Munsch NPC, MPC, MPC-B, NPC-B Operating Manual
Standard Chemical Pump
Operating manual NPC series
Version BA-2005.07
Print-Nr. 02
VM-Nr. EN
Munsch Chemie-Pumpen GmbH
Im Staudchen
56235 Ransbach-Baumbach
Germany
Phone: +49 (0) 26 23-8 98-90
Fax: +49 (0) 26 23-8 98-95
E-mail: munsch@munsch.de
Internet: http://www.munsch.de
Technical alterations reserved.
Table of contents
Table of contents
1 About this document ............................... 6
1.1 Target groups ................................. 6
1.2 Other applicable documents . .. . .. . .. .. . .. . . 6
1.3 Warning labels and symbols ................ 7
1.4 Technical terms ............................... 7
2 Security ... ........................................... 8
2.1 Intended use ........ .......................... 8
2.2 General safety instructions .................. 8
2.2.1 Product safety ......... ....................... 8
2.2.2 Duties of the operating company . . . .. . .. . .. 9
2.2.3 Duties of the operating personnel . . .. .. . .. . . 9
2.3 Special hazards ............ .................. 9
2.3.1 Explosion hazard area ..................... .. 9
2.3.2 Hazardous pumped media . .. . . .. . .. . .. .. . .. 9
3 Layout and function ................................ 10
3.1 Labels ............ ............................. 10
3.1.1 Type plate ........................... .......... 10
3.1.2 ATEX plate ....................... ............. 10
3.1.3 Pump type code . .. . . . .. . .. . .. .. . .. . .. .. . .. . .. 10
3.2 Layout ............... .......................... 11
3.3 Shaft seals ............... ..................... 11
3.3.1 Mechanical seals ........ ..................... 11
3.4 Auxiliary operating systems ................. 12
3.4.1 Sealing systems ....................... ....... 12
4 Transport, storage and disposal .................. 13
4.1 Transport .................... .................. 13
4.1.1 Unpacking and inspection on delivery .. . .. . 13
4.1.2 Lifting .. ........................................ 13
4.2 Preservation ..................... ............. 14
4.3 Storage ................................ ....... 14
4.4 Disposal ............................. .......... 14
5 Setup and connection ............................ .. 15
5.1 Preparing the setup ................... ....... 15
5.1.1 Checking the ambient conditions . ... .. .. . .. 15
5.1.2 Preparing the setup site ..................... 15
5.1.3 Preparing the foundation and setup
surface ........................................ 15
5.1.4 Installing the heat insulation .. .. . .. .. . ... .. .. 15
5.2 Setup with foundation ........... ............. 16
5.2.1 Setting the pum p aggregate on the
foundation .... ................................ 16
5.2.2 Fastening the pump aggregate .. . .. . ... . .. . 16
5.3 Setup without foundation ..... ............... 17
5.4 Mounting the moto
5.5 Planning the piping .... ....................... 17
5.5.1 Avoid contamination of the piping . . .. . .. .. . . 17
5.5.2 Specifying supports and flange
connections . . .. . ... . .. . .. . .. .. . .. . .. .. . ... . .. . 17
r ..........................
17
5.5.3 Specifying nominal widths ................... 18
5.5.4 Specifying pipe lengths .................. .... 18
5.5.5 Optimizin g cross-section and direction
changes ....................................... 18
5.5.6 Arranging for safety and control devices
(recommended) .............................. 18
5.6 Connecting the pipes ........................ 18
5.6.1 Installing auxiliary pipes ................... .. 18
5.6.2 Installing the suction pipe . . ... . .. . .. . . .. . .. . . 18
5.6.3 Installing the pressure pipe . .. . ... . .. . ... .. .. 18
5.6.4 Inspection for stress-free pipe
connections . . .. . ... . .. . .. . .. .. . .. . .. .. . ... . .. . 19
5.6.5 Inspecting the support foot for
distortion .................... .................. 19
5.7 Electrical connection ......................... 19
5.7.1 Connecting the motor ........................ 19
5.7.2 Checking the direction of rotation .. . .. . . .. . . 19
5.8 Fine alignment of the coupling . ... . .. . .. . . .. 20
5.9 Aligning the motor .......... .................. 20
5.9.1 Aligning the motor using sets of shims . .. . . 20
6Operation ............................................ 21
6.1 Preparations for the initial start-up .. .. . . . .. . 21
6.1.1 Identifying the pump type ....... ............. 21
6.1.2 Lubricating the bearings ..................... 21
6.1.3 Preparing auxiliary operating syste ms (if
available) ........ ............................. 21
6.1.4 Filling and bleeding .......................... 21
6.2 Start up ....................................... 22
6.2.1 Switching on .................................. 22
6.2.2 Switching off .................................. 22
6.3 Shut-down ..................... ............... 23
6.4 Start-up following a shutdown period .. . .. . . 23
6.5 Running the stand-by pump .. ............... 23
7 Maintenance . ........................................ 24
7.1 Inspections . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. 24
7.2 Maintenance ........ .......................... 24
7.2.1 Roller bearings with grease lubrication ... . . 24
7.2.2 Roller bearings with oil lubrication . . . .. . .. . . 25
7.2.3 Stationary seal rings .. ....................... 25
7.3 Disassembling . . .. . .. . . .. . .. . .. .. . .. . .. .. . .. . . 25
7.3.1 Returning the pump to the manufac-
turer ................................. .......... 26
7.3.2 Preparations for disassembl ing . . ... . .. . .. . . 26
7.3.3 Loosening connectors (if available) . .. . .. . .. 2 7
7.3.4 Extract ing the volute casing . ... . .. . .. . . .. . .. 27
7.3.5 Disassemblin g the impeller .. .. . ... . .. . .. . . .. 27
7.3.6 Disassemblin g a casing cover with
MUNSCH-REA-C mechanical seal .. . .. .. . . 28
7.3.7 Disassemblin g the atmosphere-side
stationary seal ring ........................... 28
7.3.8 Disassemblin g the bearing bracket . ... . .. . . 29
7.3.9 Disassemblin g the pump shaft . ... . .. . .. . . .. 29
7.4 Assembli
ng ...... .............................
30
2 NPC series BA-2005.07 EN – 02
7.4.1 Preparations for assembling . ... . .. . ... .. .. . 30
7.4.2 Fitting the pump shaft ........ ................ 30
7.4.3 Fitting the bearing bracket . .. . .. . . .. . .. . .. .. . 30
7.4.4 Fitting the casing cover . . .. . ... . .. . .. . .. .. . .. 30
7.4.5 Fitting the pump into the installation . .. . . .. . 30
7.5 Ordering replacement parts ................. 30
8 Disturbance recovery ........... ................... 31
9 Appendix ....... ...................................... 34
9.1 Sectional drawings ........................... 34
9.1.1 Part numbers and designations ............. 34
9.1.2 Overview sect ional drawing . .. . ... . .. . ... .. . 36
9.1.3 Variants .................................. ..... 36
9.2 Technical specifications ................. ..... 40
9.2.1 Ambient conditions ..... ...................... 40
9.2.2 Paramet ers for auxiliary operating
systems ............................ ........... 40
9.2.3 Noise pressure level .. . ... . .. . .. . . .. . .. . .. .. . 40
9.2.4 Tightening torques ........................... 41
9.2.5 Lubricants . . .. . .. .. . ... .. .. . ... .. .. . ... .. .. . ... 42
9.2.6 Detergents .................................... 42
9.2.7 Socket loads according to ISO 5199 .. . . .. . 42
9.3 Replacement parts for 2 years of continuous
operation according to DIN 24296 .. . .. . .. .. 43
Table of contents
EN – 02 BA-2005.07 NPC series 3
Table of contents
List of figures
Fig. 1 Type plate (example) .................... .... 10
Fig. 2 ATEX plate (example) ................. ....... 10
Fig. 3 Pump type code (example) . . .. . ... . .. . .. . .. . 10
Fig. 4 Layout NPC ......................... .......... 11
Fig. 5 Double mechanical seal with quench
(operating principle) ................ .......... 12
Fig. 6 Double mechanical seal with foreign blocking
(operating principle) ................ .......... 12
Fig. 7 Fastening the lifting gear to the pump
aggregate ..................................... 13
Fig. 8 Fastening the lifting gear to the pump . . .. . . 13
Fig. 11 Setup without foundation ..... ............... 17
Fig. 12 Straight pipe lengths upstream and down-
stream of the pump (recommended) . .. . ... 18
Fig. 16 Oil level in sight glass .............. .......... 21
Fig. 17 Loosening the flushing connector or supply
connectors REA-C/D .. . ... . .. . .. . .. .. . ... .. .. 27
Fig. 18 Extracting the volute casing .. . ... . .. . ... . .. . 27
Fig. 19 Disassembling the impeller . . . . .. . .. . .. .. . .. . 27
Fig. 20 Disassembling a casing cover with
MUNSCH-REA-C mechanical seal .. . .. .. . . 28
Fig. 21 Disassembling MUNSCH-REA-D stationary
seal ring ................ ....................... 28
Fig. 22 Disassembling the bearing bracket (grease
lubrication, L16A, L18B, L20A) .. . .. . .. .. . .. . 29
Fig. 23 Disassembling the pump shaft (no lifetime
lubrication) .................................... 29
Fig. 24 Disassembling the pump shaft (with lifetime
lubrication) .................................... 29
Fig. 25 Fitting the casing cover .................. .... 30
Fig. 26 NPC – overview sectional drawing . ... . .. . . 36
Fig. 27 NPC – casing foot .......... .................. 36
Fig. 28 Emptying (optional) .......................... 36
Fig. 29 MUNSCH-REA-C single mechanical
seal ....................... ..................... 37
Fig. 30 MUNSCH-REA-C/D double mechanical
seal ....................... ..................... 37
Fig. 31 Stationary seal ring holder (o
mechanical seal) ............................. 37
Fig. 32 Shutdown/continuous flushing (flushing of
pump interior) ............ ..................... 37
Fig. 33 Single mechanical seal with spring chamber
flushing (supply connectors) . .. . .. . .. .. . .. . . 37
Fig. 34 MUNSCH-REA-C/
tors ............ ................................ 38
Fig. 35 Casing cover (split) ................ .......... 38
D supply connec-
nly for double
Fig. 36 Bearing bracket L16A (grease-lubricated
bearing) ....................................... 38
Fig. 37 Bearing bracket L16A (grease-lubricated
bearing, lifetime lubrication) ................. 38
Fig. 38 Bearing bracket L16A (oil-lubricated
bearing) ....................................... 39
Fig. 39 Bearing bracket L18B (grease-lubricated
bearing) ....................................... 39
Fig. 40 Bearing bracket L18B (oil-lubricated
bearing) ....................................... 39
Fig. 41 Blocking – pressure of sealing medium . . ... 40
Fig. 42 Socket loads at the pump ... . .. . .. . .. .. . .. . . 42
4 NPC series BA-2005.07 EN – 02
List of tables
Tab. 1 Target groups and their duties . .. .. . ... .. .. . 6
Tab. 2 Other applicable documents and their
purpose ....................................... 6
Tab. 3 Warning labels and consequences of
disregarding them .................... ........ 7
Tab. 4 Symbols and their meaning ................. 7
Tab. 5 Technical terms and their meaning .. . .. . .. . 7
Tab. 6 Quenching – variants and characteris-
tics ............... .............................. 12
Tab. 7 Foreign blocking – variants and
characteristics ............................. ... 12
Tab. 8 Action to be taken for pump shutdowns . ... . 23
Tab. 9 Measures depending on pumped medium
behavior ....................... ................ 23
Tab. 10 Actions to be taken after prolon ged shutdow n
periods ....... ................................. 23
Tab. 11 Actions for return ........................ ..... 26
Tab. 12 Fault/number assignment .. . .. . .. .. . .. . .. .. . 31
Tab. 13 Troubleshooting list .......................... 33
Tab. 14 Designations of components listed with part
numbers ................................. ..... 35
Tab. 15 Ambient conditions ................ ........... 40
Tab. 16 Operating parameters for sealing medium in
open flow system ....... ...................... 40
Tab. 17 Noise pressure level . .. . .. .. . ... . .. . .. . .. .. . . 40
Tab. 18 Steel/cast pairing . .. . .. .. . .. . .. .. . .. . . .. . .. . .. 41
Tab. 19 Socket head cap screw 914.1 - steel/steel
pairing ......................................... 41
Tab. 20 Lubricating greases .......................... 42
Tab. 21 Minimum amounts for grease lubrica-
tion ............................................ 42
Tab. 22 Lubricating oils ............................... 42
Tab. 23 Minimum amounts for oil lubrication . . .. . ... 42
Tab. 24 Detergents ... ................................. 42
Tab. 25 Socket loads – forces .. ... .. .. . ... .. .. . ... .. . 42
Tab. 26 Socket loads – torques . . . .. . .. . .. .. . .. . .. .. . 42
Tab. 27 Replacement parts for 2 years' continuous
operation ..... ................................. 43
Table of contents
EN – 02 BA-2005.07 NPC series 5
About this document
1 About this document
This manual
• is part of the pump
• applies to the pump series mentioned above
• describes safe and appropriate operation during all operating phases
1.1 Target groups
Target group Duty
Operating company Keep this manual available at the site of operation of the
installation, including for later use.
Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
information and warnings.
Observe any additional rules and regulation referring to the
installation.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable
documents, especially all safety information and warnings.
Tab. 1 Target groups and their duties
1.2 Other applicable documents
Document Purpose
ATEX additional instructions
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions, etc.
Technical description
Sectional drawing Sectional drawing, parts numbers, component designations
Supplier documentation Technical documentation for parts supplied by subcontractors
Replacement parts list
Safety certificate Returning the pump to the manufacturer
Tab. 2 Other applicable documents and their purpose
Operation in explosion hazard areas
Technical specifications, operating limits
Ordering replacement parts
6 NPC series BA-2005.07 EN – 02
1.3 Warning labels and symbols
About this document
Warning label Risk level
Immediate acute risk Death, grievous bodily harm
DANGER
Potential acute risk Death, grievous bodily harm
WARNING
Potential hazardous situation Minor bodily harm
CAUTION
Potential hazardous situation Material damage
CAUTION
Tab. 3 Warning labels and consequences of disregarding them
Symbol
1. , 2. , ...
→
Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the respective instructions to avoid injury or death.
Safety instruction
Step-by-step safety instructions
Precondition
Cross reference
Information, hint
Consequences of disregard
Tab. 4 Symbols and their meaning
1.4 Technical terms
Ter m Me a n ing
Sealing medium Medium for locking or quenching of shaft seals
Auxiliary operating systems
Tab. 5 Technical terms and their meaning
Systems for operating the pump
EN – 02 BA-2005.07 NPC series 7
Security
2 Security
The manufacturer does not accept any liability for events
resulting from disregard of the entire documentation.
2.1 Intended use
• Only use the pump for pumping the agreed pumped media
(→ Order data sheet).
• Adhere to operating limits and size-dependent minimum
flow rate.
• Avoid dry running:
Initial damage such as destruction of mechanical seal and
plastic parts within only a few seconds.
– Make certain that the pump is never put into operation
and never operated without a pumped medium.
• To avoid cavitation:
– Fully open the suction-side armature and do not use
for adjusting the flow rate.
– Do not open the pressure-side armature beyond the
agreed operating point.
• To avoid overheating:
– Do not operate the pump while the pressure-side arma-
ture is closed.
– Observe the minimum flow rate (→ Order data sheet).
• To avoid damage to the motor:
– Do not open the pressure-side armature beyond the
agreed operating point.
– Observe the allowed number of motor swi tch-ons per
hour (→ Manufacturer's specifications).
• Consult with the manufacturer about any other use of the
pump.
2.2 General safety instructions
Take note of the following instructions before carrying out
any work.
2.2.1 Product safe ty
The pump has been constructed according to up-to-date technology and established technical safety rules. Nevertheless,
operation of the pump can involve risks to life and health of the
user or of third parties, or risks of damaging the pump and other
property.
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents complete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would
expose personnel or third parties to any risk.
• Should there be any safety-relevant fault, deactivate the
pump immediately and have the fault corrected by appropriate personnel.
• In addition to the entire documentation for the product,
always comply with statutory or other safety and accident-prevention rules and with the applicable standards
and guidelines in the country where the pump is operated.
Prevention of self-evident misuse (examples)
• Observe the operating limits of the pump regarding operating temperature, pressure, flow rate and speed (→ Order
data sheet).
• The power uptake of the pump will increase with increasing
density of the pumped medium. To avoid any overload for
the pump, the coupling and the motor, do not exceed the
allowable density (→ Order data sheet).
A lower density is allowed. Adapt auxiliary system s accordingly.
• Adhere to limits on solids content and grit size when pumping solids-carrying fluids (→ Order data sheet, technical
description).
• When using auxiliary operating systems, en sure that
there is a continuous supply of the appropriate operating
medium.
8 NPC series BA-2005.07 EN – 02
Security
2.2.2 Duties of the operating company
Safety-conscious operating
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– adherence to intended use
– statutory or other safety and accident-prevention rules
– safety regulations governing the handling of hazardous
substances
– applicable standards and guidelines in the country
where the pump is operated
• Make protective equipment available.
Qualified personnel
• Make certain that all personnel tasked with work on the
pump have read and understood this manual and all other
applicable documents, especially the safety, maintenance
and repair instructions, before they begin the job.
• Organize responsibilities, who is in charge of any specific
duty and how personnel is supervised.
• Ensure that all work is carried out by specialist technicians
only:
– fitting, repair and maintenance work
– work on the pump electrical system
• Make certain that trainee personnel is supervised by a specialist technician when performing tasks on the pump.
Safety installations
• Provide the following safety installations and verify their
integrity:
– for hot and moving parts: device-side contact protec-
tion on the pump
– in case of potential electrostatic charging: appropriate
grounding
2.2.3 Duties of the operating personnel
• Observe and keep legible all directions given on the pump,
e.g. the arrow indicating the direction of rotation and the
markings for fluid connections.
• Do not remove the contact protection f or hot, cold and moving parts during operation.
• Use protective equipment if necessary.
• Carry out work on the pump only while the pump is not
running.
• Isolate the motor from its supply voltage and keep it locked
in that state while carrying out any fitting or maintenance
work.
• Mount the safety installations on the pump according to
instructions after completion of work on the pump.
2.3 Special hazards
2.3.1 Explosion hazard area
• (→ ATEX additional instructions).
2.3.2 Hazardous pumped media
• Observe the safety regulations for the handling of hazardous substances when working with hazardous pumped
media (e.g. hot, flammable, poison ous or potentially harmful).
• Use protective equipment when carrying out any work on
the pump.
Warranty
• Obtain the manufacturer's approval prior to carrying out
any modification, repair or alterations during the warranty
period.
• Only use original parts or parts that have been approved
by the manufacturer.
EN – 02 BA-2005.07 NPC series 9
Layout and function
3 Layout and function
3.1 Labels
3.1.1 Type plate
MUNSCH Chemie-Pumpen GmbH
Typ
type
W.-Nr.
serial-no.
10
Lfrd.
impeller
9
8
7
Fig. 1 Type plate (example)
1Pumptype
2 Serial number
3 Construction year
4 Total differential head
5 Density
6Torque
7 Speed
8 Power consumption
9Flowrate
10 Impeller di ameter
D-56235 Ransbach-Baumbach
3
Q
P
n
m /h
kW
min
-1
Baujahr
year
3.1.3 Pump type code
NPC
50 - -32 200
1
1
2
3
H
M
m
kg/dm
Nm
4
3
5
6
2
3
4
Fig. 3 Pump type code (example)
1 Pump series
2 Suction flange DN [mm]
3 Pressure flange DN [mm]
4 Impeller nominal diameter [mm]
3.1.2 ATEX plate
1
Fig. 2 ATEX plate (example)
1 Explosion protection mark
2 Reference to ATEX additional instructions
2
10 NPC series BA-2005.07 EN – 02
3.2 Layout
Layout and function
1
2 3 4
56
Fig. 4 Layout NPC
1 Impeller
2 Casing armour plating
3.3 Shaft seals
Only one of the following shaft seals can be used.
EN – 02 BA-2005.07 NPC series 11
3 Volute casing
4 Bearing bracket
5 Pump shaft
6 Casing cover
3.3.1 Mechanical seals
Mechanical seals will always show some functional drip
leakage.
• Single mechanical seal
• Double mechanical seal with quench
• Double mechanical seal with foreig
n blocking
Layout and function
3.4 Auxiliary operating systems
3.4.1 Sealing sy stems
Only one of the following sealing systems can be used.
Quenching
1 2
3
Fig. 5 Double mechanical seal with quench
(operating principle)
1 Pumped medium
2 Sealing medium (unpressurized)
3 Double mechanical seal
With quenching, the pressure of the pumped medium exceed s
the pressure of the sealing medium. The sealing friction surfaces of the product-side seal are lubricated by the pumped
medium.
Application examples:
• pumped media that crystallize in air, cau sing long-term
damage to the seal
• prevention of odors
• seal cooling
Varia nt
Open system
Closed system
Tab. 6 Quenching – variants and characteristics
Sealing medium
characteristics
• supplied and drained
continuously
• unpressurized
• circulates in a closed
cycle
• unpressurized
Blocking
1 2
3
Fig. 6 Double mechanical seal with foreign blocking
(operating principle)
1 Pumped medium
2 Sealing medium (pressurized)
3 Double mechanical seal
With foreign blocking, the pressure of the sealing m edium
exceeds the pressure of the pumped medium. The sealing
friction surfaces are lubricated by the sealing medium.
Application examples:
• pumped media that crystallize or carry solids, causing longterm damage to the seal
• toxic pumped media
• pumped media presenting an environmental hazard
Varia nt
Open flow system
Closed flow system
Tab. 7 Foreign blocking – variants and characteristics
Sealing medium
characteristics
• supplied and drained
continuously
• pressurized
• circulates in a closed
cycle
• pressurized
12 NPC series BA-2005.07 EN – 02
4 Transport, storage and disposal
Transport, storage and disposal
4.1 Transport
Weight specifications (→ Individual order documentation).
4.1.1 Unpacking and inspection on delivery
1. Unpack the pump/aggregate on delivery and inspect for
transport damage.
2. Report any transport damage to the manufacturer without
delay.
3. Dispose of packaging material according to local regulations.
4.1.2 Lifting
DANGER
Death or crushing of limbs caused by falling loads!
Use lifting gear appropriate for the total weight to be transported.
Fasten the lifting gear as shown in the illustrations below.
Do not stand under suspended loads.
Fig. 7 Fastening the lifting gear to the pump aggregate
Fig. 8 Fastening the lifting gear to the pump
Lift the pump/aggregate appropriately.
EN – 02 BA-2005.07 NPC series 13
Transport, storage and disposal
4.2 Preservation
No preservation required.
Do not preserve the pump.
4.3 Storage
CAUTION
Material damage due to inappropriate storage!
Store the pump appropriately.
1. Seal all openings with blind flanges, blind plugs or plastic
covers.
2. For mode ls with oil-lubricated bearings and downtimes in
excess of one year:
– Dismount any existing reservoir
– Dismount any existing oil level controller
– Seal the tap hole
– Fill the bearing bracket with oil, up to the brim
– Seal the bleeding hole
3. Make certain that the storage room meets the following
conditions:
–dry
– frost-free
– vibration-free
4. Turn shaft once a month.
5. Make certain that the shaft and the bearing change their
rotational position in the process.
4.4 Disposal
Plastic parts can be contaminated by poisonous or radioactivepumpedmediatosuchanextentthatcleaningwill
be insufficient.
WARNING
Risk of poisoning and environmental damage caused by
pumped medium or oil!
Use protective equipment when carrying out any work on
the pump.
Prior to disposal of the pump:
– Collect pumped medium and oil or grease running out
and dispose of the pumped medium according to local
regulations.
– Neutralize residues of pumped medium in the pump.
Dismount plastic parts and dispose of the parts according
to local regulations.
Dispose of pump according to local regulations.
14 NPC series BA-2005.07 EN – 02
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