OSNA GH, GV Original Operating Manual
Ver.17-01
Original Operating Manual
GH/GV High-Pressure
Centrifugal Pump
OSNA-Pumpen GmbH
Brückenstrasse 3
49090 Osnabrück, Germany
Phone: +49 541 1211 - 0
Fax: +49 541 1211 - 220
Internet: http://www.osna.de
E-mail: info@osna.de
GH/GV High-Pressure Centrifugal Pump 1
Contents
1 GENERAL ...................................................................................................................................5
1.1 About this operating manual ................................................................................................5
1.2 Target groups......................................................................................................................5
1.3 Other valid documents.........................................................................................................5
1.4 Warning notices and symbols ..............................................................................................6
1.5 Copyright/changes...............................................................................................................6
2 SAFETY ......................................................................................................................................7
2.1 Correct and proper use ........................................................................................................7
2.2 General safety instructions...................................................................................................8
2.2.1 Product safety..................................................................................................................8
2.2.2 Duties of the system owner ..............................................................................................8
2.2.3 Duties of personnel ..........................................................................................................9
2.3 Dangers of non-observance of the safety instructions ........................................................10
2.4 Unauthorized conversion and production of spare parts .....................................................10
2.5 Unauthorized modes of operation ......................................................................................10
2.6 Special hazards.................................................................................................................10
2.6.1 Explosion area...............................................................................................................10
2.6.2 Hazardous pumping media ............................................................................................10
2.6.3 Noise emissions.............................................................................................................10
3 LAYOUT AND FUNCTION ........................................................................................................ 12
3.1 Labeling.............................................................................................................................12
3.2 Scope of delivery for a type-GH/GV high-pressure centrifugal pump...................................12
3.3 General information ...........................................................................................................12
3.4 Technical data...................................................................................................................13
3.5 Operating point..................................................................................................................13
3.6 Minimum output rates ........................................................................................................13
3.7 Functional and operating elements ....................................................................................14
4 TRANSPORT AND INTERMEDIATE STORAGE ....................................................................... 16
4.1 Transport...........................................................................................................................16
4.1.1 Unpacking and checking the delivery condition ..............................................................16
4.1.2 Lifting.............................................................................................................................16
4.2 Intermediate storage..........................................................................................................17
4.3 Storage..............................................................................................................................17
4.4 Disposal ............................................................................................................................18
5 ASSEMBLY AND INSTALLATION ............................................................................................ 19
5.1.1 Preparing the installation location...................................................................................19
5.1.2 Preparing the base surface and foundations...................................................................19
2 GH/GV High-Pressure Centrifugal Pump
5.2 Installation .........................................................................................................................19
5.2.1 Installing the pump.........................................................................................................19
5.2.2 Assembling the motor ....................................................................................................20
5.2.3 Fine alignment of the coupling........................................................................................21
5.2.4 Electrical connection......................................................................................................22
5.3 Pipelines............................................................................................................................22
6 COMMISSIONING / DECOMMISSIONING ............................................................................... 25
6.1 Commissioning..................................................................................................................25
6.1.1 Determining the pump configuration...............................................................................25
6.1.2 Filling the pump .............................................................................................................25
6.1.3 Checking direction of rotation.........................................................................................25
6.1.4 Starting the pump ..........................................................................................................26
6.2 Decommissioning ..............................................................................................................27
6.2.1 Draining the pump and protecting against frost...............................................................28
6.3 Recommissioning ..............................................................................................................28
6.4 Shaft seal ..........................................................................................................................29
6.4.1 Mechanical seal.............................................................................................................29
6.4.2 Gland packing................................................................................................................29
7 MAINTENANCE AND REPAIR .................................................................................................. 30
7.1 General information ...........................................................................................................30
7.2 Servicing the electric motors ..............................................................................................31
7.3 Operational monitoring.......................................................................................................31
7.4 Gland packing maintenance...............................................................................................32
7.5 Sending the pump to the manufacturer ..............................................................................34
8 FAULTS AND TROUBLESHOOTING........................................................................................ 35
9 APPENDIX ................................................................................................................................ 38
9.1 Spare parts list for constant operation over two years as per DIN 24296 ............................38
9.2 Cross-sections...................................................................................................................39
9.3 Declaration of Conformity as per EC Directive 2006/42/EC, Annex IIA ...............................45
9.4 Clearance Certificate .........................................................................................................46
GH/GV High-Pressure Centrifugal Pump 3
List of Tables
Table 1: Target groups and their tasks ................................................................................................5
Table 2: Other valid documents and their purposes ............................................................................5
Table 3: Warning notices and consequences of non-observance........................................................6
Table 4: Symbols and their meanings..................................................................................................6
Table 5: Sound pressure level...........................................................................................................11
Table 6: Minimum output rates with closed shut-off valve .................................................................13
Table 7: Maximum authorized operating temperature and pressure at the shaft seal .........................14
Table 8: Maximum authorized operating temperature and pressure on the casing .............................15
Table 9: Settings for the time relay when using three-phase motors with star-delta switch .................22
Table 10: Measures in the event of operational interruption..............................................................27
Table 11: Measures depending on the behavior of the pumping medium...........................................27
Table 12: Measures following longer shut down times .......................................................................28
Table 13: Stuffing box in the GH........................................................................................................33
Table 14: Stuffing box in the GV........................................................................................................33
Table 15: Measures for return ...........................................................................................................34
Table 16: Fault/number allocation .....................................................................................................35
Table 17: Troubleshooting table ........................................................................................................37
Table 18: Spare parts for constant operation over two years .............................................................38
Table 19: GH parts list ......................................................................................................................41
Table 20: GV parts list.......................................................................................................................44
4 GH/GV High-Pressure Centrifugal Pump
List of Images
Figure 1: Model code ........................................................................................................................12
Figure 2: Scope of delivery for a GH pump with free shaft ................................................................12
Figure 3: Scope of delivery for a GH pump as a complete unit..........................................................12
Figure 4: Gland packing....................................................................................................................14
Figure 5: Mechanical seal .................................................................................................................14
Figure 6: Lifting a GH centrifugal pump (unit) ....................................................................................16
Figure 7: Lifting a GH centrifugal pump (free shaft end).....................................................................16
Figure 8: Lifting a GV centrifugal pump..............................................................................................17
Figure 9: Mounting material for complete units ..................................................................................20
Figure 10: Mounting material for pump with open shaft end..............................................................20
Figure 11: Positional alignment of the shafts .....................................................................................21
Figure 12: Directional alignment of the shafts ....................................................................................21
Figure 13: Functional and operating elements...................................................................................23
Figure 14: Stuffing box on the GH/GV ...............................................................................................32
Figure 15: Cross-section of GH with mechanical seal ........................................................................39
Figure 16: Cross-section of GH with gland packing............................................................................40
Figure 17: Cross-section of GV with mechanical seal ........................................................................42
Figure 18: Cross-section of GV with gland packing............................................................................43
1 General
GH/GV High-Pressure Centrifugal Pump 5
1 General
1.1 About this operating manual
This operating manual contains important instructions that must be observed during installation, operation and maintenance. For this
reason, ensure that it is read by specialist personnel and the responsible operator/owner
prior to assembly and commissioning. The
manual must be available at all times at the
location where the system is used.
Please observe the safety instructions described in this operating manual, along with the
relevant national accident prevention regulations and any internal work, operational and
safety specifications of the operator. We assume no liability for damages and operational
interruptions resulting from non-observance of
this operating manual.
WARNING
Pay particular attention to section 2 "Safety
instructions" during commissioning and all
maintenance work.
Section 2 also provides an explanation of the
symbols used in this manual. Knowledge of
this operating manual is essential to preventing
errors and ensuring safe and uninterrupted
operation.
The operating specification does not take local
safety regulations into account. The owner
bears full responsibility for compliance with
these, including on the part of the assembly
personnel used.
This operating manual:
• is part of the pump
• is valid for all type series mentioned
• describes safe and proper use in all
phases of operation
1.2 Target groups
Target group
Task
System owner
► Ensure that this manual is available at the location where the system is
used, including for later
reference.
► Ensure that personnel
read and observe this
operating manual and the
other valid documents, in
particular the safety and
warning information.
► Observe additional
system-related regulations and specifications.
Specialist personnel,
assembly staff
► Read, observe and
follow this operating
manual and the other
valid documents, in particular the safety and
warning information.
Table 1: Target groups and their tasks
1.3 Other valid documents
Document
Purpose
Installation diagram Installation dimensions,
connection dimensions, etc.
Spare parts list Ordering spare parts
Clearance certificate Returning the pump
Declaration of
conformity
Conformity with standards,
content of the declaration of
conformity
Table 2: Other valid documents and
their purposes
1 General
6 GH/GV High-Pressure Centrifugal Pump
1.4 Warning notices and symbols
Warning notice
Hazard
level
Consequences of nonobservance
DANGER
Immediate
hazard
Death, severe
physical injury
WARNING
Potential
hazard
Death, severe
physical injury
CAUTION
Potentially
dangerous
situation
Minor physical
injury
NOTICE
Potentially
dangerous
situation
Material damage
Table 3: Warning notices and consequences
of non-observance
Symbol
Meaning
Safety sign
► Follow all instructions
identified with safety signs
in order to avoid death or
injuries.
► Instruction
1. , 2. , … Instruction with multiple
steps
Condition
→ Reference
Information, note
Table 4: Symbols and their meanings
1.5 Copyright/changes
The intellectual property and all copyrights
related to this technical documentation remain
exclusively with OSNA-Pumpen GmbH. All
rights reserved, in particular the right to reproduction and distribution of this documentation,
including translations thereof.
No part of this documentation may be reproduced in any form (print, photocopy, microfilm
or any others process), stored, processed,
reproduced or distributed using electronic systems without written permission.
Editorial changes reserved exclusively by OSNA-Pumpen GmbH.
Any violation is punishable and subject to
compensation.
OSNA GmbH reserves the right to change the
contents of this documentation without notice.
2 Safety
GH/GV High-Pressure Centrifugal Pump 7
2 Safety
The manufacturer shall not bear any liability
for damages caused as a result of nonobservance of this documentation.
2.1 Correct and proper use
• Only use this pump for the purposes of
conveying the agreed pumping media.
• Comply with operating limits.
• The water may not contain any abra-
sive or long-fibered components that
may damage the pump materials.
Consult the manufacturer if using other
media.
• Ensure that the pump is only commissioned with pumping medium and is
not operated without it.
• Open the suction-side fitting, and do
not use it to control the flow rate.
• To avoid damaging the motor, observe
the permitted number of times per
hour that the motor can be switched
on (→ Manufacturer information).
• Any other use must be agreed with the
manufacturer.
• The temperature of the pumping medium must not exceed 90 °C.
Avoiding obvious misuse (examples)
• Observe the operating limits of the
pump for temperature, pressure, flow
rate and speed.
The main areas of use are:
• Pressure boosting systems, heating
systems, hot and cold water circulation, water supply systems, power stations, filtering systems, filling and emptying of tanks, water circulation in
pools and sprinkler systems
• Fresh water, drinking water, boiler
feed water, process water, sea and
brackish water, hot water, condensate
and many media without aggressive
components that do not chemically
corrode the materials used in the
pump
Do not operate the pump without water. Dry
running can lead to damage to the pump.
WARNING
Any use that goes beyond the purposes
described above shall be considered improper use. OSNA shall bear no liability for
any resulting damages. The owner bears
full risk for improper use.
2 Safety
8 GH/GV High-Pressure Centrifugal Pump
2.2 General safety instructions
Please observe the following specifications
before performing any activities.
2.2.1 Product safety
This pump is constructed according to the
latest state of the art and accepted safety
rules. Nevertheless, risks to life and limb for
the user or third parties are still possible when
using the pump, as are impairments to the
pump and other material assets.
• Only use the pump in a technically
perfect state and for the intended purpose. Ensure compliance with this operating manual and be aware of the
hazards and safety issues during operation.
• Keep this operating manual and all
other valid documents in a complete
and legible state, and store in a location that is accessible at all times to
personnel.
• Do not permit any activity that endangers personnel or uninvolved third parties.
• In the event of a safety-relevant fault,
stop the pump immediately and have
the fault rectified by responsible personnel.
• In addition to this documentation, ensure compliance with the statutory or
other regulations for safety and accident prevention, as well as the relevant standards and specifications of
the respective country.
• Do not remove any technical stickers.
2.2.2 Duties of the system owner
Safety-conscious work
Observe the safety specifications detailed in
this operating manual, along with the occupational safety regulations and all additional internal safety regulations.
• Only use the pump in a technically
perfect state and for the intended purpose. Ensure compliance with this operating manual and be aware of the
hazards and safety issues during operation.
• Ensure compliance and monitoring:
- correct and proper use
- statutory or other safety and acci-
dent prevention regulations
- safety specifications for handling
hazardous substances
• Provide personal protective equipment.
• Do not remove contact protection during operation.
• Prevent any dangers from electrical
energy (for details, please refer to the
specifications of the VDE and the local
energy supplier).
• Switch off the motor during all assembly and maintenance works, and secure against reactivation.
• Only work on the system when the
pump is at a standstill.
2 Safety
GH/GV High-Pressure Centrifugal Pump 9
Personnel qualification
The owner of the system must ensure that the
personnel tasked with working on the pump
have read and understood this operating manual and all other valid documents before beginning work, in particular information on safety, maintenance and repair.
Work of any kind on the machine may only be
performed when it has been completely decommissioned. Reinstall and reactivate all
safety mechanisms after work.
Before restarting the machine, ensure that all
necessary commissioning steps have been
completed (→ Fehler! Verweisquelle konnte
nicht gefunden werden. Fehler! Verweisquelle konnte nicht gefunden werden., pg
Fehler! Textmarke nicht definiert.).
• Determine responsibilities, tasks and
monitoring for personnel.
• Only allow work of any kind to be performed by specialist technical personnel:
- assembly, maintenance and repair
work
- work on the electrical systems
• Only allow personnel undergoing training to perform work on the pump under
the supervision of specialist technical
personnel.
Safety mechanisms
• Provide the following safety mechanisms and ensure that they function
correctly:
- for moving components: contact
protection for the pump, installed
by the customer
- for potential electrostatic charges:
provide appropriate earthing
Guarantee
• Please consult the manufacturer before carrying out any conversions, repairs or changes during the guarantee
period.
• Only use original parts or parts approved by the manufacturer.
2.2.3 Duties of personnel
• Observe the information on the pump
and ensure it is legible (e.g. direction
of rotation arrow, fluid connection indicators).
• Do not remove the contact protection
for moving parts during operation.
• Use personal protective equipment if
necessary.
• Only work on the system when the
pump is at a standstill.
• Switch off the motor during all assembly and maintenance works, and secure against reactivation.
• Reinstall the safety mechanisms after
working on the pump according to
specifications.
2 Safety
10 GH/GV High-Pressure Centrifugal Pump
2.3 Dangers of non-observance of
the safety instructions
• Non-observance of the safety instructions can lead to hazards to personnel,
the machine and the environment.
• Non-observance of the safety instructions can also lead to the loss of any
damage claims.
• In particular, non-observance can lead
to the following dangers:
- failure of important system func-
tions
- electrical and mechanical hazards
to personnel
2.4 Unauthorized conversion and
production of spare parts
Conversions or changes to the machine are
only permitted following consultation with the
manufacturer. Original spare parts and accessories authorized by the manufacturer help
ensure safety. The manufacturer bears no
liability for the consequences of the use of
other parts.
2.5 Unauthorized modes of operation
The operational safety of the machine is only
guaranteed when it is used for the intended
purpose according to the operating manual (→
2.1 Correct and proper use, pg 7).
Never exceed the limit values indicated in the
technical data (→ Data sheet).
2.6 Special hazards
2.6.1 Explosion area
• Do not use the pump in areas where
there is a risk of explosion.
2.6.2 Hazardous pumping media
• Observe the safety regulations for
handling hazardous substances (e.g.
toxic, hazardous to health).
• Use personal protective equipment
when performing work on the pump.
2.6.3 Noise emissions
Conditions for measurement:
• Distance to pumping unit: 1 m
• Operation: Free of cavitation
• Motor: IEC standard motor
• Tolerance: ± 3 dB(A)
2 Safety
GH/GV High-Pressure Centrifugal Pump 11
Drive power in
kW
Noise emissions in dB(A)
1450 min-1 2900 min-1
0.75 50 58
1.1 53 62
1.5 55 62
2.2 56 63
3.0 58 65
4.0 60 66
5.5 64 70
7.5 65 71
11.0 68 73
15.0 69 74
18.5 69 74
22.0 70 75
30.0 71 75
37.0 72 76
45.0 73 77
55.0 73 79
75.0 74 81
90.0 74 82
110.0 75 83
132.0 76 84
Greater power upon request
Table 5: Sound pressure level
Low-noise motors can be provided if the expected noise values exceed the permitted limits.
3 Layout and function
GH/GV High-Pressure Centrifugal Pump 12
3 Layout and function
3.1 Labeling
This operating manual applies to the GH/GV
type series.
Model code:
Figure 1: Model code
3.2 Scope of delivery for a typeGH/GV high-pressure centrifugal
pump
The customer can order the pump:
− with a free shaft, i.e. delivery without motor
or foundation (à Figure 2, pg 12)
− as a complete unit, i.e. fully assembled on a
baseplate with drive motor, coupling and
coupling guard (à Figure 3, pg 12)
1 Pump
2 Drive motor
3 Baseplate
4 Coupling
5 Coupling guard
The scope of delivery corresponds to the
scope indicated in the order. Please check that
the delivery is complete upon receipt. Notify
the delivery company of any transport damage
immediately. Please also refer to our conditions of sale and delivery. If using other motor
brands, please ensure that the motors have
the following drive torques as a multiple of the
nominal torque.
Figure 2: Scope of delivery for a GH pump
with free shaft
Figure 3: Scope of delivery for a GH pump
as a complete unit
3.3 General information
The GH/GV is a non self-priming, multistage,
high-pressure centrifugal pump in horizontal
(GH) and vertical (GV) configuration. These
models have proven themselves thanks to
their quiet running and long service lives. The
suction and discharge nozzles can be produced variably at different stages of 90°.
Depending on requirements, the GH/GV
pumps are fitted with either gland packing or
mechanical seals (cooled version also available).
The horizontal configuration uses lubricated
anti-friction bearings, whilst the vertical configuration uses both a lubricated anti-friction
bearing and a liquid-lubricated plain bearing.
Depending on the demands of the pumping
medium or customer requirements, it is also
possible to use materials such as gray cast
iron, spheroidal graphite iron, cast steel,
bronze or stainless steel (also Duplex and
Super Duplex).
3 Layout and function
GH/GV High-Pressure Centrifugal Pump 13
The pumps are driven via standard IEC electronic motors. The horizontal pumps can also
be driven by combustion motors or turbines.
The drive is on the discharge side in the
standard configuration. Drive on the suction
side or on both sides is possible upon request.
The pump can be delivered as a complete unit
(assembled on baseplate with drive motor,
coupling and coupling guard), or with a free
shaft end.
3.4 Technical data
Main parameters:
Output: Up to 550 m³/h
Delivery head: See table
Speed: n= 950, 1450 and 2900 rpm
(at 50 Hz)
n= 1150, 1750 and 3500 rpm
(at 60 Hz)
Diesel and hydraulic motor
with special speed limited to
max. 3500 rpm.
Ambient temperature: Max. 40 °C
Medium temperature: See table
Continuous sound
pressure level: 70 dBA
Flange:
Suction nozzle: From DN 50 to DN 200, PN 40
Discharge
nozzle: From DN 32 to DN 150, PN 40
BS and ANSI flanges possible
Drive unit:
GH: 50 and 60 Hz electric motor, diesel
motor or turbine
GV: Electric motor with IEC flange, V1 con-
figuration or hydraulic motor with special flange
3.5 Operating point
In order to reach the required operating point,
it may be necessary to fit the pump with two
different sizes of impeller blade. For this reason, please provide the impeller blade diameter or position on the shaft when ordering
spare parts (1st, 2nd impeller, etc., beginning
at the suction side of the pump).
Please always indicate the pump type and
order number when ordering spare parts, or in
the event of any queries.
3.6 Minimum output rates
Pump temperature
range
Minimum output rate
at design point
–10 to +100 °C 15% of Qopt
+100 to +140°C 20% of Qopt
Table 6: Minimum output rates with closed
shut-off valve
3 Layout and function
14 GH/GV High-Pressure Centrifugal Pump
3.7 Functional and operating elements
Shaft wearing sleeve:
Shaft wearing sleeve GH GV
Uncooled gland packing Up to 110 °C Up to 100 °C
Cooled gland packing (cooling units) From 110 °C to 160 °C -
Uncooled mechanical seal Up to 120 °C Up to 120 °C
Cooled mechanical seal Up to 160 °C -
Table 7: Maximum authorized operating temperature and pressure at the shaft seal
The pumps can be fitted with gland packing or
mechanical seal as required.
Gland packing consists of a number of compression-molded rings in a stuffing box. Gland
packings can be adjusted by hand with tools.
Figure 4: Gland packing
Mechanical seals are mechanical shaft seals
with internal flushing of the rotating seal rings
(self-adjusting).
Figure 5: Mechanical seal
The technical dry running properties of gland
packing and mechanical seals are extremely
limited. For this reason, avoid dry running.
Ensure that the pump is vented before commissioning.
Casings:
Max. operating temperature and pressure:
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