JSL

30/207 P3-KMDP3-KNDP3-KPDP3-KQDP3-KRDP3-KSDP3-KTDP3-KVDP3-KWD

35/241 P3-KJEP3-KKEP3-KLEP3-KMEP3-KNEP3-KPEP3-KQEP3-KREP3-KSEP3-KTEP3-KVEP3-KWE

36/248

P3-KJFP3-KKFP3-KLFP3-KMFP3-KNFP3-KPFP3-KQFP3-KRFP3-KSFP3-KTFP3-KVF

36/248 P3-KHGP3-KJGP3-KKGP3-KLGP3-KMGP3-KNGP3-KPGP3-KQGP3-KRGP3-KSGP3-KTG

40/276 P3-KJHP3-KKHP3-KLHP3-KMHP3-KNHP3-KPHP3-KQHP3-KRHP3-KSH

40/276 P3-KLJP3-KMJP3-KNJP3-KPJP3-KQJ

48/331 P3-KMKP3-KNK

48/331

P3-LGBP3-LHBP3-LJBP3-LKBP3-LLBP3-LMBP3-LNBP3-LPB

50/345 P3-LFCP3-LGCP3-LHCP3-LJCP3-LKCP3-LLCP3-LMCP3-LNCP3-LPC

50/345 P3-LEDP3-LFDP3-LGDP3-LHDP3-LJDP3-LKDP3-LLDP3-LMDP3-LNDP3-LPD

50/345 P3-LDEP3-LEEP3-LFEP3-LGEP3-LHEP3-LJEP3-LKEP3-LLEP3-LMEP3-LNE

50/345 P3-LFFP3-LGFP3-LHFP3-LJFP3-LKFP3-LLFP3-LMF

50/345

P3-LGGP3-LHGP3-LJGP3-LKG

70/483 P3-LJH 70/483 P3-MDBP3-MEBP3-MFBP3-MGBP3-LHBP3-LJBP3-LKBP3-LLBP3-LMBP3-LNB

70/483 P3-MCCP3-MDCP3-MECP3-MFCP3-MGCP3-MHCP3-MJCP3-MKCP3-MLC

70/483 P3-MCDP3-MDDP3-MEDP3-MFDP3-MGDP3-MHDP3-MJDP3-MKD

70/483

*Seal Cavity Pressure Rise (SCPR) in psi / kPa(Table 6)


P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 50 Hz) (con’t)MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*P3-MEEP3-MFEP3-MGEP3-MHEP3-MJE

70/483 P3-MGFP3-MHF

70/483 P3-NCBP3-NDB

77/531 P3-NEBP3-NFBP3-NGBP3-NHBP3-NJB

81/558 P3-NCCP3-NDCP3-NECP3-NFCP3-NGCP3-NHC

81/558

P3-NCDP3-NDDP3-NEDP3-NFDP3-NGD

81/558 P3-NEEP3-NFE

81/558

* Seal Cavity Pressure Rise (SCPR) in psi / kPa(Table 6 con’t)


2.0 OPERATION

2.1 GEARBOX OIL FILL

Remove the fill plug and fill the gearbox until fluid reaches the designated level on the sight glass.

Oil Capacities:

P-1500 - 1.0 quart / 0.946 litersP-2000 - 2.5 quarts / 2.4 litersP-3000 - 8.0 quarts / 7.6 liters

WARNINGOverfilling the gearbox will cause seal leakage, excess foaming and excessive use of horsepower.

The following lube oil specifications must be met by any oil used in Sunflo gearboxes:

Gravity, API 28 – 37Pour Point, °C (°F) -7 (20) max.Flash Point, °C (°F) 204 (400 min.Viscosity,

cSt at 40°CcSt at 100°CSUS at 100°FSUS at 210°F

28.8 to 35.25.2 min.150 to 18044 min.

Viscosity Index 95 min.ISO Viscosity Grade 32Color, ASTM D 1500 1 to 5Neutralization Number, Maximum 0.20Rust Protection, ASTM D 665, A & B PassDemulsibility, ASTM D 1401

Time to 0 ml emulsionAt 54°C (130°F) after 30 min.At 82°C (180°F) after 60 min.

PassPass

Foam Limits, ASTM D 892Sequence 1Sequence 2Sequence 3

25/0 max.50/0 max.25/0 max.

NOTE: NO other additives are recommended.

Table 7. Recommended Gearbox Lube Oil Specifications

2.2 START-UP

Perform the following steps to start the Sunflo pump:

A. Review pump specification sheet noting design parameters and possible seal system requirements.

B. Check to ensure that the driver has been serviced per instructions provided by the driver manufacturer.

C. Check to ensure suction screen has been installed on inlet side for initial start-up (40 Mesh Recommended).


D. If buffer fluid or external seal flush is required, this system should be pressurized prior to admitting process fluidinto the pump casing. If the buffer fluid is not pressurized, process fluid will contaminate the buffer fluid. If the sealflush is not pressurized, contaminants may cause seal face damage.

E. Check oil level in gearbox.

F. Open suction and discharge block valve fully.

WARNINGNever start the pump against a closed discharge valve.

G. Adjust control valve so that pump will operate near the design point when pump is started.

H. Insure that the motor shaft rotation is in the same direction as the arrow on the gearbox marked “MOTORROTATION”. To determine shaft rotation, observe the motor shaft or fan while “jogging” the motor in ashort, one-second interval. Rotation of the high speed shaft must be in the same direction as the arrow on thegearbox housing marked “PUMP ROTATION”.

NOTEThree-phase motor rotation may be reversed by interchanging any two motor leads. Motor and pump rotate inopposite directions due to the single step gear arrangement.

NOTEP-3000 Journal Bearing Units - On initial start-up or after extended shutdown time, (periods in excess of one week)“jog” the motor for several one-second intervals to pre-lubricate the bearings prior to full speed operation.

WARNINGReverse rotation may cause damage to the pump.

I. Start the motor and adjust the discharge throttle valve to the proper operating condition.

WARNINGDo not overload the pump or motor (an ammeter is recommended to determine motor load).

3.0 PUMP CONTROL

3.1 RECOMMENDED CONTROL OF CENTRIFUGAL PUMPS

A. Obtaining satisfactory performance from any centrifugal pump requires that the pump be operated in the followingmanner:

1. A flow range where the system head curve and pump performance curve intersect at a significant angle.2. The pump is not operated below the recommended minimum flow. Minimum flow considerations are

discussed further in the Sunflo Pump Control Bulletin. Actual minimum hydraulic stable flow must bedetermined during system commissioning.

3. The pump is not operated beyond the recommended maximum flow. Maximum flow considerations arediscussed further in the Sunflo Pump Control Bulletin.

B. The flow at which a centrifugal pump operates depends upon the point of intersection of the system head andpump characteristic curves. In order for control to be steady, the system curve must intersect the pumpcharacteristic curve at a significant angle. Examples of satisfactory and unsatisfactory angles of intersection areshown in Figures 1 and 2.


Figure 1In Figure 1, the angle of intersection between the system curve and the pump performance curve is small. Note thatSystem Curve C intersects the pump performance curve resulting in Pressure Pc and Flow Qc. System Curve Ccould represent a system curve in which the control valve is wide open. As the control valve is closed, the additionalpressure moves the system curve to that of System Curve D resulting in Pressure Pd and Flow Qd. Note that for avery small change in pressure, there is a large change in flow.

Figure 2

In Figure 2, the angle of intersection between the system curve and the pump performance curve is much larger thanthat shown in Figure 1. The pump performance curve shown in Figures 1 and 2 are identical. In this example, notethat System Curve A intersects the pump performance curve resulting in Pressure Pa and Flow Qa. As was the casein Figure 1, Curve A could represent a system curve in which the control valve is wide open. As the control valve isclosed, the additional pressure moves the system curve to that of Curve B resulting in Pressure Pb and Flow Qb.Since the angle of intersection between the system curve and the performance curve is much larger, a larger changein pressure is required to provide the same change in flow as shown in Figure 1.

C. Because of the characteristic flat pump performance curve shape of Sunflo pumps, flow control rather thanpressure control is recommended. Pressure and flow control schemes both operate by throttling a discharge flowvalve. The control signal to the valve comes from either a flow or pressure controller. When trying to operate theSunflo pump in the flat area of the performance curve, a small change in pressure will result in a large change inflow. Since a flow controller responds to changes in flow rather than pressure, pump control is more stable in thisregion of the curve.

D. As the pump is operated closer to BEP, the Sunflo pump performance curve provides a more responsive changein flow for a given change in pressure. Either pressure or flow control of the Sunflo pump is suitable in this area.However, flow control is still recommended because of the problems associated with pressure control that werediscussed in the previous paragraph.


E. In the portion of the performance curve beyond BEP, the Sunflo pump performance curve shape provides forsmall changes in flow for large changes in pressure. Operation in this portion of the performance curve isdiscouraged because of control problems and the potential to exceed the driver capabilities and to exceed theNPSH requirements.

F. If the user requires that the pump be operated on pressure control, contact Sunflo or your local salesrepresentative. It is possible to modify the pump to steepen the pump performance curve so that pressure controlis more practical.

PARALLEL OPERATION

G. When centrifugal pumps are operated in parallel, their control becomes more critical because one pump maytend to “overpower” the other pump in terms of head at total lower flows. If pumps are connected together atdischarge by a simple, unrestricted manifold, the discharge head of one pump is upon another; all pumps see thesame discharge head at any given moment in time. This situation is shown on the following curves anddiscussion.

Figure 3

Figure 3 shows that the characteristic curves of 2 duplicated pumps designated as Pump A and Pump B. Since no 2pumps will have exactly the same performance, the curves in Figure 6 shows that Pump A produces a very slightmore amount of head than Pump B. The pumps arranged with a manifold having a common control valve are asshown in Figure 4.

Figure 4

With the manifold pressure set at P1, the flow through Pump A is indicated as A1 and the flow through Pump B isindicated as B1. If the throttle valve is closed to set the manifold pressure at P2, the flow through pumps A and B areA2 and B2 respectively. If the control valve were closed even further, then Pump B would cease to flow entirelyresulting in damage for deadheading the unit. This situation can be avoided through the proper selection of thecontrol system.


H. The best way of ensuring that one of the pumps in a parallel pump system is not deadheaded is to provide aseparate control valve for each pump as Shown in Figure 5. Sunflo also recommends that individual minimumflow lines be installed for each pump operated in parallel.

Figure 5

4.0 TROUBLESHOOTING

4.1 GEARBOX, PUMP, AND MECHANICAL SEAL

Pump performance characteristics are shown in the pump selection procedure. Tables 8 and 9 present informationwhich is useful in the analysis of gearbox, pump performance, and seal problems.


TROUBLESHOOTING

GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONNo flow, no pressure atstartup.

Pump not completely primed. Bleed all vapors and gases from system. Also bleedvapor or air from the seal flush port.Allow more cool-down time if pumping a lowtemperature fluid.Verify that pump and suction line are full of liquid.

NPSH available actually lowerthan requirement specified onspecification sheet.

Suction line blocked. Check suction strainer andvalves.

Excessive pressure drop through suction piping.Flow restricted by vapor pockets in high points ofsuction and discharge piping.Inability to vent past a check valve in the dischargepiping.Suction tank level or pressure too low.Entrained gases in pumped liquid.NPSH reduced by a more volatile process liquid.

Failure of drive componentsuch as missing drive gear,sheared or missing impellerkey, or failed high-speed shaftbearing.

Replace as necessary with Genuine Sundyne Parts.

Wrong direction of rotation onmotor.

Direction of driver shaft rotation is as shown by arrowon gearbox housing. Note: Impeller and driver rotatein different directions. Rotation can be checked byviewing driver fan or input shaft on frame-mountedunits. Reverse any 2 leads on motor to changedirection of rotation.

Pump starts and thenstops pumping.

Improperly primed pump. Attempt to prime pump. If priming is not possible,inspect suction piping for obstructions.Determine if there is a check valve on the discharge.If so, determine if the vapors between the pump andthe check valve are being vented.

Suction screen plugged. Suction line blocked. Check suction strainer andvalves.

Air or vapor pockets in suctionline.

Vent suction piping at the highest point. Determine ifthe piping must be redesigned to eliminate theformation of air or vapor pockets.

(Table 8) PUMP AND GEARBOX TROUBLESHOOTING


GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONInsufficient flow orpressure.

Flow rate is higher than pumpdesign allows.

Check head rise and flow rate against performancecurve.

Wrong direction of driver shaftrotation.

Direction of driver shaft rotation is as shown by arrowon gearbox housing. Note: Impeller and driver rotatein different directions. Rotation can be checked byviewing driver fan or input shaft on frame-mountedunits. Reverse any 2 leads on motor to changedirection of rotation.

Air trapped in pump orpumping entrained vapors orgases.

Check shutoff pressure. If deficient, vent pump.

Determine if there is a check valve on the discharge.If so, determine if the vapors between the pump andthe check valve are being vented.

Available NPSH actually lowerthan required NPSH listed onpump specification sheet.

Refer to solutions provided under “No Flow, NoPressure at Startup”.

Flow too low causingoverheating of fluid and loss ofNPSH after a short period ofsatisfactory operation.

Increase pump flow rate.

Increase bypass flow rate or use seal cavity bypassto continuously increase inlet flow rate. Vent to thehighest point of the pump.Install bypass to recirculate part of pump dischargeback to the supply tank.

Impeller damage by passageof solid particles.

Inspect impeller for nicked, bent, or worn blades.Replace impeller if damaged.

Process fluid specific gravity orviscosity different from whatwas specified.

Check actual viscosity and specific gravity at theoperating temperature. A viscosity higher than 5centipoise will cause reduced head and flow andincreased power consumption. A specific gravityhigher than what was specified will cause increasedpower consumption.

Pressure gauges or flowmeters in error.

Remove and replace with calibrated instrument.

(Table 8 con’t) PUMP AND GEARBOX TROUBLESHOOTING


GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONCorrosion pitting on pumpcasing.

Minor pitting may be polished with emery cloth.Major pitting indicates a failed part and should bereplaced.Inspect remainder of pump to determine if otherareas of pump are damaged from corrosion.Replace damaged parts.Establish corrosion mechanism. Determine ifprocess conditions can be changed. Consult yourauthorized Sunflo sales representative for assistanceon different pump materials of construction.

Corrosion and/or erosion ofdiffuser throat (may also beaccompanied by corrosionand/or erosion of diffusersurface adjacent to theimpeller).

If edge of throat has opened in size, head-rise maybe reduced. Opening of the throat will result inhigher flow rate and horsepower consumption.Corrosion and/or erosion of the diffuser and coversurfaces will also result in a significant increase inhorsepower consumption.

Pump discharge throat partiallyplugged.

Disassemble pump and inspect pump casing for anyobstructions. Replace hardware with GenuineSundyne Parts if necessary.

Driver speed too low. Check driver speed against value provided on thepump specification sheet.

Driver Overloaded. Fluid specific gravity orviscosity is higher than whatthe pump was initially designedfor.

Decrease specific gravity and/or viscosity.

Reduce pump flow to the level that will reduce driverpower consumption to an acceptable level.

Electrical Failure in Motor. Check circuit breaker heater size and setting.Check motor voltage.Check motor current in each phase. The currentshould be balanced within 3 percent.

Mechanical failure in driver,gearbox, or pump.

Remove casing and check for impeller rub on coverplate and pump casing.Rotate high speed shaft assembly and check forease of rotation.Inspect ball bearings and journal bearings. Replacefailed parts with Genuine Sundyne Parts.

Pump operating beyond designflow.

Check actual pump flow and head against the valuesprovided on the pump specification sheet.



GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONDriver Overloaded(cont’d)

Corrosion pitting on surface ofdiffuser adjacent to impellerblades.

Disassemble pump and inspect. Rough or pittedsurfaces can cause additional friction losses whichwill significantly increase driver horsepowerconsumption. Clean these areas of all obstructionsand use emery cloth to restore all surfaces to asmooth, polished finish. Check the diffuser throat.Erosion and corrosion will cause roughness that willincrease horsepower consumption. Note: A largerthan designed diffuser throat will allow for a higherflow and horsepower consumption for a given headrise.

Excessive DischargePressure Pulsation(May be associatedwith a “hammering”sound or may soundlike “gravel” beingpumped).

Flow rate too low Increase flow through pump. Add bypass If required.

Insufficient NPSH Refer to solution for insufficient NPSH under “NoFlow, No Pressure at Startup”.

Defective flow control valve. Repair or replace valve.Change of gearbox oilfrom normal color tomilky pink or yellow.

Gearbox lubricant iscontaminated with water orprocess fluid.

Check for excessive pump or seal leakage. Changegearbox oil and replace all worn or damaged partswith Genuine Sundyne Parts.Inspect shaft sleeve o-rings. Replace if necessary.Check for restricted seal drain port. Change gearboxoil and remove restriction.

Shaft sleeve rubs oninside diameter of seal.

Gearbox bearing failure. Inspect and replaced damaged hardware withGenuine Sundyne Parts.

Excessive gearbox oilconsumption.

Gearbox seal leakage. Check for fluid leakage from drain port. Disassembleand replace worn or damaged hardware.

High lube oiltemperature

Heat exchanger fouled or nocoolant flow to heat exchanger.

Clean heat exchanger.

Check coolant flow.



GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONExcessive oil foaming. High oil level. Check oil level. If too high, shut down the unit a

drain the oil to the correct level.Incorrect lubricant.

Excessive noise andvibration.

Rotation incorrect. Direction of driver shaft rotation is as shown by arrowon gearbox housing. Note: Impeller and driver rotatein different directions. Rotation can be checked byviewing driver fan or input shaft on frame-mountedunits. Reverse any 2 leads on motor to changedirection of rotation.

Worn or damaged bearings. Disassemble pump and replace damagedcomponents with Genuine Sundyne Parts.

Insufficient NPSH Refer to solution for insufficient NPSH under “NoFlow, No Pressure at Startup”.

Damaged impeller or shaft. Replace as required with Genuine Sundyne Parts.Partially clogged impellercausing imbalance.

Back-flush pump to clean impeller. Determine causeof clogging.

Foundation not rigid. Tighten down hold-down bolts of pump and motor.Suction or discharge piping notanchored or properlysupported.

Anchor piping per the Hydraulic Institute StandardsManual recommendations.

Damaged drive or pinion gear. Disassemble pump and replace damaged gear withGenuine Sundyne Parts.

Improper pump & driveralignment.

Align pump and driver shafts.

Resonance of pumpfoundation.

Perform vibration testing to determine if there is anatural frequency of the installation close to that ofthe driver. Modify installation to dampen the naturalfrequency.

Improper location of dischargecontrol valve.

Install discharge control valve within 5 feet of thepump discharge.



PUMP MECHANICAL SEALS

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONSudden Increase inSeal Leakage

Severe cavitation or loss ofsuction pressure causingvibration and bouncing of sealface.

Correct pump suction condition causing cavitation.Bleed vapor from seal cavity and restart pump.Install double seal system if loss of suction cannot beprevented.Replace seal and rotating face with GenuineSundyne Parts if either part is shown to be worn ordamaged.

Seal icing on low temperaturepumps or icing when handlingfluids which have high vaporpressures at a temperature ofless than 32 DegF (0 DegC).

Use purge of dry nitrogen gas into seal drain area.Install double seal system and use a compatible,nonaqueous, nonvolatile external seal flush.

Solid particles in seal cavity orseal spring area.

Replace seal and rotating face.

Supply clean, external seal flush or install doubleseal system if particles cannot be removed by aseparator or filter.

Seal stationary spring action isrough and sticky.

If parts are corroded, check for material compatibility.

Check for the accumulation of solids in the sealretainer area. If solids are found, consider theinstallation of a double seal system.

Worn or damaged seal. Disassemble high speed shaft assembly and replaceworn or damaged components with GenuineSundyne Parts.

Wear pattern on seal rotatingfaces not uniform in thecircular direction.

Inspect shaft sleeve and impeller hub for high spots.Replace if necessary. Install new seal and rotatingface.Shaft sleeve not parallel causing rotating face to becocked. Dirt or debris caught between sleeve,rotating face, or adjacent parts.

Wear pattern on stationaryface of seal is smooth but notuniform.

Replace seal and rotating face.

(Table 9) MECHANICAL SEAL TROUBLESHOOTING


PUMP MECHANICAL SEALS

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTIONEdges of stationary facechipped and seal face is worn.(Usually caused by vaporformation in the seal cavity)

Prevent loss of pump suction. Install double sealsystem if loss of suction cannot be prevented.

Supply cool seal flush. Consult with your authorizedSunflo sales representative to see if a heatexchanger is required.

Seal rotating face is cracked orbroken. This may be causedby damage during assembly orby thermal shock from runningthe seal dry.

Prevent loss of pump suction. Install double sealsystem if loss of suction cannot be prevented.

Supply cool seal flush. Consult with your authorizedSunflo sales representative to see if a heatexchanger is required.

Wear on seal rotating facenear the area where theoutside of the stationary facecontacts. (Usually cause byicing from air in drain).

Install nitrogen purge in drain area.

Install a double seal system.Chemical attack of seal faces,seal parts, or o-rings.

Investigate process fluid properties and change sealand o-ring materials if needed.

(Table 9 con’t) MECHANICAL SEAL TROUBLESHOOTING

5.0 SPARE PARTS

When ordering replacement parts, give the pump serial number, and list each part required by item number and partname along with quantities desired. When requesting information concerning your Sunflo Pump, always refer to thepump model number and pump serial number as they appear on the nameplate.

All SUNFLO products are available on an expedited basis. The factory should be contacted prior to order placementto ensure part availability. Stock spare parts requiring no machining will be shipped 24 hours after receipt of order atthe factory and parts requiring additional machining will be shipped within 96 hours after receipt of order at the factory.

The kits shown below simplify maintenance and inventory control. They are available through your Sunflo distributor.

O-RING REPAIR KITS

Packages all o-rings in one kit.

Color coded o-ring material.

Easy-to-read instructions describe exact location of each o-ring.

SEAL REPAIR KITS

Custom tailored for the specific pump and seal type.

Single and double seal options.

Easy-to-read instructions prevent installation mistakes.

Eliminates misplacement of parts and simplifies inventory control.


EXCHANGE HIGH SPEED SHAFT ASSEMBLIES

Easier to perform routine seal and bearing maintenance.

Normal delivery is 2 weeks.

Same quality construction, testing and warranty as new shaft assemblies.

Can ship on an expedited 3-day basis when needed. Old shaft assembly returned for credit within 60 days.

Order kits through your Sunflo distributor.

NOTEA HIGHLY RECOMMENDED OPTION TO NORMAL PUMP MAINTENANCE IS THE PURCHASE OF A SPAREHIGH SPEED SHAFT ASSEMBLY WHICH CAN BE REPLACED QUICKLY AND EASILY AS A COMPLETE UNIT.

6.1 ORDERING REPLACEMENT PARTS

Order parts through your Sunflo distributor. For information or assistance contact:

Sundyne Corporation14845 West 64th AvenueArvada, Colorado 80007Telephone: 303-425-0800Fax: 303-425-0896Attention: Parts Order Coordinator

or

Sundyne Corporation - Europe13-15 Blvd. EiffelZone Industrielle de Dijon SUD (21600)B.P. 3021600 Longvic CedexFrance

Sundyne Corporation • Arvada, CO 80007 USA • +1-303-425-0800 • FAX: +1-303-425-0800 • www.sundyne.comSundyne Europe • Longvic Cedex, France • +33-380-383300 • FAX: +33-380-383371

• ANSIMAG • ANYSPEED • CASTER • HMD/KONTRO • MASO/SINE • SCMP • COMPRESSORS • SUNDYNE • SUNFLO •

sunflo pumps - ipp · 2011-09-02 · c. the piping, both suction and discharge, should have no...

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