Page 1
VERTICAL MULTI-STAGE
CENTRIFUGAL PUMPS
HPV
OPERATING INSTRUCTIONS
Rev. 0
Page 2
INDEX
DECLARATION OF CONFORMITY
INTRODUCTION
Chap. 1: IDENTIFICATION, PACKAGING, TRANSPORT AND STORAGE
Chap. 2: SAFETY .
Chap. 3: INSTALLATION .
Chap. 4: OPERATION AND USE .
Chap. 5: MAINTENANCE .
Chap. 6: UNIT SCRAPPING .
Chap. 7: SPARE PARTS
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1. IDENTIFICATION, PACKAGING, TRANSPORT AND STORAGE
1.1 IDENTIFICATION
Each pump is fitted with a metal identification plate (Fig. 1)
which as well as indicating the manufacturer's name and address
and CE mark, displays its technical data, such as:
- Type of pump
- Serial Number
- Flow rate
- Speed (RPM)
- Head
In the case of an assembly (Fig. 2) also:
- Maximum pressure
- Motor power
- Voltage
- Frequency
The serial number uniquely identifies each constructed machine.
Use this number as reference for all communication with the manufacturer.
Fig.2
Fig.1
-
-
-
/h
-
MADE IN ITALY
-
-
-
-
MADE IN ITALY
CAUTION !
PACKING, LIFTING, HANDLING, TRANSPORT AND UNPACKING OPERATIONS
MUST BE EXCLUSIVELY ENTRUSTED TO PERSONNEL WHO ARE SKILLED IN
THESE PROCEDURES AND KNOW WELL THE PUMP AND THIS MANUAL
1.2 PACKING
Depending on their size, the pumps are shipped in the following way:
- in a wooden crate for some types of pumps and for vertical electric pumps. (Fig. 3)
CAUTION !
The dimensions and relevant net and gross weights are
shown on the packages.
Fig.3
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1. IDENTIFICATION, PACKAGING, TRANSPORT AND STORAGE
1.3 LIFTING AND HANDLING
Le pompe imballate possono essere sollevate e spostate con carrelli elevatori o con mezzi di sollevamento (Fig. 4). Tutti i gruppi dotati di supporto in acciaio sono dotati di fori per sollevamento con gru.
CAUTION!
The selected equipment must be suitable for lifting and
safe handling, taking into account the dimensions and weights shown on the
packing. (Fig. 3)
CAUTION!
Handling may only be done by experienced and authorised personnel.
1.4 STORAGE
The packages must always be stored in covered, dry and sheltered areas at temperatures between -10°C and +40°
C and must not be exposed to direct sun radiation. (Fig. 5)
In the event of prolonged storage, once a month turn the pump over in the two rotation directions using a suitable
tool.
In the event of storage longer than 6 months, in any event contact the manufacturer.
For protection against corrosion, the outer parts of the pump may be oiled and greased.
Fig. 4
Fig. 5
1.5 STACKING OF PACKAGES
The type of packing provides for the possibility to stack in the warehouse and on
truck decks up to 2 stacked crates, as well as they are correctly arranged and
secured against falling. (Fig. 6)
1.6 OPENING THE PACKAGES
Upon arrival ensure the parts have not incurred damage during transport and that
all the pieces listed in the delivery note are there. (Any anomalies or damage must
be reported to the manufacturer).
The packages must be opened adopting all precautions to prevent damage to persons and machine parts (prevent pieces from dropping out of the box during opening)
1.7 DISPOSAL OF THE PACKAGING
The wood of the crate and pallet may be reused or recycled in compliance with
the laws in force in the country of installation of the pump.
The other materials such as straps and plastic must be disposed of in compliance with the laws in force in the country.
Fig. 6
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2. SAFETY
It is extremely important to read this chapter carefully and in all parts as it
contains important information on the risks that operator and
maintenance technician may incur in the event of incorrect pump use.
ATTENZIONE!
The electric pumps have been designed and constructed for processing geothermal water in
the industrial sector.
Limitaons for pump usage are indicated in chapter 2 “TECHNICAL SPECIFICATIONS”.
THE MANUFACTURER DECLINES ALL RESPONSIBILITY FOR ANY DAMAGE TO
PERSONS OR THINGS DUE TO EITHER WRONG OR NOT ALLOWED INTERVENTIONS ON THE PUMPS NOT
ALLOWED.
GENERAL PRECAUTIONS
The operator and maintenance technician are bound to comply with the provisions of laws and accident
prevention regulations in force in the country of installation of the pump.
Furthermore, they:
- Must not remove or de-activate casings and mechanical, electrical or other types of protections.
- Pay attention to the safety warnings contained in the plates applied to the machine and in the manual.
- Always use personal protective equipment such as safety shoes and gloves.
The safety warnings shall be highlighted in the following ways:
DANGER: Indicates an imminent hazard that may cause harm to people (serious injury or even
death).
ATTENTION: Indicates hazardous situations and/or behaviours that may cause harm to
people (injury of varying severity and/or even death).
CAUTION: Indicates hazardous situations and/or behaviours that may cause less severe harm
to people and/or damage to property.
RISK OF ELECTROCUTION: It is a special safety warning that is displayed on the
panel of the pump, via a plate, in certain points where the risk of strong electric shock is particularly high.
RISKS AND PROTECTIONS
Below is a detailed list of the risks the operators or the maintenance technician
may incur during assembly or maintenance and what protections have been adopted by the manufacturer to reduce these risks to the minimum (Fig.16)
ATTENTION!
It is the buyer's duty to check conformity of use of the pump and compliance with
safety aspects of the premises where it is installed.
ATTENTION!
Connection operations with the piping line and relevant plant must be performed by
skilled personnel in compliance with the laws in force in the Country where the
pump is installed.
RISK OF COLLISION!
Due to pump parts at a man's height.
RISK OF ENTRAPMENT
Always restore safety protections due to rotating parts.
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2. SAFETY
RISK OF CRUSHING
During all handling, assembling, maintenance stages always use personal protective equipment
such as gloves, safety shoes and anything else set forth by the laws in force in the country.
RISK OF SLIPPING
Due to wet areas of the floor or with oil.
In order to prevent the risk of slipping use the suitable personal equipment
(safety shoes).
RISK OF BREAKAGE OR LEAK OF HIGHLY PRESSURISED WATER
Pay attention to accidental leaks: immediately alert maintenance.
Upon starting up always remember to prime the pump and open the delivery valve: Danger
of overheating.
RISK OF COMPONENT BREAKAGE DURING OPERATION
The manufacturer has used materials and design and constructive procedures suitable for the
intended use and to obtain a reliable and safe device but it is necessary
to comply with the use the assembly (motor / pump) has been designed for as well as with the
inspections and maintenance recommended in chapter 6 "MAINTENANCE".
RISK OF ELECTROCUTION
Jets of water, steam, solvents or paints must be avoided near parts of the pump containing
electrical wires, and especially in close proximity to the electrical panel.
Always power off the electric pump before performing any maintenance operation
Always earth the pump.
RISK FROM UNSUITABLE LIGHTING (where appl icabl e)
The operator and maintenance technician must ensure all areas of the pump are always lit
consistently and in compliance with the provisions
of the regulations in force in the place of installation.
NOISE HAZARD
In the event of application of the pump with motor by other supplier, and in any case of
installation in the pump room, the overall noise level of the premises must be assessed in
compliance with the laws in force in the country.
Pay attention to any abnormal noise emissions during operation.
RISKS FOR UNAUTHORISED USE
Every use of the pump other than that for which it has been designed may cause accidents,
even very severe, to the persons working in its close proximity.
It is therefore extremely important to strictly comply with all rules concerning use, maintenance
and safety contained in this manual.
CAUTION! Do not intervene on the pump before closing all gate valves and discharging
the pump's pressure; only with pump stopped and powered off.
RISKS DUE TO HIGH TEMPERATURE
With cold liquids, the pumps are sized and protected so that the temperature of mechanical parts falls within the limits set by the standards.
CAUTION! DANGER OF HIGH TEMPERATURES in the event of applications with hot or
pressurised liquids, in certain areas of the pump especially supports; do not go close to the
pump and only effect procedures with the pump stopped and powered off.
(Fig. 17)
RISKS DUE TO HAZARDOUS LIQUIDS AND ENVIRONMENTS
See special requirements supplied by the plant manufacturer.
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3. INSTALLATION
ATTENTION!
The lifting equipment to be used (including ropes, harnesses and eyebolts) must be
suitable to the stated weights of parts also considering any accessories (the weights
of piping).
In the case of bare shaft pump, never connect ropes to the end of the shaft.
ATTENTION!
IN THE EVENT OF PURCHASING THE PUMP ONLY AND COUPLING IT TO ANOTHER COMPANY'S MOTOR, THE PERSON PERFORMING THIS COUPLING
MUST ASSURE COMPLIANCE WITH ALL SAFETY REQUIREMENTS.
Do not lift assemblies using the motor eyebolts.
In any case follow the instructions given in the coupling joint booklet and in chapter 5
"MAINTENANCE".
3.1 INSTALLATION OF THE ELECTRIC MOTOR PUMP ASSEMBLY
In this case the electric pump is supplied by the manufacturer already mounted.
Handling must always be performed with lifting equipment of load capacity suitable to the unit (see the weights on the packages). (Fig. 7-8)
Fig.8
TIGHTENING TORQUES NM
Fig.7
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3. INSTALLATION
3.2 LUBRICATION
Bearings lubricated with oil.
The support must be filled with one of the following types of oil:
- AGIP : ACER 46
- ESSO Teresso 68
- MOBIL D.TE Oil Medium
- SHELL Tellus 68
FILLING WITH OIL
Through the breather cap, pour the oil until it reaches the level of the sight
glass and stabilises at that level.
Close the filling cap again.
3.3 ELECTRICAL SYSTEM
ATTENTION!
Connection to the motor and relevant electrical installation must be performed by a skilled electrical technician in compliance with electrical
standards in force.
Connection operations must be performed with no electrical voltage.
Ensure the power supply voltage matches that set out on the motor plate.
The connecting cable must be sized based on motor absorption and cable length (refer to the motor plate).
THREE-PHASE MOTORS
For motors of power greater than 7.5 KW it is good practice to provide stardelta start-up.
Check the type of connection set out in the electrical motor plate. The connection varies depending on the type of motor winding and voltage.
Ensure the terminals of the electrical box are connected according to the correct diagram (Fig. 9).
ATTENTION!
Always perform earthing connection. The motor crankcase must be earthed
via the suitable connection.
Check resistance to insulation before commissioning.
The motor must always be protected from overloads by a thermal breaker
installed downstream of the cut-out switch calibrated to a tripping current not
exceeding 1.15 times the motor's rated current.
It will be the technician's duty and responsibility to perform final electrical testing set out by the standards and, upon completing them, issue the certificate
of conformity concerning the electrical system.
CONNECTION DIAGRAM FOR THREE-PHASE MOTORS PROVIDED
FOR STARTING:
THREE-PHASE LINE - HIGHER CONNECTION VOLTAGE
CONNECTION:
THREE-PHASE LINE - LOWER CONNECTION VOLTAGE
CONNECTION:
(star)
(delta)
Fig.9
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4. OPERATION AND USE
CHECKS BEFORE STARTING UP
ATTENTION!
Before proceeding with starting up operations, the following guidelines must be
adhered to:
Check connections of piping lips.
Check any flushing and cooling system connections (where applicable).
Check the direction of rotation by briefly starting the pump and stopping it
immediately, as it must not operate dry.
Ensure the lubricant oil is as required and in sufficient amount.
Ensure conformity of electrical connections and relevant protections.
Ensure all protections of rotating parts are correctly installed.
Ensure the system is ready for starting up.
4.1 STARTING UP/STOPPING
PUMP COMMISSIONING AND OPERATION
- When the motor has reached the rated speed adjust the delivery valve until
achieving the rated pump head.
ATTENTION!
Avoid operating the pump for a long time with the pressing gate valve closed.
Prolonged operation with delivery valve closed causes overheating which
may damage the pump.
Pump operation must be noiseless and vibration-less, the pump must not
run dry.
If the pump is fitted with gland packing, it should drip slightly during opera-
tion. (Fig. 10)
The gland must be tightened only lightly.
If the pump is equipped with mechanical seal, it does not require monitoring
as it has no leaks.
Also ensure maximum absorption of the assembly does not exceed the value set
out in the plate.
ATTENTION!
Backup pumps must be operated at least once a week in order to assure they
are always ready for use.
Braided gasket
Fig. 10
Gland packing seal
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4. OPERATION AND USE
STOP
The pump must be stopped by powering off the motor.
Centrifugal pumps may be stopped with the adjustment valve either open or
closed; a non-return valve must be installed on the delivery piping, in order to
protect it from water hammer.
After stopping the pump also close any auxiliary shutter devices or other types of
external flushing.
Any cooling must only be interrupted after the pump has reached ambient temperature.
In the event of prolonged stops, completely empty the pump to prevent freezing
issues during the cold season or corrosion due to possible chemical alteration of
the liquid standing in the pump.
4.2 • REGULATION AND OPERATION CONTROL
Below is a description of the main checks to be carried out after starting up the
pump.
HEAD
The delivered flow rate of the pump is a function of the head developed according
to the pump's operation curve.
After starting up ensure the head developed by the pump matches the rated one.
For the calculation read the values displayed by the pressure gauge on delivery
and vacuum gauge on intake and apply the following formula:
H = differen tial head (m)
Y = sp ecific weight at pump ing temper ature (K g/dm3)
Pm= del ivery pres sure
Pa = intake pressure
In the event the pump head is lower than rated, slowly close the delivery regulation valve until reaching the
correct value.
Pressure leaks greater than the design, result in a greater head developed by the
pump than the rated one. In this case, to obtain the correct head value, the plant
must be modified to reduce
the leaks.
10,2 (Pm - Pa)
H = ———————— Y
STOP
STOP
The pump must be stopped by powering off the motor.
The pump must be stopped by powering off the motor.
Centrifugal pumps may be stopped with the adjustment valve either open or closed; a non
Centrifugal pumps may be stopped with the adjustment valve either open or closed; a non
stalled on the delivery piping, in order to protect it from water hammer.
stalled on the delivery piping, in order to protect it from water hammer.
After stopping the pump also close any auxiliary shutter devices or other types of external flushing.
After stopping the pump also close any auxiliary shutter devices or other types of external flushing.
Any cooling must only be interrupted after the pump has reached ambient temperature.
Any cooling must only be interrupted after the pump has reached ambient temperature.
In the event of prolonged stops, completely empty the pump to prevent freezing issues during the cold season or corro-
In the event of prolonged stops, completely empty the pump to prevent freezing issues during the cold season or corro-
sion due to possible chemical alteration of the liquid standing in the pump.
sion due to possible chemical alteration of the liquid standing in the pump.
VIBRATIONS / NOISE
Operation at rated pump speed must take place without abnormal vibration or
noise. Should there be any, immediately stop the pump, seek the cause and eliminate it.
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4. OPERATION AND USE
SEAL
- Gland packing seal. (Fig. 11)
To assure effective liquid containment, the gland packing seal requires correct regulation.
CAUTION!
All regulation operations must take place with pump stopped.
Gland packing regulation must be such as to allow for continuous dripping of the
liquid outside.
Lubrication and cooling of the inner rings is assured only in this way.
The amount of dripping depends on pump size and pressure in the stuffing box.
Upon first starting up keep the gland loose so that the liquid may drip copiously.
After the pump has reached full speed conditions, stop and progressively tighten the
nuts of the gland. repeat the operation until achieving
a slight continuous dripping.
After starting up, dripping must be regularly checked and if necessary act on the
gland.
Should it be no longer possible to adjust dripping, the gland packing rings must be
replaced.
MOTOR ABSORPTION
With the pump operating at rated speed, current absorption must not exceed the
electrical motor rated value.
The power absorbed by the motor may be deduced through the operating curve, the
head developed by the pump being known.
The absorbed power must be lower than the motor rated one.
MINIMUM FLOW RATE
CAUTION!
Prolonged operation with null flow rate may damage the pump.
The pump requires a minimum operation flow rate to dissipate the heat generated
inside the body during operation (minimum 20% of the maximum yield flow rate).
Braided gasket
Gland packing seal
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5. MAINTENANCE
ATTENZIONE!
All maintenance work must be entrusted EXCLUSIVELY TO EXPERIENCED
PERSONNEL WHO KNOW WELL THE ELECTRIC PUMP AND THE RELEVANT
MANUAL.
During electric pump maintenance all useful measures must be adopted to PREVENT
THE ASSEMBLY STARTING UP ACCIDENTALLY:
- The main switch on the electrical panel must be locked IN POSITION " 0 " with a
PADLOCK.
- THE KEY of the padlock must be held by the MAINTENANCE TECHNICIAN throughout the operation.
- Always bear in mind all possible main risks and the safety instructions set out
in chapter 2 "SAFETY".
RISK OF ELECTROCUTION
IT IS FORBIDDEN TO PERFORM
MAINTENANCE OPERATIONS ON MOVING PARTS.
IN THE EVENT OF HARMFUL / TOXIC LIQUIDS, ALWAYS DECONTAMINATE THE
PUMP BEFORE THE PROCEDURES.
AFTER EVERY MAINTENANCE OPERATION THE MACHINE AND RELEVANT INSTALLATION MUST ALWAYS BE RESTORED TO ITS INITIAL STATUS INCLUDING
PROTECTIONS AND SAFETY DEVICES THAT HAVE BEEN TAKEN DOWN.
For good maintenance it is important to:
- Immediately check the causes of any anomalies (excessive noise, overheating, liquid leaks,
etc.).
- Pay special attention to safety devices.
- Use all the documentation provided by the manufacturer (operating booklet, system electri-
cal diagrams, etc.).
- Only use tools suitable for the work and original spare parts.
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5. MAINTENANCE
5.1 • REGULAR LUBRICATION
OIL LUBRICATION (Fig. 12)
Use high quality mineral-based oil with anti-oxidation, anti-corrosion and antifoaming additives.
Below is a list of some recommended types of oil:
AGIP…………… ACER 46 BLASIA 68
ESSO…............... TERESSO 68
SHELL………….TELLUS OIL 68
MOBIL………... DTE 15 - DTE 16
IP………………. HIDRUS 68
CASTROL… …..HY SPIN VG 46
The support must be free from any solid contamination or liquid seepage that may
cause rapid deterioration of bearings.
As a periodic check, check the neutralisation number of the oil and the degree of
oxidation. (contact the producer for reference values)
The frequency of oil changes depends on operating conditions and type of service.
Generally, high operating temperatures require more frequent oil changes; in particular:
Oil lubrication intervals (hours of actual operation).
Primo cambio Cambi successivi Durata massima
First change Subsequent changes Maximum duration
First change
300 hours 3000 hours 6 months
5.2 • DISASSEMBLY INSTRUCTIONS
Fig. 12
- Stop and secure the machine.
- Close all gate valves fitted on the delivery, intake piping and any auxiliary lines
(flushing, cooling).
- Disconnect the electrical power supply.
- In the event of oil lubrication, discharge it.
- Disconnect the pump's mouths from the piping and any auxiliary connections.
- Remove the joint cover.
- Disconnect the electrical cable from the motor.
For detailed disassembly contact the Manufacturer or technician authorised by them.
CAUTION!
In any case never force parts!
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5. MAINTENANCE
5.3 • REASSEMBLY INSTRUCTIONS
CAUTION!
For correct reassembly it is recommended to take into account the following
measures:
- Preferably use wooden or plastic mallets. Should any steel hammers be used,
always interpose a wood block.
- The bearings are locked with suitable cover and therefore they may be fitted
with no effort.
Moreover, proceed as follows (Fig. 13):
- Before reassembly, spread graphite or similar products on the fittings of
individual parts, including joining bolts.
- Ensure O-rings and radial seal rings are not damaged.
- Replace flat gaskets with the same gaskets and of the same thickness.
- Reassemble individual parts according to the right sequence in reverse order
from disassembly.
- Ensure the play of wear rings between diffusers and the impeller is not
excesive and remains within the admissible tolerances, otherwise replace the
wear rings before reassembly.
For the gaps of wear rings between diffusers and the impellers (Fig. 13) see tab.1 for
cast iron and steel construction
OVERHAULING COMPONENTS
Fig. 13
The pump must be regularly disassembled to check components; in the event they
should prove to be damaged they must be replaced with original spare parts.
Check for any liquid or lubricant leaks from gaskets of flanges and oil seal rings. The
gaskets must be reused only if they are intact.
Check the condition of the pump's inner parts and remove any deposits and scaling
using water or specific solvents.
Ensure inner and outer flushing ducts are not obstructed and that any cooling chamber is clean.
Check the condition of seals.
SEAL ON SHAFT (Fig. 14)
Before proceeding to reassembling the new gland packing gaskets, they must be
checked and in the event of scratches and abnormal signs of wear, clean with
abrasive cloth the packing box and the shaft protection bushing.
Obtain the set of new gaskets from the manufacturer.
Cut rings obliquely. Insert the first gasket ring by means of the gland.
All following gasket rings must be pushed one by one into the packing box by means
of the gland; the cutting surface of each ring must be rotated by approximately 90°
with respect to that of the
previous ring.
The gland must be tightened slightly and consistently, so that the impeller may rotate
easily.
Before starting up slightly turn the gland nuts.
After filling the pumps there must be some leaks. After about 10 minutes of operation
these leaks may be reduced by further tightening
the gland nuts; should these leaks still be excessive, repeat the operation until reducing the leaks to the minimum.
Check whether there are still sufficient leaks at the minimum operating pressure.
Braided gasket
Gland packing seal
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5. MAINTENANCE
5.4 • ROUTINE MAINTENANCE
AFTER 1 MONTH from installation ensure the tightening of crankcase fastening screws
and flange connection bolts is correct; also check correct operation of the assembly including current absorption and gland packing seal leaks.
EVERY 12 MONTHS:
- Visual inspection of all components in order to ascertain the absence of inconveniences or any anomalies.
- Have skilled technicians perform an inspection of the electrical system, including
motor, cables, levels, electrical contacts and control panel.
- Functional plant inspection.
- Seal inspection.
- Lubrication inspection (oil, see point 5.1).
CAUTION!
In the event of prolonged inactivity periods,
the assembly must be started once a month in order to prevent the rotating part from
seizing up.
Electric pump overhauling or repair must be performed by the manufacturer or authorised
workshop who possesses the relevant assembly and disassembly manuals and relevant
lists of spare parts.
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6. UNIT SCRAPPING
CAUTION!
DURING MACHINE SCRAPPING ALL THE SAFETY PRECAUTIONS SET OUT IN
CHAPTER 2 AND VALID FOR ASSEMBLY MUST BE COMPLIED WITH.
Machine scrapping must be performed by authorised technician like assembly.
Metal parts may be disposed of as metal scrap.
In any case all the materials from scrapping must be disposed of in compliance with the regulations in force in the
country of installation of the electrical pump.
7. SPARE PARTS
The overhauling or repair of the electric pump must be performed by the manufacturer or their authorised workshop who possesses the relevant manuals for
assembly and disassembly and relevant lists of spare parts.
The replacement of parts and repair procedures require compliance with
ALL SAFETY PRECAUTIONS set out in chapter 5 “MAINTENANCE”
and in chapter 2 “SAFETY”.
PROCEDURE TO ORDER SPARE PARTS
To order spare parts proceed as follows:
- Specify the motor and related pump's serial number.
- The year of construction.
- Specify the code of the required spare part.
(refer to the tables contained in the technical catalogue or in exploded drawings).
- Specify the required quantity.
The request must be sent to the Manufacturer or authorised dealer.
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