Xylem LCP User Manual

VOGEL-Volute Casing Pumps

Installation, Operation and Maintenance Instruction

Model: LS, LC, LCP

Translation of the Original Operation Manual

Keep for further use !

Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!

Artikel Nr. 25-4265105 Rev. 02 01/2010

Xylem Water Solutions Austria GmbH

Ernst Vogel-Straße 2 A-2000 Stockerau Telefon: +43 (0) 2266 / 604 Fax: +43 (0) 2266 / 65311 E-Mail: Internet: www.xylemaustria.com

info.austria@xyleminc.com

Installation, Operating and Maintenance Instruction

TABLE of CONTENTS

Pump Name Plate ..................................................... 2

ATEX-Label (only for pumps in compliance with

EC directive 94/9/EG) ................................................ 2

1. General................................................................... 3

1.1 Guarantee ......................................................... 3

2. Safety Regulations ............................................... 3

2.1 Marking of References in the Operating

Instructions .............................................................. 3

2.2 Dangers of non-observance of the Safety

Instructions .............................................................. 4

2.3 Safety Instructions for the Operator / Worker ... 4

2.4 Safety Instructions for Maintenance, Inspections

and Mounting Work ................................................. 4

2.5 Unauthorized Alteration and Spare Parts

Production ............................................................... 4

2.6 Undue Operation ............................................... 4

2.7 Explosion Protection.......................................... 4

2.8 Use acc. to Regulations .................................... 6

3. Description ............................................................ 6

3.1 Design ............................................................... 6

3.2 Shaft Sealing ..................................................... 7

3.3 Bearings ............................................................ 7

3.4 Approximate Value for Sound Pressure Level .. 8

3.5 Permitted Nozzle Loads and Torques at the

Pump Nozzles ... ..................................................... 8

4. Transport, Handling, Storage .............................. 9

4.1 Transport, Handling ........................................... 9

4.2 Storage / Conservation.................................... 10

5. Mounting / Installation ....................................... 10

5.1 Mounting of Pump / Unit .................................. 10

5.2 Connection of Pipings to the Pump ................. 10

Model LS, LC, LCP

5.3 Coupling ........................................................... 11

5.4 Drive ................................................................ 12

5.5 Electric Connection .......................................... 13

5.6 Final Control .................................................... 13

6. Start-up, Operation, Shut down ......................... 13

6.1 Initial start-up ................................................... 13

6.2 Switch on drive ................................................ 13

6.3 Restarting ........................................................ 13

6.4 Limits of Operation .......................................... 14

6.5 Lubrication of Bearings .................................... 14

6.6 Monitoring ........................................................ 15

6.7 Shutting down .................................................. 15

6.8 Storage / longer periods of non-operation ....... 15

7. Servicing, Maintenance ...................................... 15

7.1 General remarks .............................................. 15

7.2 Mechanical seals ............................................. 16

7.3 Stuffing boxes .................................................. 16

7.4 Lubrication and Change of Lubricant ............... 16

7.5 Coupling ........................................................... 16

7.6 Cleaning of pump ............................................ 17

8. Dismantling and repair of pump ........................ 17

8.1 General remarks .............................................. 17

8.2 General ............................................................ 17

8.3 Disassembly of Back Pull Out Assembly ......... 17

8.4 Removal of Impeller ......................................... 18

8.5 Removal of Shaft Sealing ................................ 18

8.6 Removal of Bearing ......................................... 18

8.7 Reconditioning ................................................. 18

8.8 Mounting .......................................................... 19

9. Recommended Spare Parts, Spare Pumps ...... 20

9.1 Spare Parts ...................................................... 20

9.2 Stand-by pumps ............................................... 20

10. Faults - Causes and Solutions ......................... 20

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Installation, Operating and Maintenance Instruction

Pump Name Plate

Model LS, LC, LCP

Type *) Type of pump S/N *) Serial number Year Year of construction Q Rated capacity at the operating point P Rated power at the operating point H Head (Energy head) at the operating point n Speed p

all w C

max op

Item No Customer related order number

Max permitted casing-operation-pressure

(=highest discharge pressure at the rated operating temperature to which the pump casing can be used).

Maximum permitted operating temperature of

pumped liquid

*) All details of design and materials are defined with this information. They must be stated on all inquiries to the manufacturer resp. orders of spare.

Imp∅ Outer diameter of the impeller

ATEX-Label (only for pumps in compliance with EC directive 94/9/EG)

CE Marking of compliance with the EC directive

94/9/EG Ex specific marking for explosion protection II Symbol for the appliance group 2G Symbol for the category (2), explosive

atmosphere due to gases, vapours or mist (G) c Symbol for used ignition protection

(constructive safety "c") T1-T. Symbol for classification of the theoretically

available range of the temperature classes -

data for temperature class refer to chapter

2.7.5; Data for maximum permitted

temperature of pumped liquid refer to pump

name plate, data sheet and / or order

confirmation.

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The conformity with the EC directive 94/9/EG "Appliances and Protection Systems for designated use in areas endangered to explosion" is declared by the issue of the EC-Declaration of Conformity and the attachment of the ATEX-label at the pump (bearing bracket). The ATEX-label is attached additionally to the pump name plate.

Revision 02

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Installation, Operating and Maintenance Instruction

The staff employed on installation, operation,

inspection and maintenance must be able to

evant

dent prevention regulations and that they

are suitably qualified for this work. If the staffs

do not have the relevant knowledge, they

observance can impair the pump and its

Products intended for use in explosive

1. General

Model LS, LC, LCP

This product corresponds with the requirements of the Machine directive 2006/42/EG.

prove that they know about the rel acci

should be provided with suitable instruction.

The operation safety of the delivered pump resp. unit (= pump with motor) can only be guaranteed on designated use according to the attached data sheet and / or order confirmation resp. chapter 6 "Start-up, Operation, Shut down". The operator is responsible for following the instructions and complying with the safety requirements given in these Operating Instructions. Smooth operation of the pump or pump unit can only be achieved if installation and maintenance are carried out carefully in accordance with the rules generally applied in the field of engineering and electrical engineering. If not all the information can be found in these Operating Instructions, please contact us. The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions are not followed. These Operating Instructions should be kept in a safe place for future use. If this pump or pump unit is handed on to any third party, it is essential that these Operating Instructions and the operating conditions and working limits given in the Confirmation of Order are also passed on in full.

These Operating Instructions do not take into account all design details and variants nor all the possible chance occurrences and events which might happen during installation, operation and maintenance. We retain all copyright in these Operating Instructions; they are intended only for personal use by the owner of the pump or the pump unit. The Operating Instructions contain technical instructions and drawings which may not, as a whole or in part, be reproduced, distributed or used in any unauthorised way for competitive purposes or passed on to others.

1.1 Guarantee

The guarantee is given in accordance with our Conditions of Delivery and/or the confirmation of order. Repair work during the guarantee period may only be carried out by us, or subject to our written approval. Otherwise the guarantee ceases to apply. Longer-term guarantees basically only cover correct handling and use of the specified material. The guarantee shall not cover natural wear and tear and all parts subject to wear, such as impellers, shaft sealing, shafts, shaft sleeves, bearings, wear rings etc. or damage caused by transport or improper handling. In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance with the operating conditions given on the name plate, confirmation of order and in the data sheet. This applies particularly for the endurance of the materials and smooth running of the pump and shaft sealing. If one or more aspects of the actual operating conditions are different, we should be asked to confirm in writing that the pump is suitable.

2. Safety Regulations

These Operating Instructions contain important instructions which must be followed when the pump is assembled and commissioned and during operating and maintenance. For this reason, these Operating Instructions must be read by the skilled staff responsible and/or by the operator of the plant before it is installed and commissioned, and they must be left permanently available at the place where the pump or pump unit is in use.

These Operating Instructions do not refer to the General Regulations on Accident Prevention or local safety and/or operating regulations. The operator is responsible for complying with these (if necessary by calling in additional installation staff).

Equally, instructions and safety devices regarding handling and disposal of the pumped media and/or auxiliary media for flushing, lubrication a.s.o., especially if they are explosive, toxically, hot a.s.o., are not part of this operating instruction. For the competent and prescribed handling only the operator is responsible.

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2.1 Marking of References in the Operating Instructions

The safety regulations contained in these Operating Instructions are specially marked with safety signs acc. to DIN 4844:

Safety reference! Nonfunction.

EC-Ex Marking

atmospheres must be marked. General Symbol for Danger!

Persons can be endangered.

Warning of electric voltage!

Safety instructions attached directly to the pump resp. unit must be followed under any circumstances. Further they must be kept in good readable condition.

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Installation, Operating and Maintenance Instruction

On application of the unit in areas endangered

to explosion special attention must be paid to

During operation of the pump the system of the

suction and pressure pipe and the pump itself

must permanently be filled with the pumped

liquid. Thus, no explosive atmosphere can

If the operator can´t guarantee that, according

In the same way, as these Operating Instructions of the pump, all possibly attached Operating Instructions of accessories (e.g. motor) must be noticed and kept available.

2.2 Dangers of non-observance of the Safety Instructions

Non-observance of the Safety Instructions can lead to loss of any claim for damages.

Further, non-observance can lead to following risks:  Failure of important functions of the machine or

facility.

 Failure of electronic appliances and measuring

instruments by magnetic fields.

 Endangering of persons and their personal

property by magnetic fields.

 Endangering of persons by electric, mechanic and

chemical influences.

 Endangering of environment through leakage of

dangerous substances.

sections marked with Ex.

2.3 Safety Instructions for the Operator / Worker

 Depending on the operating conditions, wear and

tear, corrosion or age will limit the working life of the pump/pump unit, and its specified characteristics. The operator must ensure that regular inspection and maintenance are carried out so that all parts are replaced in good time, which would otherwise endanger the safe operation of the system. If abnormal operation or any damage is observed, the pump must cease operation immediately.

 If the breakdown or failure of any system or unit

could lead to people being hurt or property being damaged, such system or unit must be provided with alarm devices and/or spare modules, and they should be tested regularly to ensure that they function properly.

 If there is any risk of injury from hot or cold

machine parts, these parts must be protected against contact by the user, or suitable warning signs must be affixed.

 Contact protection on moving parts (e.g. coupling

guards) must not be removed from systems that are in operation.

 If the sound level of a pump or pump unit is above

85 dB(A) an ear protection has to be used when staying near the pump for some time.

 If dangerous media (e.g. explosive, toxic, hot) leak

out (e.g. from shaft seals), these must be directed away so that there is no danger to people or the environment. The provisions of the law must be observed.

 Measures should be taken to exclude any danger

from electricity (e.g. by complying with the local regulations on electrical equipment). If work is carried out on live electrical components, they

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Model LS, LC, LCP

should be unplugged from the mains or the main switch turned off and fuse unscrewed. A motor protection switch is to be provided.

2.4 Safety Instructions for Maintenance, Inspections and Mounting Work

 The operator is responsible that any maintenance,

inspections and mounting work is made by authorized competent personnel, which must be informed by having read the Operating Instructions.

 Basically, all work on the pump or pump unit

should only be carried out when the pump is stationary and not under pressure. All parts must be allowed to return to ambient temperature. Make sure that no-one can start the motor during such work. It is essential that the procedure for stopping the system described in the Operating Instructions is observed. Pumps or pump systems that carry media that are dangerous to health must be decontaminated before being taken apart. Safety Data Sheets for the various liquids handled. Immediately after finishing work, all safety and protective devices must be replaced or restarted.

2.5 Unauthorized Alteration and Spare Parts Production

Alteration or changes of the machine are permitted after agreement with the manufacturer. Original spare parts and accessory authorized by the manufacturer are serving the safety. The use of other parts can lead to loss of liability for there from resulting consequences.

2.6 Undue Operation

The operating safety of the delivered machine can only be guaranteed by designated use acc. to the following chapters of the Operating Instructions. The limits stated in the data sheet and / or order confirmation must not be exceeded under any circumstances.

2.7 Explosion Protection

On application of units in areas endangered to explosion measures and references in the chapters

2.7.1 to 2.7.6 must be observed, so that explosion protection is guaranteed.

2.7.1 Filling of unit

develop and the danger of dry-run is avoided.

monitoring measures must be provided.

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Revision 02

Installation, Operating and Maintenance Instruction

Equally all seal casings, auxiliary systems of the

shaft sealing, as well as heating and cooling

The marking of the pump refers to the pump

itself. For coupling and motor resp. further

tions a separate Declaration of Conformity,

as well as a corresponding marking must be

Carry out rotation control with separated

pling halves only! Refer to chapter 5.5 and

If danger of explosion is also existing during

tion control must not be

up of the empty pump,

to avoid undue temperature increase in case of

There’s a danger, that high surface

tures are developing at the pump

casing after relatively short time, through fast

side the pump can

On pumps with mech. seals the permitted

run. Dry run not only can occur on insufficiently

but also because of too much

Operation of the pump out of the permitted

Under normal operating conditions the highest

of the pump casing and in the area of the

If the pump is heated (e. g. heating jacket), care

During operation of the pump it must be

cured that an overabundant sedimentation of

g), to prevent

heating of pump surface over the permitted

The particular allowed operating temperature of

the pump is shown in the data sheet and / or the

order confirmation resp. the type plate at the

For a secure and reliable operation it must be

secured by regular inspections, which the unit is

and is kept in good

systems must be filled carefully.

2.7.2 Marking

addi

available.

Example of of marking at pump:

CE Ex II 2 G c T... .

The marking shows the theoretically applicable range of temperature classes. The different temperatures, permitted acc. to pump design, result as shown in chapter 2.7.5. The same is valid for the drive. For a whole unit (pump, coupling, motor) with different temperature classes the lowest is valid.

2.7.3 Rotation Control

cou

6.1 as well.

installation, the rota carried out by short start-

contact of rotating and stationary parts.

2.7.4 Operation of pump

The pump must only be started up with fully opened suction side and slightly opened pressure side valve. The start-up against closed non-return valve, however, is possible. Immediately after the start-up the discharge side valve must be adjusted to the operating point. Refer to chapter 6.2, as well.

Operation with closed valve in suction and / or discharge pipe is not permitted!

tempera

Model LS, LC, LCP

temperature limits can be exceeded due to dry-

filled seal casing, gas in the medium.

operating range can lead to dry-run, as well.

2.7.5 Temperature Limits

temperatures must be expected at the surfac

bearings.

The surface temperature occurring at pump casing corresponds with the temperature of the pumped liquid.

must be taken, that the temperature classe prescribed for the plant are observed.

In the area of the bearing bracket free contact from surface to surrounding must be given.

se dust is avoided (regular cleanin

temperature.

The operator of the plant must secure that the defined operating temperature is observed. The max. allowed temperature of the pumped liquid at suction depends on the particular temperature class.

The following table shows the theoretical temperature limits of the pumped liquid in consideration of the temperature classes acc. to EN 13463-1.

Temperature class acc.

EN 13463-1 T4 (135°C) 135°C T3 (200°C) 180°C T2 (300°C) 180°C T1 (450°C) 180°C

Temperature limit of

pumped liquid

heating of the liquid inside the pump. Fast pressure increase in

lead to overload and, thus, the pump can burst.

In chapter 6.4.1 the minimum flow is stated. Longer operating phases with these flows and the named liquids don’t cause additional increase of surface temperature at the pump. Furthermore the references in chapter 6 of these operating Instructions must be taken into consideration.

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pump.

In the area of the bearings the temperature class T4 is guaranteed, provided that the ambient temperature is 40°C and the appliance is duly operated and maintained.

2.7.6 Maintenance

maintained competently technical condition.

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