USER INSTRUCTIONS
Worthington® WUC centrifugal pumps
Vertical, Multistage Can Type
Original Instructions
PCN=71569264, 71569265, 71569266, 71569267 07-14 (E)
Installation
Operation
Maintenance
CONTENTS |
|
|
PAGE |
1.0 INTRODUCTION AND SAFETY............................ |
3 |
1.1 GENERAL ................................................................. |
3 |
1.2 CE MARKING AND APPROVALS ................................ |
3 |
1.3 DISCLAIMER ............................................................. |
3 |
1.4 COPYRIGHT ............................................................. |
3 |
1.5 DUTY CONDITIONS ................................................... |
3 |
1.6 SAFETY .................................................................... |
4 |
1.7 WARNING LABEL ...................................................... |
8 |
1.8 SPECIFIC MACHINE PERFORMANCE......................... |
9 |
1.9 NOISE LEVEL............................................................ |
9 |
1.10 CE DECLARATION ............................................... |
11 |
2.0 TRANSPORT AND STORAGE............................ |
12 |
2.1 CONSIGNMENT RECEIPT AND UNPACKING............. |
12 |
2.2 HANDLING .............................................................. |
12 |
2.3 LIFTING .................................................................. |
12 |
2.4 STORAGE ............................................................... |
13 |
2.5 RECYCLING AND END OF PRODUCT LIFE ............... |
13 |
3.0 DESCRIPTION........................................................ |
13 |
3.1 CONFIGURATION.................................................... |
13 |
3.2 NOMENCLATURE.................................................... |
14 |
3.3 DESIGN OF MAJOR PARTS ..................................... |
14 |
3.4 PERFORMANCE AND OPERATING LIMITS ............... |
14 |
4.0 INSTALLATION...................................................... |
14 |
4.1 LOCATION .............................................................. |
14 |
4.2 PART ASSEMBLIES ................................................ |
15 |
4.3 FOUNDATION ......................................................... |
15 |
4.4 INITIAL ALIGNMENT................................................. |
18 |
4.5 PIPING.................................................................... |
19 |
4.6 ELECTRICAL CONNECTIONS................................... |
23 |
4.7 FINAL SHAFT ALIGNMENT CHECK........................... |
23 |
4.8 PROTECTION SYSTEMS.......................................... |
23 |
5.0 COMMISSIONING START-UP, OPERATION |
|
AND SHUTDOWN ........................................................ |
23 |
5.1 PRECOMMISSIONING PROCEDURE ........................ |
23 |
5.2 PUMP LUBRICANTS................................................ |
24 |
5.3 IMPELLER CLEARANCE........................................... |
30 |
5.4 DIRECTION OF ROTATION ...................................... |
31 |
5.5 GUARDING ............................................................. |
31 |
5.6 PRIMING AND AUXILIARY SUPPLIES ....................... |
31 |
5.7 COOL DOWN PROCEDURE FOR CRYOGENIC |
|
SERVICE ....................................................................... |
32 |
5.8 STARTING THE PUMP ............................................. |
33 |
5.9 OPERATION............................................................ |
33 |
5.10 STOPPING AND SHUTDOWN ................................ |
33 |
5.11 HYDRAULIC, MECHANICAL AND ELECTRICAL DUTY |
|
..................................................................................... |
34 |
WUC USER INSTRUCTIONS ENGLISH - 07/14
6.0 MAINTENANCE ..................................................... |
34 |
6.1 GENERAL ............................................................... |
34 |
6.2 MAINTENANCE SCHEDULE..................................... |
35 |
6.3 SPARE PARTS ........................................................ |
35 |
6.4 RECOMMENDED SPARES....................................... |
36 |
6.5 FASTENER TORQUES............................................. |
36 |
6.6 SETTING IMPELLER CLEARANCE............................ |
37 |
6.7 DISASSEMBLY........................................................ |
37 |
6.8 EXAMINATION OF PARTS........................................ |
40 |
6.9 ASSEMBLY ............................................................. |
41 |
7.0 AUXILIARIES ......................................................... |
43 |
7.1 SEAL AND SEAL SYSTEMS ..................................... |
43 |
7.2 CHANGING OF MECHANICAL SEAL.................... |
46 |
7.3 CHANGING OF MECHANICAL SEAL.................... |
46 |
8.0 FAULTS; CAUSES AND REMEDIES ................ |
47 |
9.0 CERTIFICATION.................................................... |
49 |
10.0 OTHER RELEVANT DOCUMENTATION AND |
|
MANUALS ..................................................................... |
49 |
10.1 SUPPLEMENTARY USER INSTRUCTIONS.............. |
49 |
10.2 CHANGE NOTES................................................... |
49 |
10.3 ADDITIONAL SOURCES OF INFORMATION ............ |
49 |
10.4 ABBREVIATIONS .................................................. |
50 |
Page 2 of 52
1.0INTRODUCTION AND SAFETY
1.1General
These Instructions must always be kept close to product's operating location or directly with the product.
Flowserve's products are designed, developed and manufactured with state-of-the-art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilising sophisticated quality techniques, and safety requirements.
Flowserve is committed to continuous quality improvement and being at service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services.
These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.
These instructions must be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety, noted in the instructions, have been met. Failure to follow and apply the present user instructions is considered to be misuse. Personal injury, product damage, delay or failure caused by misuse are not covered by the Flowserve warranty.
1.2 CE marking and approvals
It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially Explosive Atmospheres (ATEX).
Where applicable the Directives, and any additional Approvals, cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable this document incorporates information relevant to these Directives.
WUC USER INSTRUCTIONS ENGLISH - 07/14
To establish Approvals and if the product itself is CE Marked check the serial number plate and the Certification.
1.3 Disclaimer
Information in these User Instructions is believed to be reliable. In spite of all the efforts of Flowserve Corporation to provide sound and all necessary information the content of this manual may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy.
Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organisations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorised Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve's warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.
1.4 Copyright
All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.
The product must not be operated beyond the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice, quoting the serial number.
If the conditions of service on your purchase order are going to be changed (for example liquid pumped, temperature or duty) it is requested that the user seeks Flowserve´s written agreement before start up.
Page 3 of 52
1.6 Safety
1.6.1 Summary of safety markings
These user instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are:
This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.
This symbol indicates safety instructions where non-compliance would affect personal safety and could result in loss of life.
This symbol indicates "hazardous and toxic fluid" safety instructions where non-compliance would affect personal safety and could result in loss of life.
This symbol indicates safety instructions where non-compliance will involve some risk to safe operation and personal safety and would damage the equipment or property.
This symbol indicates "strong magnetic field" safety instructions where non-compliance would affect personal safety, pacemakers, instruments or stored data sensitive to magnetic fields.
This symbol indicates explosive atmosphere marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.
This symbol is used in safety instructions to remind not to rub non-metallic surfaces with a dry cloth; ensure the cloth is damp. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.
The sign is not a safety symbol but indicates an important instruction in the assembly process.
This symbol indicates potential risks connected with extremely high temperatures.
This symbol indicates potential risks connected with extremely low temperatures.
WUC USER INSTRUCTIONS ENGLISH - 07/14
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation, inspection and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required the operator may commission the manufacturer / supplier to provide applicable training.
Always co-ordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.
1.6.3 Safety action
This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment. For products used in potentially explosive atmospheres section 1.6.4 also applies.
PREVENT EXCESSIVE EXTERNAL PIPE LOAD
Do not use pump as a support for piping. Do not mount expansion joints so that their force, due to internal pressure, acts on the pump flange.
ONLY CHECK DIRECTION OF MOTOR ROTATION WITH COUPLING ELEMENT/ PINS REMOVED
Starting in reverse direction of rotation will damage the pump.
ENSURE CORRECT LUBRICATION
(See section 5 Commissioning, startup, operation and shutdown.)
START THE PUMP WITH OUTLET VALVE PART OPENED
(Unless otherwise instructed at a specific point in the user instructions.)
This is recommended to avoid the risk of overloading and damaging the pump motor at full or zero flow. Pumps may be started with the valve further open only on installations where this situation cannot occur. Pump outlet valve shall be adjusted to comply with the duty following the run-up process (See section 5 Commissioning, startup, operation and shutdown).
START THE PUMP WITH OUTLET VALVE FULLY OPEN
This is recommended to avoid the risk of overloading and damaging the pump motor where greater power is taken at low or shut off flow. Pump outlet valve shall be adjusted to comply with the duty following the
Page 4 of 52
run-up process (See section 5 Commissioning, startup, operation and shutdown).
NEVER RUN THE PUMP DRY
INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING
Running the pump at zero flow or below the recommended minimum flow continuously will cause damage to the seal.
DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure on the pump may overload the motor and cause cavitation. Low flow rates may cause a reduction in pump/bearing life, overheating of the pump, instability and cavitation/vibration.
When ambient temperatures are likely to drop below freezing point, the pump and any cooling and flushing arrangements must be drained or otherwise protected.
HANDLING COMPONENTS
Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components. To lift heavy pieces above 25 kg (55 lbs) use a crane corresponding to the mass and in accordance with current local regulations.
NEVER DO MAINTENANCE WORK WHILST THE UNIT IS CONNECTED TO POWER
HAZARDOUS LIQUIDS
When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate sitting of the pump, limiting personnel access and by operator training. If the liquid is flammable and/or explosive strict safety procedures must be applied.
Gland Packing must not be used when pumping hazardous liquids.
DRAIN PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP
The appropriate safety precautions should be taken where the pumped liquids are hazardous.
FLUORO-ELASTOMERS (When fitted) When a pump has experienced temperatures over 250 °C (482 ºF), partial decomposition of fluoroelastomers (example: Viton) will occur. In this
WUC USER INSTRUCTIONS ENGLISH - 07/14
condition these are extremely dangerous and skin contact must be avoided.
GUARDS MUST NOT BE REMOVED WHILE PUMP IS OPERATIONAL
THERMAL SHOCK
Rapid changes in the temperature of the liquid within the pump can cause thermal shock, which can result in damage or breakage of components and should be avoided.
NEVER APPLY HEAT TO REMOVE IMPELLER
Trapped lubricant or vapour could cause an explosion.
HOT AND COLD PARTS
If hot or freezing components or auxiliary heating supplies can present a danger to operators, they must be shielded to avoid accidental contact. If complete protection is not possible, the machine access must be limited to maintenance staff only. Note: bearing housings must not be insulated and drive motors and bearings may be hot.
If the temperature is greater than 68 °C (155 °F) o r below 5 °C (41 °F) in a restricted zone, or exceeds local regulations, action as above shall be taken.
1.6.4 Products used in potentially explosive atmospheres
Measures are required to:
∙Avoid excess temperature
∙Prevent build up of explosive mixtures
∙Prevent the generation of sparks
∙Prevent leakages
∙Maintain the pump to avoid hazard
The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection. Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC.
1.6.4.1 Scope of compliance
Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling assembly, seal and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they are to be installed.
Where Flowserve has supplied only the bare shaft pump, the Ex rating applies only to the pump. The
Page 5 of 52
party responsible for assembling the pump set shall select the coupling, driver and any additional equipment, with the necessary CE Certificate/ Declaration of Conformity establishing it is suitable for the area in which it is to be installed.
The output from a variable frequency drive (VFD) can cause additional heating affects in the motor and so, for pump sets with a VFD, the ATEX Certification for the motor must state that it covers the situation where electrical supply is from the VFD. This is particular requirement still applies even if the VFD is in a safe area.
1.6.4.2 Marking
An example of ATEX equipment marking is shown below. The actual classification of the pump will be engraved on the nameplate.
II 2 GD c IIC135ºC (T4)
Equipment Group
I = Mining
II = Non-mining
Category
2 or M2 = High level protection
3 = normal level of protection
Gas and/or Dust
G = Gas; D= Dust
c = Constructional safety
(in accordance with EN13463-5)
b = Control of ignition source
(in accordance with EN13463-6) Gas Group
IIA – Propane (Typical)
IIB – Ethylene (Typical)
IIC – Hydrogen (Typical)
Maximum surface temperature (Temperature Class) (see section 1.6.4.3)
1.6.4.3 Avoiding excessive surface temperatures
ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE
Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on an ambient in the range of -80 to +55 ºC (-112 to +131 ºF); refer to Flowserve for ambient temperatures outside this range for this product.
The surface temperature on the pump is influenced by the temperature of the liquid handled. The maximum permissible liquid temperature depends on the ATEX temperature class and must not exceed the values in the table that follows.
WUC USER INSTRUCTIONS ENGLISH - 07/14
|
Maximum |
Temperature limit of liquid |
|
Temperature |
handled (* depending on |
||
surface |
|||
class to |
material and construction |
||
temperature |
|||
EN 13463-1 |
variant - check which is |
||
permitted |
|||
|
lower) |
||
|
|
||
T6 |
85 °C (185 °F) |
Consult Flowserve |
|
T5 |
100 °C(212 °F) |
Consult Flowserve |
|
T4 |
135 °C (275 °F) |
115 °C (239 °F) * |
|
T3 |
200 °C (392 °F) |
180 °C (356 °F) * |
|
T2 |
300 °C (572 °F) |
275 °C (527 °F) * |
|
T1 |
450 °C (842 °F) |
400 °C (752 °F) * |
* The table only takes the ATEX temperature class into consideration. Pump design or material, as well as component design or material, may further limit the maximum working temperature of the liquid.
The temperature rise at the seals and bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated.
The responsibility for compliance with the specified maximum liquid temperature is with the plant operator.
Temperature classification “Tx” is used when the liquid temperature varies and when the pump is required to be used in differently classified potentially explosive atmospheres. In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in its actual installed location.
Do not attempt to check the direction of rotation with the coupling element/pins fitted due to the risk of severe contact between rotating and stationary components.
Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures it is recommended that users fit an external surface temperature protection device.
Avoid mechanical, hydraulic or electrical overload by using motor overload trips or a Power Monitor and make routine vibration monitoring.
In dirty or dusty environments, regular checks must be made and dirt removed from areas around close clearances, bearing housings and motors.
Level control shall be fitted in the sump to prevent liquid level dropping below minimum acceptable.
It is recommended that a Service Plan with vibration monitoring is adopted, alternatively the user should fit external bearing housing surface temperature protection device(s) to ensure the temperature class, i.e. maximum surface temperature, is not exceeded. For external flush the flow should be monitored.
Page 6 of 52
1.6.4.4 Preventing the build up of explosive mixtures
ENSURE THE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY
Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation, so that an explosive atmosphere is prevented. In addition it is essential to make sure that seal chambers, auxiliary shaft seal systems and any heating and cooling systems are properly filled.
If the operation of the system cannot avoid this condition the fitting of an appropriate Dry Run protection device is recommended (eg liquid detection or a Power Monitor).
To avoid potential hazards from fugitive emissions of vapour or gas to atmosphere the surrounding area must be well ventilated.
1.6.4.5 Preventing sparks
To prevent a potential hazard from mechanical contact the coupling guard must be non-sparking and anti-static.
To avoid the potential hazard from random induced current generating a spark the earth contact on the baseplate must be used.
Avoid electrostatic charge: do not rub nonmetallic surfaces with a dry cloth; ensure cloth is damp.
The coupling must be selected to comply with 94/9/EC and correct alignment must be maintained.
1.6.4.5 Preventing leakage
The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance.
Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves, which could cause dangerous excessive pressures to occur if there is heat input to the liquid. This can occur if the pump is stationary or running.
Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and ancillary systems.
WUC USER INSTRUCTIONS ENGLISH - 07/14
Where there is the potential hazard of a loss of a seal barrier fluid or external flush, the fluid must be monitored.
If leakage of liquid to atmosphere can result in a hazard, the installation of a liquid detection device is recommended.
1.6.4.6 Maintenance to the centrifugal pump to avoid the hazard
CORRECT MAINTENANCE IS REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION
The responsibility for compliance with maintenance instructions is with the plant operator.
To avoid potential explosion hazards during maintenance, the tools, cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or materials, maintenance must be conducted in a safe area.
It is recommended that a maintenance plan and schedule is adopted (see section 6, Maintenance).to include the following.
a)Any auxiliary systems installed must be monitored, if necessary, to ensure they function correctly.
b)Gland packings must be adjusted correctly to give visible leakage and concentric alignment of the gland follower to prevent excessive temperature of the packing or follower.
c)Check for any leaks from gaskets and seals. The correct functioning of the shaft seal must be checked regularly
d)Check bearing lubricant level, and if the hours run show a lubricant change is required.
e)Check that the duty condition is in the safe operating range for the pump.
f)Check vibration, noise level and surface temperature at the bearings to confirm satisfactory operation.
g)Check dirt and dust is removed from areas around close clearances, bearing housings and motors.
h)Check coupling alignment and re-align if necessary.
Page 7 of 52
WUC USER INSTRUCTIONS ENGLISH - 07/14
1.7 Warning label
Page 8 of 52
WUC USER INSTRUCTIONS ENGLISH - 07/14
1.8 Specific machine performance
For performance parameters see section 1.5, Duty conditions. When the Contract requirement specifies these to be incorporated into user instructions these are included here. Where performance data has been supplied separately to the purchaser these should be obtained and retained with these user instructions if required.
1.9 Noise level
Attention must be given to the exposure of personnel to the noise, and local legislation will define when guidance to personnel on noise limitation is required, and when noise exposure reduction is mandatory. This is typically 80 to 85 dBA.
The usual approach is to control the exposure time to the noise or to enclose the machine to reduce emitted sound. You may have already specified a limiting noise level when the equipment was ordered, however if no noise requirements were defined, then attention is drawn to the following table to give an indication of equipment noise level so that you can take the appropriate action in your plant.
Pump noise level is dependent on a number of operational factors, flow rate, pipework design and acoustic characteristics of the building, and so the values given are subject to a 3 dBA tolerance and cannot be guaranteed.
Similarly the motor noise assumed in the “pump and motor” noise is that typically expected from standard and high efficiency motors when on load directly driving the pump. Note that a motor driven by an inverter may show an increased noise at some speeds.
If a pump unit only has been purchased for fitting with your own driver then the “pump only” noise levels in the table should be combined with the level for the driver obtained from the supplier. Consult Flowserve or a noise specialist if assistance is required in combining the values.
It is recommended that where exposure approaches the prescribed limit, then site noise measurements should be made.
The values are in sound pressure level LpA at 1 m (3.3 ft) from the machine, for “free field conditions over a reflecting plane”.
For estimating sound power level LWA (re 1 pW) then add 14 dBA to the sound pressure value.
Page 9 of 52
WUC USER INSTRUCTIONS ENGLISH - 07/14
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Octave MID BAND frequency [Hz] |
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dB(A) Value |
63 |
125 |
250 |
500 |
1 K |
2 K |
4 K |
8 K |
Motorstand 0 |
|
|
|
|
|
|
|
|
|
1450 rpm |
57 |
48 |
52 |
52 |
50 |
50 |
50 |
48 |
43 |
1760 rpm |
59 |
50 |
54 |
54 |
52 |
52 |
52 |
50 |
45 |
2900 rpm |
61 |
52 |
56 |
56 |
54 |
54 |
54 |
52 |
47 |
3600 rpm |
63 |
54 |
58 |
58 |
56 |
56 |
56 |
54 |
49 |
Motorstand 1 |
|
|
|
|
|
|
|
|
|
3000 rpm |
70 |
60 |
64 |
64 |
62 |
62 |
62 |
60 |
55 |
1500 rpm |
64 |
54 |
58 |
58 |
56 |
56 |
56 |
54 |
49 |
3600 rpm |
72 |
62 |
66 |
66 |
64 |
64 |
64 |
62 |
57 |
1800 rpm |
64 |
54 |
58 |
58 |
56 |
56 |
56 |
54 |
49 |
Motorstand 3 |
|
|
|
|
|
|
|
|
|
3000 rpm |
72 |
62 |
66 |
66 |
64 |
64 |
64 |
62 |
57 |
1500 rpm |
66 |
56 |
60 |
60 |
58 |
58 |
58 |
56 |
51 |
3600 rpm |
74 |
64 |
68 |
68 |
66 |
66 |
66 |
64 |
59 |
1800 rpm |
67 |
57 |
61 |
61 |
59 |
59 |
59 |
57 |
52 |
Motorstand 4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
3000 rpm |
73 |
63 |
67 |
67 |
65 |
65 |
65 |
63 |
58 |
1500 rpm |
68 |
58 |
62 |
62 |
60 |
60 |
60 |
58 |
53 |
1800 rpm |
69 |
59 |
63 |
63 |
61 |
61 |
61 |
59 |
54 |
Motorstand 5 |
|
|
|
|
|
|
|
|
|
3000 rpm |
74 |
64 |
68 |
68 |
66 |
66 |
66 |
64 |
59 |
1500 rpm |
69 |
59 |
63 |
63 |
61 |
61 |
61 |
59 |
54 |
1800 rpm |
70 |
60 |
64 |
64 |
62 |
62 |
62 |
60 |
55 |
Motorstand 6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1500 rpm |
70 |
60 |
64 |
64 |
62 |
62 |
62 |
60 |
55 |
1800 rpm |
71 |
61 |
65 |
65 |
63 |
63 |
63 |
61 |
56 |
Motorstand 7 |
|
|
|
|
|
|
|
|
|
1500 rpm |
71 |
61 |
65 |
65 |
63 |
63 |
63 |
61 |
56 |
1800 rpm |
72 |
62 |
66 |
66 |
64 |
64 |
64 |
62 |
57 |
Motorstand 8 |
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
1500 rpm |
73 |
63 |
67 |
67 |
65 |
65 |
65 |
63 |
59 |
1800 rpm |
74 |
64 |
68 |
68 |
66 |
66 |
66 |
64 |
60 |
|
|
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|
|
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|
|
Sound pressure readings are for information only and are not subject to guarantee by Flowserve/IDP.
Decibel readings do not include driver or system noise.
Pump tested at 100% of the best efficiency point at max.impeller diameter with water.
dB correction for combining noises (pump+motor)
Difference between two |
0 |
1 |
2 |
4 |
6 |
9 |
10 |
|
levels to be combined, dB |
||||||||
|
|
|
|
|
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|
||
Add to the higher level to obtain |
3 |
2.5 |
2 |
1.5 |
1 |
0.5 |
0 |
|
the combined noise level,dB |
||||||||
|
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Note :
1)The values showed are measured at a distance of 1 mt. (horizontally) from major pump surfaces and 1.5 mt. above the floor.
2)The values shown are expressed in dB (A)
3)For Noise Test Procedure refer to Works Standard L-109
4)The values shown have been derived from actual noise-test data and are based on the following conditions:
-Equipment is located in a free field above a reflecting plane in which the reductionin noise level in all directions is 6db in each octave band for each doubling of distance.
-Background noise is 10dB minimum below all noise levels in each octave band.
-The values shown are at a distance of 1 meter (horizontally) from the major pump surface and
1,5 meters above the floor, using a standard pressure reference of 0,00002 newton per square meter.
-Overall noise level, dB(A) is determined at points of maximum noise level and the values of all
mid-band frequences are basis A scale readings.
When the required condition flow is outside the range of 75 to 125% BEP, a part load correction (PLC) must be added to the noise level as follows:
Percent of BEP @ |
PLC in |
|
required impeller |
||
dB |
||
diameter |
||
|
||
74 to 62 or 126 to 136 |
+1 |
|
61 to 50 or 137 to 150 |
+2 |
|
49 to 38 |
+3 |
|
37 to 25 |
+4 |
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WUC USER INSTRUCTIONS ENGLISH - 07/14
1.10 CE Declaration
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2.0TRANSPORT AND STORAGE
2.1Consignment receipt and unpacking
Immediately after receipt of the equipment it must be checked against the delivery and shipping documents for its completeness and that there has been no damage in transportation.
Any shortage and or damage must be reported immediately to Flowserve and received in writing within one month of receipt of the equipment. Later claims cannot be accepted.
Check any crates, boxes and wrappings for any accessories or spare parts which may be packed separately with the equipment or attached to side walls of the box or equipment.
Each product has a unique serial number. Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories.
2.2 Handling
Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction.
2.3 Lifting
To avoid distortion, the pump unit should be lifted as shown.
For lifting the driver refer to the dimension drawing of driver.
2 holes Ø 45mm (1.77 in.) for lifting the pump without can and driver
4 pieces lifting screw according DIN 580 only for CAN lifting
Depending on the pump size the pump unit is packed separately from the Can, or is put partially into the Can.
A crane must be used for all pump sets in excess of 25 kg (55 lb).
Fully trained personnel must carry out lifting, in accordance with local regulations. The driver and pump weights are recorded
WUC USER INSTRUCTIONS ENGLISH - 07/14
on their respective nameplates.
In some cases the pumps are not complete assembled (refer to section 4, Installation).
If Can and supporting flange are delivered separately, lifting shall be performed as follows:
Suction barrel [1100.1] (also referred as ‘Can’) is supplied together with supporting flange [6110] and has to be installed into the sump first. Suction barrel and supporting flange are delivered assembled together. 4 distance sleeves are installed to fix both parts together.
Install 4 lifting screws (also referred as ‘Eye Bolts’) on the supporting flange and attach slings and straps to bring the suction barrel to a vertical position. Move the barrel for installation. Provide hand support to prevent the suction barrel from swaying during movement.
Distance sleeves are only used for fixing the base plate during transportation.
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2.4 Storage
If the pump will not be put immediately into service, it should be stored in a dry room. To avoid any damage during the storage period, the influence of any low or high frequency vibration must be totally inhibited. If the pump is delivered sealed in a plastic-wrapper, it is of max. importance to avoid any damage of that wrapper, because this will protect the pump against humidity. Therefore it must be checked if this wrapper has become cracked and if so, the wrapper must be renewed. If a vertical pump will be stored in horizontal position, be sure to support the pump sufficiently to avoid any deformation or bending of the pump.
To avoid the presence of dust and humidity on the driver, it shall also be wrapped in the same way.
WUC USER INSTRUCTIONS ENGLISH - 07/14
2.4.1 Long period storage
If the pump is delivered in a plastic bag, the preservations stand up for one year. If the storage period exceeds this time, the preservation must be checked and renewed. Also the air tight plastic bag must be changed. Moreover we recommend to order a Flowserve Service Engineer for checking the pump before the first start up.
2.5 Recycling and end of product life
At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and local regulations. If the product contains substances which are harmful to the environment, these should be removed and disposed of in accordance with current regulations. This also includes the liquids and or gases in the "seal system" or other utilities.
Make sure that hazardous substances are disposed of safety and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current regulations at all times.
3.0DESCRIPTION
3.1Configuration
The model WUC covers the highly engineered specialty end of the Flowserve family of double casing vertical turbine pumps. The pump line is based on a modular system, thus providing maximum design and operating flexibility. This is combined with specific design features, including stiff shaft construction, a self-contained axial thrust bearing housing and pressure containing parts certified to various international standards. Altogether, this makes the WUC the pump of choice for the most critical applications where space considerations or marginal NPSHA values preclude the use of a horizontal multistage pump.
Liquid is flowing through the suction flange of the headstock and through the Can to the impellers. The last stage impeller is discharging the liquid via the column pipes, to the discharge flange. The thrust is balanced by back wearing rings and balancing holes. The headstock is equipped with a drain connection, which allows to flush the Can with Nitrogen before disassembly.
A vent connection for the suction is standard.
The sense of rotation of the pump is counter clockwise (CCW), looking from the coupling to the shaft end of the pump.
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3.2 Nomenclature
Example:
200WUC-2M-5+I
200 Flow at BEP
WUC Pump type - Can
WUJ = without Can
2indicates speed 2–poles 4 = 4-poles
Mindicates hydraulic Medium Head L = Low Head
H = High Head
R = Radial Flow 5 Number of stages
I indicates Inducer as option
D Dummy stage as option
3.3 Design of major parts
3.3.1 Motor stool
The motor stool supports the thrust bearing. On top the driver is mounted.
3.3.2 Headstock
Headstock has inline suction and discharge nozzle, including all the necessary vent and drain connections. It is a major part of the pump unit, which supports the column pipes with the hydraulics as well as the motor stool and driver.
3.3.3 Can
The Can is subjected to suction pressure and guides the fluid to the first stage impeller.
3.3.4 Hydraulics
3.3.4.1 Radial flow hydraulics
This are ring section type hydraulics. Suction, stage and discharge casing are hold together by strong tie bolts, which allows a very compact and short design. The radial impellers are hydraulically balanced by back wear rings and balancing holes. The diffusers are designed with 7 to 11 vanes to minimize the radial forces at part load operation. All impellers are slipped on the shaft and axially fixed by the impeller nut. The shaft is supported in the suction casing, in every diffuser and in the discharge casing.
Optional the hydraulics can be fitted with an inducer for low NPSH requirement.
3.3.4.2 Mixed flow hydraulics
The hydraulics consists of flanged bowls and a suction casing. The impellers are hydraulically
WUC USER INSTRUCTIONS ENGLISH - 07/14
balanced by back wear rings and balancing holes. The diffusers are designed with 7 to 11 vanes to minimize the radial forces at part load operation. All impellers are slipped on the shaft and axially fixed by the impeller nut. The shaft is supported in the suction casing and in each bowl.
Optional the hydraulics can be fitted with an inducer for low NPSH requirement.
3.3.4.3 10WUC-2H
The hydraulic consists of bowls, which are pushed together and hold by strong tie bolts. The impellers are secured to the shaft by split rings. Due to the small size, the impellers are only equipped with front wear rings and therefore unbalanced.
Optional the hydraulics can be fitted with an inducer for low NPSH requirement.
3.3.4.4 20WUC-2L, 45WUC-2L, 80WUC-2L
The hydraulics consists of flanged bowls and a suction casing. The impellers are secured to the shaft by split rings. Due to the small size, the impellers are only equipped with front wear rings and therefore unbalanced.
Optional the hydraulics can be fitted with an inducer for low NPSH requirement.
3.4 Performance and operating limits
In the interest of operator safety the unit must not be operated above the nameplate conditions. Such operation could result in unit failure causing injury to operating personnel. Consult instruction book for correct operation and maintenance of the pump and its supporting components.
4.0 INSTALLATION
Equipment operated in hazardous locations must comply with the relevant explosion protection regulations, see section 1.6.4, Products used in potentially explosive atmospheres.
4.1 Location
The pump should be located to allow room for access, ventilation, maintenance and inspection with ample headroom for lifting and should be as close as practicable to the supply of liquid to be pumped.
Refer to the general arrangement drawing for the pump set.
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4.2 Part Assemblies
With exception of the Can the pumps are delivered completely mounted and adjusted; also the shaft seal is in the correct position. So no further axial alignment of the rotor is necessary. If drivers and/or seal systems are delivered separately, follow the assembly procedure in section 6.9.
Axial alignment and rotor setting axial adjustment need to be distinguished. For correct axial adjustment of the rotor refer to 5.3.1 Adjusting of the rotor.
4.3 Foundation
The foundation shall be located on a place that allows a minimum of pipe work and that is easily accessible for inspection during operation. According to the environment the foundation may consist of concrete or of steel. It must be rigid and heavy enough to absorb normal vibrations and shocks. The flange of the Can must be supported on the whole surface. It should be at least 20 – 30 mm
(0.8 – 1.2 in) higher than the surrounding to avoid the deposit of dust and humidity.
4.3.1 Vertical alignment
Vertical alignment is done with leveling screws. Use a spirit level for correct horizontal alignment of the baseplate.
The max. vertical misalignment is 0.5 mm/m pump length.
4.3.2 Steel foundation
When the pump unit is mounted directly on structural steel frame, it shall be well supported by constructural beams. It is recommended to check the natural frequency of the steel frame, because it shall not coincide with the pump speed. The flange of the Can has to be fixed on a flat surface with studs or hex screws, the exact horizontal alignment is very important!
4.3.3 Concrete foundation
A concrete foundation must have an exact horizontal alignment and must be placed on solid ground. First a basic foundation shall be built with square shaped holes for embedding the foundation bolts. After putting the Can in the foundation the proper alignment can be obtained by adjusting it with shims under the flange. Now insert the foundation bolts and grout the space between the basic foundation and the Can with grouting cement (refer to illustration)
It is very helpful to use a properly made and stable wooden frame around the Can. So the grouting cement will not flow a side. When the grouting is totally set and hardened the foundation bolts shall be tightened in a firm and symmetrical way.
WUC USER INSTRUCTIONS ENGLISH - 07/14
4.3.4 Final assembly for not complete assembled pumps
Pumps exceeding a total length of approximately 6 m (19.7 ft) are delivered in various components and must be assembled on site. The main parts are: hydraulic bowls section - various line shafts and column pipes - headstock and thrust bearing.
To install the pump in the Can, clamps for the column pipes are delivered with the pump.
1)Mount the first rising main column pipe [1350.3] and line shaft to the already assembled hydraulic section.
1350.3
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2)Mount a clamp to the column pipe. The clamp has lifting lugs, which allow to use a crane for lowering this assembly into the pit (see picture).
clamp
3)Connect the next line shaft (refer to section 6, Maintenance) and put on the next rising main column pipes [1350.2] (see picture) by using a second clamp.
4)Now the assembly consists of the hydraulic section and two column sections. This assembly is taken by a crane using the second clamp.
5)Take off the first clamp and lowering down the assembly until the clamp is supported by the wooden frame (see picture).
WUC USER INSTRUCTIONS ENGLISH - 07/14
second clamp
1350.2
Repeat step 1 to 5 until the pump is completely assembled.
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