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Summary of Contents for Sundyne LMV-803Lr
- Page 1 Installation, Operation & Maintenance Manual Sundyne Pumps Model: LMV-803Lr http://www.sundyne.com...
- Page 2 Warranty Sundyne LLC warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship.
- Page 3 Revisions December 2015 Original Release Update Introduction Content Add Cryogenic Options January 2019 Revised shimming process IOM Location Numbers updated...
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Page 4: Table Of Contents
Piping Connections ........5 OPERATION & CONTROL ....16 General .............. 6 Application or Use .......... 6 Operation of Sundyne Pumps ...... 16 Suction Conditions ........16 Start Up Checklist ..........6 Minimum Flow Conditions ......16 Pressurizing the Fluid Loop ......6 Entrained Gases .......... - Page 5 Spring Energized Seal Installation ....47 Moving (OH3 Configuration) ......22 Diffuser and Pump Case ......47 Shaft ............47 Disassembling the LMV-803Lr ...... 23 Inducer ............48 Disassembly (All Configurations) ....24 Disassembly (Extended Shaft Motor) ..30 TROUBLESHOOTING ....... 50 Disassembly (Bearing Box Configuration) ...
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Page 6: Introduction
API 610 OH3 and OH5 Direct Drive Process alternative to standard seal configurations, in Pumps a convenient package that eliminates errors Sundyne API 610, OH3 and OH5 direct drive in installation. pumps are known for their high-head, low-flow This manual presents installation, servicing,... -
Page 7: Text Symbols
Installation and Operation Manual Text Symbols In accordance with general safety and handling, RECOMMENDED: Text accompanied by OSHA 1910.145, BS EN 809 and other local this symbol indicates recommended directives, the following warning symbols and usage. signs are used in this manual. REMINDER: Text accompanied by this symbol indicates a reminder to perform an DANGER: Text accompanied by this... -
Page 8: Equipment And Safety Precautions
Safety procedures must be applied prior to any installation, maintenance, Attention must be given to the safe handling of all or repair of a Sundyne pump. Failure to items. This applies to both installation and follow safety precautions may lead to maintenance. -
Page 9: Ensuring Electrical Safety
Protection from Falling Sundyne recommends that a Lock- out/Tag-out program be followed prior Fall protection and associated preventative to altering the equipment. Locks or measures are required when working on... -
Page 10: Pre-Commission Checklist
Installation and Operation Manual Pre-Commission Checklist Familiarizing Yourself with the Pump Verifying Auxiliaries Before servicing and starting up the Sundyne Before start up, verify that the following auxiliaries pump, carefully review all information on the are met: product, including: •... -
Page 11: General
Each pump is designed for operation at the conditions stated on the pump label (Fig 2). Should the need arise to operate the pump outside of the conditions indicated on the pump label, Sundyne should be contacted to check and confirm that the pump can be operated safely at the revised operating conditions. -
Page 12: Installation And Start-Up Checklist
DO NOT test the pump on water unless it is designed for water. Check with your representative or Sundyne if you must test on a different fluid than shown on the specification sheet. -
Page 13: Installation
To ensure the original quality of the Sundyne If your Sundyne pump will not be operated for a pump after storage, all components must be period of time exceeding six months from the... -
Page 14: Suction And Discharge Piping
Installation and Operation Manual Factors which affect the quality of a Sundyne Recommended Long-Term Storage pump, when stored, are: Procedures Sundyne recommends that you do the following • Humidity to prevent damage to your pump during long- • Temperature term storage: •... -
Page 15: Net Positive Suction Head
Installation and Operation Manual Figure 3. Suction Piping Net Positive Suction Head Liquids cannot be towed or dragged down a pipe, they can only be pushed along a pipe. The push Vs = Velocity Head = A seal the liquid needs to flow into the pump can only be supplied by some external energy source. -
Page 16: Seal Environmental Control System
Installation and Operation Manual Seal Environmental Control System A seal environmental control system may be Ensure that the specified seal environmental required depending upon the pump seal control system is properly installed and that the arrangement and application. ports are open (or plugged) as indicated in the final data package. -
Page 17: Electrical Installation & Grounding
Installation and Operation Manual Electrical Installation & Grounding Electrical connection of the pump motor, to a suitably rated power supply shall be carried out by electrically skilled persons or staff. Care should be taken to ensure that the motor electrical connection will not overload the power supply. -
Page 18: Lubrication
Installation and Operation Manual LUBRICATION Lubrication Specification With OH5 configurations, refer to the driver’s instruction for lubrication requirements. In units outfitted with a bearing box (OH3), refer to the Bearing Box IOM for information. SA-07-11-87, Rev A January 2019... -
Page 19: Start Up
Installation and Operation Manual START UP Start-Up Procedures Perform the following tasks to start the Sundyne 5. Check the pump specification sheet and outline drawings for seal environment pump. requirements. Be sure that the seal housing 1. Run-in of pump: If the pump is to be run port piping is properly connected. -
Page 20: Controlling The Pump During Startup
Note: Do not operate the pumps at their peak the pump can fill with liquid. head capability. Parallel Operation Sundyne recommends that separate flow controls be used on each pump to provide a lower minimum flow range than is achieved by pressure control. -
Page 21: Operation & Control
If you have entrained gas, pressure at a high enough level and contact Sundyne for further instruction. suction temperatures low enough to maintain Net Positive Suction Head (NPSH... -
Page 22: System Head Curve
Installation and Operation Manual System Head Curve Note: In Figure 7, the curve for pump A has a significant angle of intersection with system curves D and E. The system curve D could represent a system with The point of intersection between the system the control valve wide open while curve curve and the pump characteristic curve E could represent the same system but... -
Page 23: Parallel Operation
Installation and Operation Manual Parallel Operation Maximizing control is critical when operating Figure 8. Parallel Units Common Valve centrifugal pumps in parallel. One pump can overpower the other in regard to head at a lower total flow. If a simple, unrestricted manifold (Figure 8) connects two pumps at the discharge head, the discharge head of one pump is imposed on the other. -
Page 24: Maintenance
• Always wear adequate Personal Protective Equipment (PPE) when • All pumps returned to Sundyne for dismantling pumps that have been used factory servicing must be to pump toxic or hazardous products. decontaminated and labelled in... -
Page 25: Moving The Lmv-803Lr
Installation and Operation Manual Moving the LMV-803Lr Moving (OH5 Configuration) The following procedures apply to the direct drive (OH5) configuration of the LMv-803Lr. Where indicated, separate instructions for the extended shaft motor and bearing box configurations are called out. 1.01... - Page 26 Installation and Operation Manual 1.03 (Not applicable to the Bearing Box configuration) Bolt the extended shaft motor to the lifting hanger using the motor’s integrated lifting feature holes (this may require removal of the motor’s “lifting ears”). Note: that these bolts will NOT take any vertical load and are merely intended for anti-rotation of the motor assembly.
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Page 27: Moving (Oh3 Configuration)
Installation and Operation Manual Moving (OH3 Configuration) 1.01 Remove the (4) coupling guard covers (8) screws from the (4) coupling guard covers. Remove the center section of the coupling. 1.02 Remove (4) nuts from the bolts connecting the coupling housing to the bearing box. Lift motor and coupling housing off the pump assembly. -
Page 28: Disassembling The Lmv-803Lr
It is recommended to remove and discard all O-rings during disassembly and replace with new. Note: Prior to disassembling the pump, insure the correct spare parts are available. Class 1 spares will be required for the scope of this exercise. Contact your Sundyne Representative for a list of all spares to the unit. -
Page 29: Disassembly (All Configurations)
Installation and Operation Manual Disassembly (All Configurations) 1.01 Remove the (6) seal housing nuts located closest to the inlet and discharge as shown. Place two lifting brackets over each of the studs (each bracket is unique, and must go on the correct side). - Page 30 Installation and Operation Manual 1.04 Secure the Lifting Hanger to an overhead lifting devise to prevent motor assembly from tipping. Remove remaining (8) seal housing nuts. 1.05 Lift top assembly off of pump case using the Lifting Hanger shackle and an overhead lifting devise.
- Page 31 Installation and Operation Manual 1.06 Set the top assembly down onto a set of crates (or similar) as shown below. Position the crates so they are butted against the side of the diffuser cover for maximum stability. Keep the overhead lifting device attached to the Lifting Hanger shackle for stability.
- Page 32 Installation and Operation Manual 1.08 If the impeller does not immediately come off of the splined shaft, use the BK01MK04 Impeller Extraction Tool. Bolt the extraction tool to the impeller using (2) 5/16–18x1” long shoulder bolts. Hand tighten a ¾-10 jacking screw into the center hole until it presses against the shaft.
- Page 33 Installation and Operation Manual 1.10 Remove the (3) socket cap screws holding the diffuser cover to the seal housing and lift the top assembly off the cover. Place the top assembly back on top of the crates from STEP 8. Note: If the diffuser cover will not separate from the seal housing after removing the screws then...
- Page 34 Installation and Operation Manual 1.12 Loosen Set Screws on the Seal Collar in an alternating pattern of one opposite the other. Retract screws from shaft 2 to 3 turns to insure it is not in contact of the shaft. It may be necessary to slightly rotate the shaft to position the screws for access around other bolts.
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Page 35: Disassembly (Extended Shaft Motor)
Installation and Operation Manual Disassembly (Extended Shaft Motor) ONLY PROCEED WITH THESE STEPS IF STEPS 1-12 HAVE BEEN COMPLETED 1.13 To prevent tipping, ensure the motor is secured to an overhead lifting devise using the motor’s integrated lifting features. Remove the Lifting Hanger and Lifting Brackets. -
Page 36: Disassembly (Bearing Box Configuration)
Installation and Operation Manual Disassembly (Bearing Box Configuration) ONLY PROCEED WITH THESE STEPS IF STEPS 1-12 HAVE BEEN COMPLETED 1.13 Remove the (4) bolts anchoring the bearing box to the seal housing. Carefully lift the bearing box off of the seal housing using eye bolts or similar lifting devise. -
Page 37: Diffuser (Removal)
Installation and Operation Manual Diffuser (Removal) 1.01 Lift the diffuser out of the pump case using lifting lugs or eye bolts. Once removed, if the o-rings need to be replaced, remove from their respective grooves on the bottom of the diffuser. -
Page 38: Assembling The Lmv-803Lr
Installation and Operation Manual Assembling the LMV-803Lr Diffuser Assembly 1.01 Place o-ring and face seal in their respective face grooves on the diffusers. Carefully lower the diffuser into the pump case. On cryogenic applications, no seal is used on the diffuser eye diameter. -
Page 39: Assembly (Extended Shaft Motor)
Installation and Operation Manual Assembly (Extended Shaft Motor) 1.01 Place the seal housing on top of (2) blocks/crates allowing approximately 12 inches of clearance underneath. Attach the cartridge seal and it’s o- ring to the seal housing (4) bolts. Apply ½ the recommended torque to the bolts. - Page 40 Installation and Operation Manual 1.04 Install the (4) motor anchor bolts Continue to: Assembly (All Configurations) for remaining installation steps (page 38). SA-07-11-87, Rev A January 2019...
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Page 41: Assembly (Bearing Box Configuration)
Installation and Operation Manual Assembly (Bearing Box Configuration) 1.01 Place the seal housing on top of (2) blocks allowing approximately 12 inches of clearance underneath. Attach the cartridge seal and it’s o- ring to the seal housing (4) bolts. Apply ½ the recommended torque to the bolts. - Page 42 Installation and Operation Manual 1.03 Bolt the bearing box housing to the seal housing using (4) bolts. Torque to specification. Continue to: Assembly (All Configurations) for remaining installation steps (page 38). SA-07-11-87, Rev A January 2019...
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Page 43: Assembly (All Configurations)
Installation and Operation Manual Assembly (All Configurations) 1.01 For configurations which require a throat bushing, turn the seal housing over to access the bottom. Insert (2) Spring spring pins into the holes keeping Pins the seams of the pins towards the OUTSIDE of the seal housing. - Page 44 Installation and Operation Manual 1.04 (Not applicable to the Bearing Box configuration) Bolt the extended shaft motor to the lifting hanger using the motor’s integrated lifting feature holes (this may require removal of the motor’s “lifting ears”). Note: Motor bolts DO NOT take any vertical load and are merely intended for anti- rotation of the motor...
- Page 45 Installation and Operation Manual 1.07 Remove or reposition the Seal Spacers depending on the seal style. Tighten the remaining screws in a sequential order until first the screw comes in contact with the shaft and then return and tighten to ½ the recommended torque.
- Page 46 Installation and Operation Manual 1.09 Install diffuser cover under the seal housing using (3) socket head cap screws. 1.10 Install the impeller, inducer stud, and inducer. Note that the inducer stud is left hand thread – turn counter- clockwise to tighten. Tighten to ¼ of the recommended torque.
- Page 47 Installation and Operation Manual 1.11 Place the pump case o-ring in the top groove if not already installed. 1.12 Lift the top assembly off the crates using the Lifting Hanger shackle and an overhead lifting devise. Carefully lower the top assembly down onto the pump case.
- Page 48 Installation and Operation Manual 1.14 Install four seal guards (116D, 116DA) with screws (905G) and washers (916BA) to the pump assembly. SA-07-11-87, Rev A January 2019...
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Page 49: Shimming
Installation and Operation Manual Shimming Shimming Both configurations (Extended Shaft Motor & Bearing Box) of the LMV-803Lr require controlling the clearance on the front and backside of the impeller. The tolerance of each clearance is .060 +/- .010” (1.5 0+/- .25 mm). - Page 50 Installation and Operation Manual Fig. 12. Front Clearance Measurement Solder Ring Prior to installing assembly into the diffuser, construct a ring of solder wire and place it in the diffuser bowl about 1.0” (25mm) in from the outside diameter of the blade. Lower the bearing box assembly into the diffuser/pump case.
- Page 51 FC is GREATER than .060”. SHIM = .065 - .060 = .005” New Clearance Back = .06, Front = .06”, TC = .120” Sundyne can provide an Excel Spreadsheet to facilitate the calculations. Contact your Sundyne Representative. SA-07-11-87, Rev A...
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Page 52: Spring Energized Seal Installation
Installation and Operation Manual Spring Energized Seal Installation Prior to installing the seals, check surfaces for nicks or cuts that can damage the seal on installation or impact the seal performance. In cryogenic applications, the grooves for the seals are highly polished and care must be taken to avoid any scratches or nicks in the seal gland. -
Page 53: Inducer
Installation and Operation Manual Figure 13. Spring Energized Seal Installation on the shaft Groove Seal Spline Resizer Seal Tool Stretch Tool Stretcher-Shaft-TO01MK03 Resizer-Shaft-TO01MK04 Inducer The inducer requires piston style sealing and when a spring energized seal is used, it must be stretched to clear diameters that are in front of the seal gland. - Page 54 Installation and Operation Manual Figure 14. Spring Energized Seal Installation on Inducer Groove Seal Stretch Tool Stretcher-Inducer-TO01MK05 Seal Resizer Tool Resizer-Inducer-TO01MK06 SA-07-11-87, Rev A January 2019...
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Page 55: Troubleshooting
Installation and Operation Manual TROUBLESHOOTING Pump Diagnostics • Several system factors may affect the Flow rate performance of the pump. These factors are: • Control characteristics • Temperature These factors as well as internal problems must • Specific gravity be considered when analyzing pump system performance. - Page 56 Installation and Operation Manual Situation/Symptom Possible Cause Investigative/Corrective Action NPSH actually lower than NPSH Refer to solutions listed under “No requirement listed on specification sheet. flow, no pressure at start-up”. Flow too low, causing overheating of fluid Increase through-flow rate. resulting in internal boiling and unstable Bypass part of pump discharge to pump operation.
- Page 57 Installation and Operation Manual Situation/Symptom Possible Cause Investigative/Corrective Action Mechanical failure in driver or pump. Remove driver and check for freedom of rotation, correct spacing of pump shaft assemblies. Remove fluid end and search for any mechanical failure. Corrosion pitting on surface of diffuser cover Disassemble pump inspect.
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Page 58: Specifications
Installation and Operation Manual SPECIFICATIONS Table 2. Torque Values Sundyne Standard Steel Screws & Bolts Dry Thread Torque Values Item # Location Size English Metric IMPELLER BOLT 1/2 – 20 x 4 LHT 40 - 50 ft-lbs 54 - 68 N-m... -
Page 59: Parts List
Installation and Operation Manual Parts List Table 3. Parts List Typical LMV-803Lr with Extended Shaft Motor List Item Item Description Description 1 PUMP CASE 905E HEX HEAD CAP SCREW 2 IMPELLER 905G HEX HEAD CAP SCREW 5 IMPELLER TAB WASHER... - Page 60 Installation and Operation Manual Typical LMV-803Lr with Bearing Box Parts List (Grease Lube) Item Item Description Description 1 PUMP CASE 186A GREASE FITTIING 2 IMPELLER 186B GREASE FITTING 5 IMPELLER TAB WASHER 905A HEX HEAD CAP SCREW 9 INDUCER 905E HEX HEAD CAP SCREW...
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Page 61: Extended Shaft Motor Configuration
Installation and Operation Manual Extended Shaft Motor Configuration Figure 15. Extended Shaft Motor Configuration SA-07-11-87, Rev A January 2019... -
Page 62: Bearing Box Configuration
Installation and Operation Manual Bearing Box Configuration Figure 16. Bearing Box Configuration SA-07-11-87, Rev A January 2019... -
Page 63: Index
Cryogenic Seal Installation, 47 Pump Familiarization, 5 Disassembling the LMV-803, 20, 23 Pump Removal from Pipe Work, 19 Dismantling Precautions, 19 Reassembling the LMV-803Lr, 33 Driver Instructions, 5 Seal Environmental Control System, 10, 11 Driver Rotation Check, 5 Setting the Valves, 6... - Page 64 Sundyne Headquarters Sundyne European Headquarters Sundyne HMD Sealless Pumps Sundyne Marelli Pumps 14845 West 64 Avenue Sundyne International S.A. Brampton Road Ctra. Madrid-Toledo, KM.30.8 Arvada, Colorado 80007 13-15 Blvd. Eiffel – B.P. 30 Hampden Park Industrial Estate 45200 Illescas 21604 Longvic Cedex...
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