Installation Manual SKC Series Pump-1
Installation Manual SKC Series Pump-1
SELF-PRIMING PUMPS
AND PUMP UNITS
TYPE SK
(versions: SKA, SKB, SKC, SKD, SKG)
SK/WE - 4C.3
Issue 3/2006
The present manual
should be given to the final operator
and be present in the place
where the pump is mounted
Fig.1 Lay-out of pumps operating with suction
1. GENERAL.
1.1. Symbols
1.2. Personnel qualifications
1.3. Hazards associated with failure to comply with safety requirements
1.4. Unauthorized modifications and production of spare parts
1.5. Misuse
2. TRANSPORT AND STORAGE.
3. PUMP AND PUMP UNIT.
3.1. Pump and pump unit
3.2. Motor
3.3. Pump unit set-up
4. INSTALLATION AND ASSEMBLY.
4.1. Safety requirements for installation and assembly
4.2. Hydraulic system
4.3. Wiring
5. COMMISSIONING - START-UP, OPERATION AND SHUTDOWN.
5.1. Performance requirements
5.2. Operation
5.3. Shutdown
6. MAINTENANCE AND OPERATION.
6.1. Part replacement schedule
7. TROUBLESHOOTING.
8. RELEVANT DOCUMENTS.
9. GUIDELINES AND INSTRUCTIONS FOR USE IN HAZARDOUS AREAS.
9.1. Maintenance schedule for pump and coupling for use in hazardous areas.
9.2. Coupling wear
9.3. Coupling materials for hazardous areas
9.4. Motor for use in hazardous areas
9.5. Start-up.
9.6. Leakage.
9.7. Electrostatic discharge.
1. GENERAL INFORMATION
This user manual includes general guidelines for the installation, operation and
maintenance of a pump unit. Read this manual before installation and start-up to
ensure reliable and long term operation.
Hydro-Vacuum pumps are manufactured very carefully, with manufacturing process
controlled on each stage, according to ISO requirements. Before leaving our factory,
every pump is thoroughly inspected and tested to assure its quality and performance.
Proper installation, service and maintenance would ensure proper pump operation.
The present manual contains important instruction regarding safe, proper and
economical exploitation of the pump. We suggest to read this manual carefully, with
understanding, because acquaintance and compliance of this instructions will ensure a
reliable and long life operation.
This manual does not contain the local requirements and regulations, so the
responsibility for fulfilment of local rules belongs to the user.
The pump assembly shall not be exploited against its destination regarding physical
and chemical properties of the handled medium, ie. efficiency, pressure, temperature,
density, aggressiveness, abrasiveness, as well as operating parameters specified in
the Technical Data of the pump or the contract documentation.
The data plate of the pump and of the motor specifies the type-size, the mean
operating parameters and the serial number (identification number, which should be
marked in correspondence, orders, especially in spare part orders). Compare these
data with the data in your order and/or contract documentation.
All Hydro-Vacuum products are guaranteed according to the “Warranty Certificate”
Hydro-Vacuum is not liable for defects arising out of following causes:
- the pump has been damaged during transportation, by badly storage or
incorrect installation;
- the pump is installed or operated against instruction given in this
manual;
- the pump was used for handling liquid other than specified in its Technical
Data, ie. aggressiveness of handled liquid exceeds corrosion resistance
of materials used in the pump;
- pump was disassembled in the warranty period without manufacturer’s
permission.
The manufacturer is not liable for any damage resulting from failure to
CAUTION!
comply with warranty terms and conditions.
1
1.1. Symbols
2
2. TRANSPORT AND STORAGE
Check if the product has not been damaged in transport. Notify the carrier
immediately if any damage is discovered.
If the product is not installed immediately after the delivery, store in a dry room and
protect against impact and weather conditions (moisture, frost etc.).
In case of long term storage, make sure the impeller rotates freely before initial
start-up. Manually rotate pump shaft by the clutch or motor shaft after removing the fan
cover and the impeller cover.
Lockout of an impeller may be eliminated by filling the pump unit with hot
CAUTION! water, if this does not help, drain the water and contact the nearest
service centre.
Do not use special tools (chain spanner) to unlock the pump, since it
may damage the impeller and the seals
The product shall be secured against damage, impact and weather conditions.
Products over 70 kg are fitted with transport lugs, see Fig.3.
3
3. PUMPING SET DESCRIPTION
Before installation of the pump assembly, it is required that the operator checks and
compares the data specified on the data plate with the data in the order (or contract
documentation). The operator shall acknowledge himself carefully with the present
User’s Manual and Technical Data.
Guidelines and instructions for use in hazardous areas.in section 9.
Before installation and first starting up, the operator should indispensably
CAUTION!
acknowledge with the Technical Data of the delivered pump set.
4
Other power transmissions may be used, provided that the torque is the
CAUTION!
only load present at the pump shaft end.
Product dimensions, weights and specifications are specified in the product Data
Sheet.
3.3. Pump unit set-up
Install the pump unit on a concrete slab with at least 10 cm height and fasten with the
anchor bolts.
CAUTION! See pump Specification for dimensions and layout of the anchor bolts
The concrete slab must be level and the pump unit must be positioned horizontally. It is
recommended to position the concrete slab on a cement mortar. After the unit is
fastened to the concrete slab with anchor bolts and all hydraulic connections are
completed, check if the pump and motor are in a correct position in relation to each
other and the impeller rotates freely. Check coupling.
See Fig. 4 and Fig. 4a for the position two parts of the flexible coupling.
An allowable gap measured at the coupling circumference for type E, type A and type I
couplings may not exceed values specified in Table 1.
Table 1
Dimension [mm]
Coupling type
a b
E 2+0,5 0,2
A 5+0,5 0,3
I 3,8+0,5 0,2
The alignment of pump and motor shaft can be checked with a rule and a feeler
gauge. Dimension “b” can be corrected with a washer installed under the pump or
motor mounts. Install coupling guard and other safety guards, and do not run the pump
unit without the safety components in place.
5
Do not run the pump unit without coupling guard and safety guards
radial
deviation
angular
deviation
axial
deviation
Table 2
Dimension
Coupling type
E [mm] x [mm] y [mm] W [mm]
EZ 1 32 1,0 0,2 0,8
EZ3 40 1,0 0,2 0,8
EZ 7 49 1,5 0,3 1,0
EZ 9 62 1,5 0,3 1,5
EZ 10 78 1,5 0,4 1,5
x, y, W- maximum deviation for couplings
6
4. INSTALLATION AND ASSEMBLY.
4.1. Safety requirements for installation and inspection
User shall make sure, all installation and inspection works are made by an
authorized and qualified personnel. Make sure the personnel understood the Operating
Manual. Works shall be carried out with disconnected power supply only. The pump
units for hazardous media are subject to neutralization.
All protective devices must be reinstalled and restarted before the compressor unit
is reactivated. Follow the procedure.
4.2. Hydraulic connections
The pump may operate with suction (Fig. 1) or with onflow (Fig. 2).
- When pumping from a container placed below the pump, the whole suction line
should be arranged upwards.
- At the inflow of pumps type SKC and SKD, a straight pipe section of length
equal 20 times of the suction pipe diameter should be installed.
- Protect the pump against dry running.
- Keep the suction level according to the NPSH value of the pump.
- Take in mind that the altitude and temperature of the handled liquid affect the
suction lift.
Table 3 Table 4
Altitude Drop of suction lift Temperature Drop of suction lift
(m) (m) ºC (m)
0 0 20 0,20
500 0,60 30 0,40
1000 1,15 40 0,70
1500 1,70 50 1,20
2000 2,20 60 1,90
2500 2,65 70 3,10
3000 3,20 80 4,70
90 7,10
100 10,30
7
The above table refers to handling water. In case of other liquids,
especially with high vapour pressure, check if your pump should not be
installed with inflow.
Any foreign matter getting into the pump will cause its breakdown. To
avoid this, install an adequate filter and/or separator in the suction pipe.
During installation make sure, that the applied washers do not obstruct
CAUTION!
the clearance of the suction pipe.
- Diameters of the suction and pressure pipelines shall not be smaller than the
diameter of the pump stub (these data are included in the Technical Data of the
pump).
If the above principles are not observed, the flow resistance will increase
and the pump efficiency would be lower than given in the manual.
The following terms and conditions apply. Any damage resulting from
failure to comply with the terms and conditions are not covered by the
CAUTION! warranty. Do not use the pump unit to deliver products with corrosive
properties exceeding the corrosion resistance parameters of materials
used for its construction.
8
Permissible forces and moments exerted on ports of pumps type SK version A, B, C, D, G
as per PN-EN-ISO -5199
Table 5
Pump Stub pipe DN Family Material Force [N] Torque [Nm]
type location mm no. marking Fy Fz Fx ∑F
b
My Mz Mx ∑M
b
5A cast iron, bronze 255 315 270 495 88 123 210 492
SKA 32
5B cast steel 510 630 540 990 176 246 420 984
„z” axis
SKB 5A cast iron, bronze 300 375 385 585 140 193 280 490
SKC 40
5B cast steel 600 750 770 1170 240 386 560 980
SKD
SKG 5A cast iron, bronze 405 495 450 780 175 228 315 543
50
5B cast steel 810 990 900 1560 350 456 630 1096
5A cast iron, bronze 510 630 555 990 210 245 350 595
65
5B cast steel 1020 1266 1110 1980 420 490 700 1190
1A cast iron, bronze 525 473 578 910 350 403 490 718
50
1B cast steel 1050 946 1156 1820 700 806 980 1436
Pump port in
1A cast iron, bronze 648 595 735 1155 385 420 525 770
horizontal
65
„x” axis
SKC 1B cast steel 1296 1190 1470 2310 770 840 1050 1540
SKD 1A cast iron, bronze 788 718 875 1383 403 455 560 823
80
1B cast steel 1576 1436 1750 2766 806 910 1120 1646
1A cast iron, bronze 1050 945 1173 1838 438 508 613 910
100
1B cast steel 2100 1890 2346 3676 876 1016 1226 1820
b
- ∑F and ∑F are vector totals of forces and torques.
9
If not all actual loads reach permissible maximum values, one of the loads may exceed
permissible value, when an additional condition is met:
- no force or moment exceeds 1.4 x permissible value from table 5
- actual force and moment exerted on each port meets the following equation:
2 2
ΣFrzeczywiste ΣMrzeczywiste
+ ≤2
ΣFdopuszcz. ΣMdopuszcz.
The effect of material and temperature on permissible values of forces and moments.
Table 6
Temperature ºC
Material type 20 60 100 140 180 220
Correction factor „K”
Grey iron 1 0.983 0.968 0.952 0.929 0.904
Alloy steel 18-8 1 0.990 0.987 0.974 0.964 0.953
Carbon steel 1 0.990 0.980 0.971 0.961 0.952
All force and moment data included in table 5 are specified for 20ºC. For other
temperatures, data must be corrected in accordance with:
Ft = K × F[N ]
Mt = K × M[Nm]
4.3. Wiring
- The voltage must correspond to the data specified in the motor rating plate.
Follow the motor manufacturer specification.
- Use bimetallic thermal overload relay set to rated current, as per the rating
plate.
10
Incorrect connection may cause motor damage. Check if the power
supply line is able carry the starting current, which is 5 - 7 times higher
than the nominal current. If possible use soft start or a star-delta array
With wrong sense of rotational, will the pump not reach proper working
CAUTION!
parameters (Q and H).
11
5. TECHNICAL ACCEPTANCE INCLUDING START-UP, OPERATION AND
SHUTDOWN.
5.1. Operational requirements
- Each time before the compressor start-up check, if the compressor is filled with
medium.
- For pumps operating with suction (Fig. 1) install a check valve and a strainer at
the suction line. Rapid reversal of a liquid stream at pump shutdown may lead
to liquid drain, preventing suction. Prime the pump and the suction line. Open
pressure valve.
- For pumps operating with inflow (Fig. 2), install a gate valve at the suction side
(open during operation). Prime the pump. Open pressure valve.
Do not use the gate valve (at the suction side) to adjust pump
parameters.
Before first start, fill up the pump and the seal chamber with the handled
CAUTION! liquid. A chamber with double sealing should be exactly deaerated and
a proper pressure should be applied.
Do not start the pump with a discharge valve fully closed. Run the pump
CAUTION! with the discharge valve partially closed. The lower the pump efficiency,
the higher the power input. (As opposed to the centrifugal pumps).
The pumps are factory filled with an inhibitor, readily soluble in water.
CAUTION! Do not use water for food purposes for the first 5 minutes of initial
pumping.
The pump shall not work without flow of liquid longer than 1 min. For a
continuous running pump shall the minimal flow not be smaller than 10%
of the full pump output
12
5.2. Operation
Mounting new mechanical seals make sure to install rubber washers in the
chamber and in the sliding ring. When mounting the mechanical seal onto the shaft it is
recommended to moisten the shaft with water. If the shaft shoulder has a sharp edge,
an auxiliary directing sleeve “1” (see Fig. 5) should be used, in order to avoid damage
of the O- ring “2". Sealing ring faces must be clean and free from cracks and scratches.
2 3 1
13
Pumps with gland packing demand regardful regulation
- Before the first start, must the nuts for tightening the packing be turned only
manually, without excessive force. Do not overstrain the packing!
A full stoppage of the outflow would cause the stuffing to wear out
CAUTION!
and a excessive shaft wearing.
When replacing the stuffing, take care not to scratch the shaft. The stuffing sections
should be arranged as presented on Fig.6.
5.3. Shut-down
Make sure the liquid will not freeze; remove the liquid from the pump and the
system.
14
6. SUPERVISION AND MAINTENANCE
During pump operation, special maintenance procedures are not
necessary. The pump and its vicinity should be kept clean. If the temperature drops
down below the freezing point, draw the water off the pump and pipelines. Fill the
pump up with a non-freezing liquid, eg. glycol solution, to avoid blocking of the rotating
assembly.
The bearings do not require lubrication.
Do not exceed permissible torques (see Table 7) for bolted joints. Most of the
threaded joints are secured with Loctite thread locker. It is recommended to heat the
threaded joints with hot air (temp. 200ºC) before removing.
Tightening torques - bolted joints.
Table 7
Size M6 M8 M10 M12 M16 M20
Do not use excessive force. Before disassembly, mark the position and order of
each part.
Follow the assembly procedure (note different number of holes for the SK type
pumps). The running clearance between each section and the impeller must not
exceed 0.1 ÷ 0.15 mm.
When mounting the coupling on the pump shaft, remove the bearing
CAUTION! cover on the opposite side and support the pump on the shaft end to
avoid damage to the bearing cover.
6.1. Spare part replacement.
15
Table 8
Motor bearings
Wearing part Mechanical seal Motor winding
Pump bearings
20 000 h
10 000 h 20 000 h
for outside
Durability to to
temperature
20 000 h 30 000 h
up to 40ºC
Continuous
Replacing 1 - 2 years 2-3 years 3 years
work
frequency
according to
the working 15 h/day 9
load 2-5 years 4-8 years 6 years
months/year
16
Fig. 8 Arrangement of pumps type SKA.3 - 8, SKG.3 – 8
1 - Bearing housing, 2 - pressure casing, 3 - pressure member, 4 - impeller of the first step,
5 - pressure-suction member, 6 - impellers of the succeeding steps, 7 - suction member,
8 - suction casing
17
7. TROUBLESHOOTING.
Any works on the compressor within the warranty period without manufacturer’s
authorization will void the warranty.
Table 9
Trouble Cause Remedy
Pump does a) Obstruction by foreign a) Dismount and clean the pump
not supply matter
medium b) Suction side blocked b) Clean the pump
c) Leaky suction side, air is c) Remove leakage
sucked
d) Pump not filled with water d) Fill up
e) Too low pressure on suction e) Suction head to high
side (cavitation)
f) Wrong sense of rotation f) Exchange two phase conduits in the
motor
g) Supply voltage too low g) Check and correct
Pump a) Pump not proper mounted on a) Make steady
vibrates the basement
b) Improper basement b) Reinforce the foundation
c) Foreign matter in the pump c) Dismount and clean the pump
d) Damaged bearing d) Exchange the bearing
e) Damaged impeller e) Exchange the impeller
Motor a) Pump blocked a) Locate the reason and correct
warmed up b) Voltage too low b) Check voltage on clamps. It should
not differ from nominal value more
than ± 5%
c) Foreign matter in the pump c) Dismount and clean the pump
d) Improper outside temperature d) Highest temperature cannot exceed 115ºC
e) Improper connection e) Check and put right
Pressure too a) Wrong pump selected a) Exchange the pump
low b) Wrong motor speed (foreign matter, b) Dismount the pump and put right
wrong power supply etc.)
c) Wrong sense of rotation c) Exchange connection of two phase
conduits in the motor
Self acting a) Too low thermal relay setting a) Set value specified on data plate
motor shut off b) Too low voltage b) Check conduit section
c) Thermal relay defected c) Replace relay
d) Rotating impeded d) Check and remove blockage
Uneven a) Diameter of suction conduit a) Check the conditions and installation
supply smaller than sucking opening in suggestions
the pump
b) Sucking pipe and inlet filter b) Dismount and clean
obstructed
18
8. RELEVANT DOCUMENTS
To be agreed upon between the Client and the Manufacturer. The following
documents are included with the pump unit: User Manual, Technical Data, and
Warranty Card.
9. GUIDELINES AND INSTRUCTIONS FOR USE IN HAZARDOUS AREAS.
9.1. Maintenance schedule for pump and coupling for use in hazardous areas.
Table 10
Explosion
Inspections
proof class
1. Check circumferential clearance of a flexible insert after 2,000
hours of operation from the initial start-up. Or every 4 months.
2. If no wear of the flexible insert is observed, next inspection after
HI2GcIIBT4- 4,000 hours of operation. Or every 12 months.
T3 3. If excessive wear of flexible insert is observed, identify the cause
and replace the insert.
4. Replace rolling bearings (lower values, see Table 8).
5. Replace end face seals (lower values, see Table 8).
1. Check circumferential clearance of a flexible insert after 2,000
hours of operation from the initial start-up. Or every 2 months.
2. If no wear of flexible insert is observed, next inspection after 2000
hours of operation. Or every 6 months.
IM2cT4-T3 3. If excessive wear of flexible insert is observed, identify the cause
and replace the insert.
4. Replace rolling bearings (lower values, see Table 8).
5. Replace end face seals (lower values, see Table 8).
Use feeler gauge to check the gap between the hub centres and a
CAUTION! flexible insert. If acceptable wear is exceeded, replace the insert
irrespective of maintenance schedule.
Correct shaft alignment guarantees long service life and safe operation
in the hazardous areas.
19
Table 11
Coupling type series
Acceptable wear ∆max [mm]
EZ
1 1,5
3 2
7 2
9 3
10 3
CAUTION! Coupling hubs made of light metal alloys e.g. aluminium are not allowed.
For hazardous areas, apply Loctite thread locker on the coupling hub
retaining screw.
The distance between the guard and the coupling must be at least
CAUTION! 5 mm.
Guards can be removed with the pump unit completely stopped.
20
Immediately deactivate the drive in case of coupling malfunction.
Identify the cause.
Remedy the problem.
9.6. Leakage
The pump or pump unit for flammable, toxic, caustic or other hazardous liquids or
o
liquids with temperature over 60 C must be fitted with components, e.g. tubes for
collecting and draining the liquid leaking from the packing box or discharged by the
pressure safety valve.
Protect the environment against leakage with fixed guards, screens and other safety
devices.
21
86-300 GRUDZIĄDZ/ Mniszek head office: 56/ 45 07 400, fax 56/ 46 259 55
ul. Droga Jeziorna 8 46 236 23
factory outlet: 56/ 45 07 310, fax 56/ 46 264 16
46 230 08
orders: 56/ 45 07 476, fax 56/ 45 07 338
46 211 41
46 226 29
Internet: www.hv.pl
E-mail: [email protected]