SPX Cooling Technologies API 610 manual

Instruction Manual CombiPro Heavy duty process pump according to API 610 Orginal instructions Read and understand this manual prior to operating or servic ing this product. CR/EN (1004) 4.0[...]

EC/EN (1001) 5.1 1 E C Declaration of conformity (Directive 2006/42/ E C, appendix I I-A) Manufacturer SPX Process Equipment N L B.V . Dr . A.F . Philipsweg 51 9403 AD Assen The Ne therlands hereby declares that all pumps member of productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiDirt, CombiFlex(U)(B), CombiPrime H, CombiLine, CombiLineBl[...]

2 EC/EN (1001) 5.1[...]

CR/EN (1004) 4.0 3 CombiPro Instruction manual CombiP ro All tec hnical and tec hnological information in this manual as well as possible drawings made available by us remain our property an d shall not be used (otherwise than for the operation of this pump), copied, duplicated, ma de availabl e to or brought to the notice of third parties without [...]

4 CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 5 CombiPro Ta b l e o f C o n t e n t s 1 Introduction 9 1.1 Preface 9 1.2 Safety 9 1.3 Guarantee 10 1.4 Inspection of delivered ite ms 10 1.5 Instructions for transport and storage 10 1.5.1 Weight 10 1.5.2 Use of pallets 10 1.5.3 Hoisting 11 1.5.4 Storage 11 1.6 Ordering parts 12 2 General 13 2.1 Pump description 13 2.2 Applicatio[...]

6 CR/EN (1004) 4.0 3.6 Accessories 23 3.7 Connection of the electric moto r 23 4 Commissioning 25 4.1 Inspection of the pump 25 4.2 Inspection of the motor 25 4.3 Pumps w ith oil-bath lub ricated bearings 25 4.4 Preparing the pu mp un it for commissioning 26 4.5 Checking the sense of rotation 26 4.6 Start-up 26 4.7 Pump in operation 26 4.8 Noise 26[...]

CR/EN (1004) 4.0 7 CombiPro 9P a r t s 43 9.1 Ordering parts 43 9.1.1 Order form 43 9.1.2 Recommended spare parts 43 9.2 Pump 44 9.2.1 Sectional drawing pump 44 9.2.2 Parts list pump 45 9.3 Mechanical seal piping plan 11 - tubin g 47 9.3.1 Drawing plan 11 - tubing 47 9.3.2 Parts list plan 11 - tubing 47 9.4 Mechanical seal piping plan 11 - flanged [...]

8 CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 Introduction 9 CombiPro 1 Introduction 1.1 Preface Thi s manual is intended for tec hnicians and maintenance staff and for those who are in c harge of order ing spare p arts. This manual contains important and useful information for the proper operation and maintenance of this pump. It also contains important instructions to preven[...]

10 Introduction CR/EN (1004) 4.0 1.3 Guarantee Johnson Pump shall not be bound to any gu arantee other than the guarantee accepted by Johnson Pump. In particular , Johnson Pump will not assume any liability for explicit and/or implicit guaran tees suc h as but not limited to the marketability and/or suitability of the products supplied. The guarant[...]

CR/EN (1004) 4.0 Introduction 11 CombiPro 1.5.3 Hoisting W hen hoisting a pump or complete pump units the straps must be fi xed in accordance with figure 1 and figure 2.  When lifting a pump or a complete pump unit alway s use a p roper and sound lifting device, approved to bear th e total weight of the load! Never go underneath a load that is b[...]

12 Introduction CR/EN (1004) 4.0 1.6 Ordering p arts Thi s manual contains a survey of the spare parts recommended by Johnson Pump as well as the instructions for ordering them. A fa x-order form is included i n this manual. Y ou should always state all dat a stamped on the type plate when ordering parts and in any other correspondence regarding th[...]

CR/EN (1004) 4.0 General 13 CombiPro 2 General 2.1 P ump description The CombiPro represents a range of horizo ntal "heavy duty" centrifu gal pumps. Th e design of this range of pumps is based on the guidelines for: "Centrifugal Pumps for Pet roleum, P etroch emical and Natural Gas In dustries" from the "American Petroleum [...]

14 General CR/EN (1004) 4.0 2.3 T ype code Pumps are available in various designs. T h e main c har acteristics of the pump are shown in the type code. Example: CR 50A-200 A-8 1C W -FX Pump family CR C ombiP r o Pum p si ze 50A discharge conn ection [mm]. A and B design pump types have the same designation though they have different hydraulic perfo[...]

CR/EN (1004) 4.0 General 15 CombiPro 2.4 Serial number Serial number of the pump or pump unit are shown on the name plate off the pu mp and on the label on the cover of this manual. 2.5 Constructi on The pump has a modular des ign. T he main components are: • Pump casing •I m p e l l e r • Shaft sealing •B e a r i n g In general for each in[...]

16 General CR/EN (1004) 4.0 2.7 Impeller The bac k of the closed impeller is provided wi th bac k vanes in order to limit the pressure on the shaft seal and to allow the flushing liquid to circulate. Contamination of the shaft seal is also prevented. On the inl et side the impeller is provided with an interc hangeable wear ring. Running clearances [...]

CR/EN (1004) 4.0 General 17 CombiPro 2.13 Application area The applic ation area globally looks as follows:, However , the maximum allowable pressures an d temperatures depend strongly on the selected materials and components. Al so working conditions may cause difference s. 2.14 Re-use The pump may only be used for other applicat ions after prior [...]

18 General CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 Inst allation 19 CombiPro 3I n s t a l l a t i o n 3.1 Safety • Read this manual carefully prior to installation and commissioning. Non-observance of these instructions can result i n serious damage to the pump and this will not be covered under the terms of our guarantee. F o llow the instruct ions given step by step. • Ensure[...]

20 Installation CR/EN (1004) 4.0 3.4 Mounting 3.4.1 Installation of a pump unit Pump and motor shafts of complete pump units are adjusted perfectly in line in the works. 1 Horizontal alignment of the base plate is do ne with levelli ng screws. Use a spirit level for correct horizontal alignment of the base plate. 2 Grout the base plate, see paragra[...]

CR/EN (1004) 4.0 Inst allation 21 CombiPro Parallel alignment 1 Mount dial gauge (A) on the coupling halve motor side, see figure 3. 2 Make index lines on the two coupling halves. 3 Set the dial gauge pointer to zero, turn motor shaft 360 °. 4 Read dial gauge (A). Add or remove shims under the motor until the reading of the dial gauge is within th[...]

22 Installation CR/EN (1004) 4.0 5 W hen the grout has thoroughly hardened, c heck th e base plate bolt nuts and tighten if necessary . 3.5 Piping • The pipi ng to the suction and delivery connect ions must fit exactly and must not be subject to stress during operation. F or the maximum allowable forces and moments on the pump flanges see paragra[...]

CR/EN (1004) 4.0 Inst allation 23 CombiPro • Sudden changes in the rate of flow can lead to high pressure impulses in the pu mp and the piping (water shoc k). Therefore, do not use quick- acting closing de vices, valves etc. 3.6 Accessories • Fit any parts that may have been supplied separatel y . • If the liquid does not flow towards the pu [...]

24 Installation CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 Commissioning 25 CombiPro 4 Commissioning 4.1 Inspection of the pump Check whet her the pump shaft turns freely . Do this by turning the shaft end at the coupling a few times by hand. 4.2 Inspection of the motor Check whet her the fuses have been mounted. 4.3 Pumps with oil-bath lubricated bearings ! Pumps provided with oil-bath lu[...]

26 Commissi oning CR/EN (1004) 4.0 4.4 Preparing the pump unit for commissioning Proceed as follows, both when the unit is put in to operation for the first time and after the pump has been overhauled. 1 Fully open the stop valve in the suction pipe. Cl ose the delivery stop valve. 2 Fill the pump and the suction pipe with the liquid to be pumped. [...]

CR/EN (1004) 4.0 Maintenance 27 CombiPro 5 Maintenance 5.1 Daily maintenance • Regularly c heck the oil level, see fi gure 7.  No water should get into the terminal box of the elec tric motor when the pump room is sprayed clean! Never spray water on hot pump parts! T he sudden cooling down may cause them to burst and hot water may flow out! 5.[...]

28 Maintenance CR/EN (1004) 4.0 5.4 Environmental in fluences • Regularly clean the fi lter in the suction pipe or the suction strainer at the bottom of the suction pipe, as the inlet pres sure may beco me too low if the filter or the suction strainer is fouled. • If there is a risk that the pu mped liquid expands during solidification or freez[...]

CR/EN (1004) 4.0 Problem solving 29 CombiPro 6 P roblem solving Faults in a pump installation can have vari ous causes. The fault may not be in the pump, it may also be caused by the pipe system or th e operating condi tions. Firstly , always chec k that installation has been executed in accordance with the instruc tions in this manual and that the[...]

30 Problem solving CR/EN (1004) 4.0 T able 4: Possible causes of pump failures. Possible causes 1 Pump or suction pipe is not sufficiently filled or de-aerated 2 Gas or air coming from the liquid 3 Air lock in the suction pipe 4 Air leak in the suctio n pipe 8 The manometric suction head is too high 9 Suction pipe or suction strainer is blocked 10 [...]

CR/EN (1004) 4.0 Disassembly and assembly 31 CombiPro 7 Disassembly and assembly 7.1 Precautionary measures  T ake adequate measures to avoid that the motor is started while you are working on the pump. This is especial ly i mportant for electric motor s with remote control: • Switc h the operating swi tch near the pu mp (if available) to &quo[...]

32 Disassembly and assembly CR/EN (1004) 4.0 7.4 Back-P ull-Out system The pumps are designed wit h a Back-Pull-Out system. The pump un it is designed with a spacer-coupling, the spacer of this coupl ing can easily be removed. After t hat the bearing brac ket with the entire rotating part can be removed. T his means that almost the whole pump can b[...]

CR/EN (1004) 4.0 Disassembly and assembly 33 CombiPro 7.4.4 Assembling the guard 1 Place the guard (0270) on the coupling. 2 Fit the guard with bolts (0237). 7.5 Replacing the impeller and the wear ring If the play has risen to 0,9 mm or greater d ue to wear then both wear rings are replaced. 7.5.1 Disassembling the impeller 1 Remove the Back-Pull-[...]

34 Disassembly and assembly CR/EN (1004) 4.0 7.5.3 Disassembling the wear rings After removing the Back- Pull-Out unit (see paragraph 7.4.2 "Disassembling the Back- Pull-Out unit") the wear rings can be removed. In most cases the ring has been fixed so tightly that it cannot be removed undamaged. 1 Disassembling the impeller , see paragra[...]

CR/EN (1004) 4.0 Disassembly and assembly 35 CombiPro 7.5.4 Assembling the wear rings 1 Clean and degrease the fitting edge of t he pump casing and impeller where the wear ring is to be mounted. 2 Fit the casing wear ring in the pump casing. T ake care it is not pushed out of alignment! 3 Fit the impeller wear ring on the impeller . T ake care it i[...]

36 Disassembly and assembly CR/EN (1004) 4.0 7.6 Mechanical seal 7.6.1 Instructions for moun ting a cartridge seal ➢ First read the following instructions regarding mountin g a cartridg e seal. Follow these instructions closely when mounting a car tridge seal. • Thi s mec hanical seal comes as a ’full cart ri dge seal’ . This means that thi[...]

CR/EN (1004) 4.0 Disassembly and assembly 37 CombiPro 7.7 Be aring 7.7.1 Instructions for assembl y and disassembly of bearings ➢ First read the following instructions rega rding a ssembly and disassembly . Follow these instructions closely when assembling and di sassembling bearings. Disassembly: •U s e a proper puller to remove the bearings f[...]

38 Disassembly and assembly CR/EN (1004) 4.0 7.7.3 Assembling bearing 1 Clean t he interior of th e bearing bracket prop erly . 2 Preheat the angular contact ball bearings and the inner ring of the cylindrical roller bearing and fit them onto the pump shaft. Make sure they are positioned straight on the pump shaft and push them firmly against the s[...]

CR/EN (1004) 4.0 Dimensions 39 CombiPro 8D i m e n s i o n s 8.1 P ump dimensions Con nections Con nections (optional) Figure 12: Pump dimensions. BM Oil drain ½ B S P BV Oil filling plug ½ N PT BD Inlet oil c hamber jacket ½ N PT B E Outlet oil c hamber jacket ½ N PT BN Drain oil chamber jac ket ½ N PT DN1 DN2 ab ad ah ajx al aa ac ag aix ak [...]

40 Dimensions CR/EN (1004) 4.0 8.2 Flange dimensions 8.2.1 Flange dimensions ASM E B16.5 150lbs (I SO7005 PN20) 8.2.2 Flange dimensions ASM E B16.5 300lbs (I SO7005 PN50) DN 1 - DN2 aa ab ac ad ae af ag ah aixak ajxal am an 50 (2") 40 (1½") 92 73 120,5 98,5 165 156 4x18 4x16 22 21 80 (3") 50 (2") 127 92 152,5 120,5 210 165 4x18[...]

CR/EN (1004) 4.0 Dimensions 41 CombiPro 8.3 P ump dimensions 8.4 Pump-motor unit For dimension see GAD enclosed with the delivery. aa ab ga db ea eb ec ed mg tb va vb vc vd ve vf vi vj vk vv zb zc zd zl* zn* [kg] 40A-125 140 50 8 27 24 100 511 100 270 320 60 20 314 160 190 100 411 300 - - - - 52 40A-160 1 40 50 8 27 24 100 511 100 300 350 18 60 20 [...]

42 Dimensions CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 Parts 43 CombiPro 9P a r t s 9.1 Ordering p arts 9.1.1 Order form Y ou can use the order form included in this manual for ordering parts. W hen ordering parts always quote the following data: 1Y o u r address . 2 The quantity, the item number and the description of the part. 3 The pump number . T he pump number is st ated on the la[...]

44 Parts CR/EN (1004) 4.0 9.2 Pump 9.2.1 Sectional drawing pump Figure 13: S ectional drawing pump. 0810 0276 0235 0236 2145 2135 2420/2425 2130 2210 2200 2100 2820 2830 2810 1860 2300 2160 0140 2150 2410/2415 0805 0800 0820 0850 0855 1905 1930 2815 2140 2400/2405 2190 2250 2160 2570 0150 0155 0135 0130 1820 1825 2260 0100 1920 1915 2155 1900 2180 [...]

CR/EN (1004) 4.0 Parts 45 CombiPro 9.2.2 Parts list pump Item Quantity Description API-610 Mater ial Classes S-1 S-6 S-8 C-6 A-8 0100 1 pump casing carbon steel c hrome st eel stainless steel 0110 1 pump cover carbon steel chrome steel st ainless steel 0120 3) 1 impeller cast iron c hrome s teel st ainle ss steel c hrome steel st ainless steel 0130[...]

46 Parts CR/EN (1004) 4.0 * For Class S-6, the standard shaft material for boiler feed service and for liquid temperatures above 175°C is chrome steel ** Quantity depend s on pump type *** Quantity depends on bearing group **** For bearing group 3 quantity 1 2190 2**** set screw stainless steel 2200 3) 1p u m p s h a f t 4140 steel *) stainless st[...]

CR/EN (1004) 4.0 Parts 47 CombiPro 9.3 Mec hanical seal piping pl an 11 - tubing 9.3.1 Drawing pl an 11 - tubing 9.3.2 Parts list plan 11 - tubing Figure 14: Drawing plan 11 - tubing. Item Quantity Description API-610 Material Classes S-1 S-6 S-8 C-6 A-8 1400 1 pipe nipple stainless steel 1410 1 female connector stainless steel 1420 1 pipe stainles[...]

48 Parts CR/EN (1004) 4.0 9.4 Mec hanical seal piping pl an 11 - fl anged 9.4.1 Drawing pl an 11 - flanged 9.4.2 Parts list plan 11 - flanged Figure 15: Drawing plan 11 - flanged. Item Quantity Description API-610 Material Classes S-1 S-6 S-8 C-6 A-8 2000 4 stud bolt carbon steel 2010 1 welding nec k flange + pipe nipple stainless steel 2015 1 pipe[...]

CR/EN (1004) 4.0 Parts 49 CombiPro 9.5 Oil c hamber jack et 9.5.1 Drawing oil c hamber jacket 9.5.2 Parts list oil c hamber jacket Figure 16: Drawing oil chamber jacket. Item Quantity Description API-610 Material Classes S-1 S-6 S-8 C-6 A-8 0330 1 plug stainless steel 0340 2 plug stainless steel 2840 6 bolt stainless steel 2845 6 washer stainless s[...]

50 Parts CR/EN (1004) 4.0 9.6 P ump casing jac ket 9.6.1 Drawing pump casing jac ket 9.6.2 Parts list pu mp casing j acket Figure 17: Drawing pump casing jacket. Item Quantit y Description API-610 Material Classes S-1 S-6 S-8 C-6 A-8 0100 1 pump casing jac ket carbon steel stainless steel 0100[...]

CR/EN (1004) 4.0 Technical data 51 CombiPro 10 T ec hnical data 10.1 T ightening moments 10.1.1 Tightening mome nts for bolts and nuts ! For nuts for pump casing (item 0810), see p aragraph 10.1.3 "T orques settings for nuts for pump casing"! 10.1.2 Tightening mome nts for cap nut T able 5: Tightening moments for bolts and nuts. Materials[...]

52 Technical data CR/EN (1004) 4.0 10.1.3 T orques settings for nuts for pump casing T able 7: T orques settings fo r nuts (0810) for pump casing B earing group Size Lubricated Not-lubricated [Nm] [Nm] 40A-125 1 M10 (8x) 40 47 40A-160 1 M12 (8x) 69 80 40AA-160 1 M12 (8x) 69 80 40A-200 1 M12 (8x) 71 83 40A-250 2 M12 (12x) 71 82 50A-125 1 M10 (8x) 40[...]

CR/EN (1004) 4.0 Technical data 53 CombiPro 10.2 Permissible forces and moments on the flanges Forces and momen ts acting on the pump flanges due to pipe loads can cause misa lignment of the pump and driver shafts, deformation and overstressing of the pump casing, or overstressing of the fixing bolts be tween the pump and the base plate. Figure 18:[...]

54 Technical data CR/EN (1004) 4.0 10.2.1 Allowable forces and moments on suction and dis charge flan ges Pump mounted on a grouted base plate of carbon steel Fr , Mr = result ant T able 8: A ccording API 610 - table 4 "Nozzle loadings" Allowable fo rces [N] Allowable moments [Nm] Allowable forces [N] Allowable moments [Nm] Suction Discha[...]

CR/EN (1004) 4.0 Technical data 55 CombiPro 10.2.2 Allowable forces and moments o n the drain flange Pump mounted on a grouted base plate of carbon steel Fr , Mr = result ant 10.3 Lubricants 10.3.1 Oil 10.3.2 Oil contents T able 9: A ccording API 610 - table 4 "Nozzle loadings" Allowable forces [ N] Allowable moments [Nm] F x F y F z F r [...]

56 Technical data CR/EN (1004) 4.0 10.4 Hydraulic performance 10.4.1 Performance overview cast st eel material class S-1 Figure 19: Performance overview 3000 min -1 . Figure 20: Performance overview 1500 min -1 .[...]

CR/EN (1004) 4.0 Technical data 57 CombiPro Figure 21: Performance overview 3600 min -1 . Figure 22: Performance overview 1800 min -1 .[...]

58 Technical data CR/EN (1004) 4.0 10.4.2 Performance ove rview materi al classes S-6, S-8, C-6, A-8 Figure 23: Performance overview 3000 min -1 . Figure 24: Performance overview 1500 min -1 .[...]

CR/EN (1004) 4.0 Technical data 59 CombiPro Figure 25: Performance overview 3600 min -1 . Figure 26: Performance overview 1800 min -1 .[...]

60 Technical data CR/EN (1004) 4.0 10.5 Noise data 10.5.1 Pump noise as a function of pump power Figure 27: Noise level as function of pump power [kW] at 1450 min -1 A = sound energy , B = sound pressure. Figure 28: Noise level as function of pump power [kW] at 2900 min -1 A = sound energy , B = sound pressure. 54 56 58 60 62 64 66 68 70 72 74 76 7[...]

CR/EN (1004) 4.0 Technical data 61 CombiPro 10.5.2 Noise level of entire pump unit In order to determine the total noise level of the entire pump unit, the noise leve l of the motor must be added to that of the pump. T his can be easily done by using the graph above. 1 Determine the noise level (L1) of th e pump, see figure 27 or figure 28. 2 Deter[...]

62 Technical data CR/EN (1004) 4.0[...]

CR/EN (1004) 4.0 63 CombiPro Index A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 23 Application area . . . . . . . . . . . . . . . . . . . . . 17 Applications . . . . . . . . . . . . . . . . . . . . . . . . . 13 B Back-Pull-Out unit assembling . . . . . . . . . . . . . . . . . . . . . . 32 disassembly . . . . . . . . . . . . . . .[...]

64 CR/EN (1004) 4.0 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 28 O Oil contents . . . . . . . . . . . . . . . . . . . . . . . . . 55 P Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Performance overview . . . . . . . . . . . . . . . . 56 Pe[...]

ORDFORM (0804) 3.1 EN 65 Order form for spare parts Y our order will only be dealt w ith if this or der form has been correctly completed and signed. FA X N r . AD D R E S S Order date: Y our order nu mber: Pum p ty pe : Execution: Quantity Item. No. Part Article number pump Delivery address: Invoicing address: Ordered by: Signature: T elephone:[...]

66 ORDFORM (0804) 3.1 EN[...]

Your local contact: SPX Process Equipment NL B.V. Dr. A. F. Philipsw eg 51, 9403 AD Assen, THE NETHERLANDS P.O. Box 9, 9400 AA Assen, THE NETHERLANDS Phone: + 31 (0 ) 592 37 67 67 F ax: + 31 (0) 592 37 67 60 E-Mail: johnson-pump.nl@p rocessequip ment.spx.com For more information about our worldwide locations, approval s, certifications, and local r[...]