Page 1 Centrifugal pump ACP STANDARD, C-01-000000 Instruction handbook Centrifugal pump ACP Machine: Equipment No.: Year of manufacture: 2022 Order code: STANDARD Order no.: C-01-000000 Original language: German Issued: KPRop/Schorn, 11-2022 Rev.: Checked: HPUSP/Poglitsch, 11-2022 Checked: Rev. 2.9...
Page 2 The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or partly re- produced without authorization by ANDRITZ. Non-compliance will result in damages claims and may have consequences under criminal law. All rights shall also be reserved for any patents granted, registration of trade marks and technical modifications without prior notification.
Page 3: Table Of Contents
Centrifugal pump ACP STANDARD, C-01-000000 Table of contents Introduction ............................. 7 General information......................... 7 Gender declaration.......................... 7 Use..............................7 Standards and guidelines........................ 8 Use of manual ..........................8 1.5.1 Item numbering ........................8 Warranty and liability........................9 Service address ..........................9 Copyright............................
Page 4 Turning off (machining) the impeller ................109 8.8.4 Balancing the impeller ....................109 Changing the seal ........................110 8.9.1 ANDRITZ cartridge seal – single-action ................ 111 8.9.2 ANDRITZ cartridge seal – double-action ............... 113 8.9.3 Mechanical seal – single-action ..................115 8.9.4...
Page 5 SHAFT SEAL ..........................129 MOTOR............................129 FOUNDATION WORK ........................ 129 9.4.1 Adhesive anchor capsule - HVU (HILTI) - Instruction ............ 130 10 Certificates............................141 10.1 Declaration of Conformity......................142 10.2 ANDRITZ Certificate ISO9001 ....................143 Rev. 2.9 Table of contents...
Page 6 Centrifugal pump ACP STANDARD, C-01-000000 Table of contents Rev. 2.9...
Page 7: Introduction
This instruction handbook is part of the technical documentation from ANDRITZ for the machine. It is intended to provide the operating company with the essential knowledge for safe, proper and economical use of the machine supplied by ANDRITZ. Paying at- tention to these instructions helps prevent hazards, reduce repair costs and downtime, and increase the reliability and service life of the machine.
Page 8: Standards And Guidelines
Centrifugal pump ACP STANDARD, C-01-000000 Standards and guidelines The pump is delivered together with a CE declaration of conformity according to Ma- chinery Directive 2006/42/EC Annex II, 1.A. It is confirmed that harmonized European standards EN 809 and EN ISO 12100, Parts 1 and 2, have been observed. Any elec- trical equipment supplied (motor, measuring instruments, etc.) has CE marking if it falls within the scope of a directive, for example the low-voltage or EMC Directive.
Page 9: Warranty And Liability
• Unauthorised structural changes to the machine/system. • Failure to observe the maintenance and upkeep instructions. • Use of non-original spare parts. In the event of a warranty claim, ANDRITZ reserves the right to assess damage to the machine/system. Service address Our service department is available for ordering spare parts, for troubleshooting and for extensive maintenance and repair work.
Page 10 Centrifugal pump ACP STANDARD, C-01-000000 Introduction Rev. 2.9...
Page 11: Safety
Supplementary safety notes relating to individual tasks are set out in the individual chapters of the instructions. These are highlighted in the text by special warning no- tices. Safety notes for components not supplied by ANDRITZ are contained in the subsup- plier documentation. These safety notes supplement the ANDRITZ instructions.
Page 12: Intended Use
The machine may only be used for the process described in the chapter "Application area". Any other use or secondary use is considered improper use. Any modifications to the scope of delivery not approved by ANDRITZ qualify as im- proper use. Proper use includes compliance with the installation, operating and instruction hand- book.
Page 13: General Information About Machine Safety
Centrifugal pump ACP STANDARD, C-01-000000 General information about machine safety The machine/system is designed in accordance with state-of-the-art standards and the recognised safety rules. Nevertheless, its use may constitute a risk to life and limb of the user and of third parties, or cause damage to the machine/system and to other material assets.
Page 14: General Obligations Of Personnel
In addition, ANDRITZ recommends mounting the following devices, symbols and signs in as far as these are not already included in the local regulations.
Page 15: Safety Devices
Centrifugal pump ACP STANDARD, C-01-000000 • Familiarize yourself with the function and any failure of monitoring equipment (log book) before starting work. • No smoking in the vicinity of the machine/plant. • Wear personal protective apparel when working on the machine/plant. •...
Page 16: Safety Covers
Centrifugal pump ACP STANDARD, C-01-000000 2.8.1 Safety covers The following safety devices are provided on the machine: Fig. 1: Safety covers Pos. Designation Pos. Designation 680 Safety cover at the sealing cham- 681 Coupling guard Safety Rev. 2.9...
Page 17: Warning Signs
Centrifugal pump ACP STANDARD, C-01-000000 2.8.2 Warning signs If surface temperatures of more than 65°C should occur, the safety sign with the word- ing "Danger - hot surface” must be affixed. Warning: hot sur- face! Tab. 1: Safety signs Chemicals If the machine is used in the chemicals sector, the operating company must install ap- propriate safety notes on the plant.
Page 18 Centrifugal pump ACP STANDARD, C-01-000000 No. Description Symbol 02 Marked components or machines are to be lubricated with oil. >> Oil lubrication Tab. 3: Lubrication sign Safety Rev. 2.9...
Page 19: Personal Protective Equipment
Centrifugal pump ACP STANDARD, C-01-000000 Personal protective equipment Personal protective equipment must be used and carried along in accordance with the country-specific regulations or the regulations of the system operator. Wearing safety shoes and eye protection should be mandatory on the entire plant grounds. In addition to the applicable regulations, we recommend using the following protective equipment for certain tasks.
Page 20: Safety At The Installation Site
Centrifugal pump ACP STANDARD, C-01-000000 2.10 Safety at the installation site The machine does not have a permanent workstation. Presence at the machine is only necessary for inspection and maintenance tasks. All operating and maintenance areas of the machine must have adequate lighting and ventilation (industrial lighting).
Page 21: Table Of Sound Power Levels
Centrifugal pump ACP STANDARD, C-01-000000 2.12.2 Table of sound power levels 1180 1450 1780 3000 3560 ACP 32-125 ACP 32-160 ACP 32-200 ACP 32-250 ACP 40-125 ACP 40-160 ACP 40-200 ACP 40-250 ACP 40-315 ACP 50-125 ACP 50-160 ACP 50-200 ACP 50-250 ACP 50-315 ACP 65-125...
Page 22 Centrifugal pump ACP STANDARD, C-01-000000 1180 1450 1780 3000 3560 ACP 150-480 ACP 150-500 ACP 200-400 ACP 200-480 ACP 200-500 ACP 200-625 ACP 250-315 ACP 250-480 ACP 250-625 ACP 300-400 ACP 300-500 ACP 300-550 ACP 300-700 ACP 350-480 ACP 350-650 ACP 400-330 ACP 400-530 ACP 400-700...
Page 23 Centrifugal pump ACP STANDARD, C-01-000000 1180 1450 1780 3000 3560 ACP 200-400 BS75-2 (HD) ACP 450-550 BS100-2 (HD) Tab. 6: Sound power level (dB) Rev. 2.9 Safety...
Page 24: Electrical Equipment
2.14 Welding work In general, welding work is only permitted after consultation with the national authorit- ies and after consultation with ANDRITZ. Welding work that is described in detail in the maintenance instructions is exempt from this rule. The relevant safety regulations must be observed for welding work.
Page 25: Fluids (Liquids, Gases, Steam Or Smoke)
Centrifugal pump ACP STANDARD, C-01-000000 2.15 Fluids (liquids, gases, steam or smoke) In various media, in case of a longer standstill, unwanted chemical reactions can oc- cur and vapours harmful to health can be generated. After prolonged stoppages, the machine must be thoroughly cleaned. Sufficient ventilation and degassing must be ensured.
Page 26: Chemicals
Centrifugal pump ACP STANDARD, C-01-000000 2.17 Chemicals Chemicals can damage the skin and cause the formation of hazardous gases, which may subsequently cause breathing problems. Personnel handling these materials must not be allergic to them. Safety data sheets If chemicals are used, the measures prescribed in the safety data sheets of each chemical must be adhered to.
Page 27: Data Sheet, Characteristic Curve, Drawing
Centrifugal pump ACP STANDARD, C-01-000000 Data sheet, characteristic curve, drawing Rev. 2.9 Data sheet, characteristic curve, drawing...
Page 28 Centrifugal pump ACP STANDARD, C-01-000000 Data sheet, characteristic curve, drawing Rev. 2.9...
Page 29: Description
The centrifugal pump is used to convey the specified media or materials in compliance with the manufacturer's instructions. If modifications are planned or the pump is to be used for a non-specified application or in an ATEX environment, ANDRITZ must be contacted.
Page 30: Type Specification
STANDARD, C-01-000000 Type specification 4.3.1 Type code 400 - 700 . 5 S CL e1 e2 Description ACP series centrifugal pump Nominal width of delivery branch (mm) Nominal impeller diameter (mm) Number of impeller blades Impeller variant • F = open impeller •...
Page 31: Name Plate
Medium The centrifugal pump serves to pump incombustible liquids and fibrous pulps. It is es- sential to consult ANDRITZ before any planned pumping of combustible liquids (solvents, fuel, alcohol, etc.)! If combustible liquids with a low flash point are pumped, there is a risk of risk of fire and explosion.
Page 32: Permitted Loads On Connecting Branches
Centrifugal pump ACP STANDARD, C-01-000000 4.4.1 Permitted loads on connecting branches The permitted forces and torques stated in the following tables must not be exceeded. In general, the suction and delivery pipes must be connected up stress-free. We re- commend checking this item before start-up. 4.4.1.1 Spiral casing made of grey cast iron The specified values apply to a spiral casing made of grey cast iron with a moulded base frame.
Page 33 Centrifugal pump ACP STANDARD, C-01-000000 Nominal Force (N) Torque (Nm) Ø (DN) Σ F Σ M 8384 7540 9308 14604 11360 8120 9200 16200 9584 8620 10640 16696 13840 10480 11600 18800 10784 9696 11972 18784 16320 12840 14000 21400 1000 11988 10776 13304 20876 18800...
Page 34 Centrifugal pump ACP STANDARD, C-01-000000 4.4.1.2 Spiral casing made of steel casting The values stated apply to a spiral casing made of steel casting with grouted base frame. Fig. 4: Flange forces ΣF and ΣM are the vector sums of the forces and moments. Delivery flange Nom.
Page 35 Centrifugal pump ACP STANDARD, C-01-000000 Suction flange Nom. Ø Force (N) Torque (Nm) (DN) Σ F Σ M 1155 1120 1365 1330 1155 1050 1820 1435 1470 1295 1190 2310 1050 1540 1750 1575 1435 2765 1120 1645 2345 2100 1890 3675 1225 1015 1820...
Page 36 Centrifugal pump ACP STANDARD, C-01-000000 4.4.1.3 Spiral casing made of steel casting – Centerline version The values stated apply to a spiral casing made of steel casting, pump design "Centerline" with grouted base frame. Fig. 5: Flange forces - Centerline version ΣF and ΣM are the vector sums of the forces and moments.
Page 37 Centrifugal pump ACP STANDARD, C-01-000000 Nom. Ø Force (N) Torque (Nm) (DN) Σ F Σ M 1200 35970 32340 39920 62650 59400 49800 53000 73000 Tab. 14: Permitted forces and torques at the delivery flange Suction flange Nom. Ø Force (N) Torque (Nm) (DN) Σ F Σ M...
Page 38: Main Components
Centrifugal pump ACP STANDARD, C-01-000000 Main components Fig. 6: Main components Pos. Designation Pos. Designation Centrifugal pump Base frame (891) Coupling (840) Slide rails (593) or supports (592) Coupling guard (681) Motor (800) Fig. 7: ACP pump with motor block Description Rev. 2.9...
Page 39: Centrifugal Pump
Centrifugal pump ACP STANDARD, C-01-000000 4.5.1 Centrifugal pump The design of the centrifugal pump with spiral casing is suitable for use in industrial processes. The impeller, the wear lining, the casing cover, and the stuffing box hous- ing with shaft seals and bearing support can be assembled and disassembled without detaching the suction and delivery pipes.
Page 40 Centrifugal pump ACP STANDARD, C-01-000000 • Suction and delivery flanges • Holding the bearing housing with bearing assembly, shaft, and impeller • Standard design: single spiral casing or double spiral casing Impeller (230) Function Increased twist by charging the medium with rotational energy. Designs •...
Page 41 Design There are different types of shaft seal depending on operational requirements. • Mechanical cartridge seal from ANDRITZ – single-action • Mechanical cartridge seal from ANDRITZ – double-action • Mechanical standard seal – single-action • Mechanical standard cartridge seal – single-action •...
Page 42: Bearing Support
Centrifugal pump ACP STANDARD, C-01-000000 4.5.2 Bearing support 4.5.2.1 Bearing support with grease lubrication 636.1 321.1 931.1 636.2 321.2 423.2 901.1 507.2 940.2 901.3 507.3 412.14 904.2 412.1 903.1 411.1 904.1 903.2 411.2 Fig. 9: Bearing support with grease lubrication Item Component Item Component...
Page 43 Centrifugal pump ACP STANDARD, C-01-000000 4.5.2.2 Bearing support with oil lubrication 903.4 903.3 321.1 931.1 411.4 411.3 321.2 423.2 901.1 507.4 940.2 901.3 507.3 412.14 914.10 411.10 412.1 903.1 411.1 914.11 411.11 Fig. 10: Bearing support with oil lubrication Item Component Item Component Bearing housing...
Page 44 Centrifugal pump ACP STANDARD, C-01-000000 4.5.2.3 Bearing types Bearing type Bearing type Coupling end Bearing support Pump type Pump end Grease-lubric- Oil-lubricated ated bearings bearing ACP 32-125 ACP 32-160 ACP 32-200 2 x 7307 BECBP ACP40-125 ACP 40-160 BS24 6305/C3 6305Z/C3 ACP 40-200 2 x 7307B-TVP-UA...
Page 45 Centrifugal pump ACP STANDARD, C-01-000000 Bearing type Bearing type Coupling end Bearing support Pump type Pump end Lubricated Lubricated with grease with oil ACP 100-500 ACP 200-400 2 x 7316 BECBP ACP 250-480 BS60 6314/C3 6314Z/C3 ACP 300-400 ACP 450-370 2 x 7316B-TVP-UA ACP 450-410 ACP 600-505...
Page 46: Shaft Seal
4.5.3.1 ANDRITZ Cartridge seal - single 551.1 412.5 551.2 551.3 433.1 902.5 920.5 554.5 Fig. 11: ANDRITZ – Cartridge seal (BS42 – BS100) Pos. Designation Pos. Designation 433.1 Shaft seal 920.5 Hexagon nut 902.5 Stud bolt 412.5 O-ring 554.5 Washer 551 Spacer plates Function Seal between the medium and the atmosphere.
Page 47 Centrifugal pump ACP STANDARD, C-01-000000 551.1 902.4 551.2 433.1 920.4 554.4 551.3 Fig. 12: ANDRITZ – Cartridge seal (BS24 – BS32) Rev. 2.9 Description...
Page 48 4.5.3.2 ANDRITZ Cartridge seal - double 551.1 412.5 551.2 551.3 433.1 902.5 920.5 554.5 Fig. 13: ANDRITZ – Cartridge seal (BS42 – BS100) Pos. Designation Pos. Designation 433.1 Shaft seal 920.5 Hex nut 902.5 Stud 412.5 O-ring 554.5 Plain washer 551 Spacer plates Function Sealing between medium and the atmosphere by the use of sealing water.
Page 49 Sealing water quality: 75 microns (fresh water) Sealing water temperature: min. 10 °C – max. 30 °C Solids content: 2 mg/l max. 551.1 902.4 433.1 551.2 920.4 551.3 554.4 Fig. 14: ANDRITZ – Cartridge seal (BS24 – BS32) Rev. 2.9 Description...
Page 50 Centrifugal pump ACP STANDARD, C-01-000000 4.5.3.3 Mechanical seal – single-action 551.1 551.2 433.1 412.5 551.3 902.5 920.5 554.5 Fig. 15: Mechanical seal – single-action (BS42 – BS100) Pos. Designation Pos. Designation 433.1 Shaft seal 145 Adapter 902.5 Stud bolt 412.5 O-ring 554.5 Washer 504 Spacer ring 920.5 Hexagon nut...
Page 51 Centrifugal pump ACP STANDARD, C-01-000000 551.1 551.2 433.1 551.3 Fig. 16: Mechanical seal – single-action (BS24 – BS32) Rev. 2.9 Description...
Page 52 Centrifugal pump ACP STANDARD, C-01-000000 4.5.3.4 STANDARD Cartridge seal - single 551.1 902.4 412.5 551.2 920.4 551.3 554.4 433.1 902.5 920.5 554.5 Fig. 17: STANDARD Cartridge seal (BS42 – BS100) Pos. Designation Pos. Designation 433.1 Shaft seal 920.5 Hexagon nut 145 Adapter 412.5 O-ring 902.4 Stud bolt 504 Spacer ring...
Page 53 Centrifugal pump ACP STANDARD, C-01-000000 551.1 902.4 551.2 433.1 920.4 551.3 554.4 Fig. 18: STANDARD Cartridge seal (BS24 – BS32) Rev. 2.9 Description...
Page 54 Sealing between medium and the atmosphere by the use of sealing water. Application limits The limit values listed in the table below must be observed in any event. If the limit val- ues are exceeded, ANDRITZ must be contacted! T max P max N max 180 °C...
Page 55 Centrifugal pump ACP STANDARD, C-01-000000 Connections The sealing water connections are to be taken from the supplier documentation in ac- cordance with the manufacturer's specifications. Monitoring In order to guarantee proper operation, the seal water must be monitored by suitable monitoring units in accordance with the diagrams provided below.
Page 56 Centrifugal pump ACP STANDARD, C-01-000000 4.5.3.6 Stuffing box Fig. 21: Stuffing box (BS42 – BS100) Pos. Designation Pos. Designation 451 Stuffing box casing 920.5 Hex nut 452 Stuffing box gland 412.5 O-ring 458 Seal water ring 412.8 O-ring 461 Stuffing box packing 524 Shaft protective sleeve 902.5 Stud 551 Spacer plates...
Page 57 Centrifugal pump ACP STANDARD, C-01-000000 Bearing Shaft Ø Seal Ø Packing Ø Packing No. of pack- support size [mm] [mm] [mm] [mm] ings BS75 12x12 BS100 12x12 Tab. 31: Dimensions Seal water Bearing support size Seal water pressure Seal water quantity [bar] [l/min] BS24...
Page 58 The limit values listed in the table below must be observed in all cases. If the limit val- ues are exceeded, ANDRITZ must be contacted! During a shutdown, the inlet pressure must be atmospheric at least so that the seal is tight.
Page 59 Centrifugal pump ACP STANDARD, C-01-000000 Size Min. Max. Diagram [rpm] [rpm] BS42 1200 3000 BS48 1800 BS60 1800 Rev. 2.9 Description...
Page 60 Centrifugal pump ACP STANDARD, C-01-000000 Size Min. Max. Diagram [rpm] [rpm] BS75 1800 BS100 1200 Description Rev. 2.9...
Page 61: Installation
General information This chapter describes work processes for the erection of the machine/system that may be the responsibility of the operating company. The description does not include tasks of pre-assembly work carried out by ANDRITZ at its factory. Safety regulations General safety reg- All applicable accident prevention rules must be observed.
Page 62 Do not accept the goods in the event of transport damage or short supply, and notify the forwarder and the ANDRITZ shipping department accordingly. Stability Stability during transport or erection work is also guaranteed at an angle of 10° out of the normal position.
Page 63: Lifting The Pump
Centrifugal pump ACP STANDARD, C-01-000000 5.3.1 Lifting the pump The pump and components may be lifted only in accordance with the following instruc- tions and figures. The lifting equipment must be short enough to prevent the pump from tipping. DANGER Lifting the pump incorrectly Danger due to the pump tilting when raised.
Page 64 Centrifugal pump ACP STANDARD, C-01-000000 Entire pump Lifting the entire pump (pump is mounted on the base frame) Appropriate lifting equipment must be attached under the suction flange and on the base frame (as shown in the figure). Fig. 24: Lifting the entire pump (with the base frame) Pump with free Lifting the pump with free shaft shaft...
Page 65: Storage
Centrifugal pump ACP STANDARD, C-01-000000 Storage Short-term storage If the pump is stored for less than 3 months until the start of installation, observe the following notes: • Store the machine in a dry location where it is protected against dirt and corrosion. •...
Page 66: Installation
Centrifugal pump ACP STANDARD, C-01-000000 Installation General Completion of the various steps must be documented in the certificate of completion of erection work. CAUTION Risks during assembly Disregarding the installation procdure and installation instructions may result in haz- ardous situations causing a danger to life and limb. •...
Page 67: Pump Installation
Centrifugal pump ACP STANDARD, C-01-000000 5.5.1 Pump installation Erecting and foundation laying Steps 1) Mark the fixing points of the base frame according to the installation plan on the foundation. 2) Drill the anchor holes and insert the compound anchor cartridges (6). ð...
Page 68 Centrifugal pump ACP STANDARD, C-01-000000 5.5.1.1 Mounting the motor Mount the motor if it has not yet been installed. Steps 1) Mount the drilled coupling half flush on the motor stub and secure on the feather key with a set screw. 2) Bolts or threaded rods cut to a suitable length are used to secure the motor in place.
Page 69: Pipes
Centrifugal pump ACP STANDARD, C-01-000000 5.5.2 Pipes CAUTION Potential injury hazard from breaking machine parts Improperly installed pipe and hose lines can cause machine parts to break. • All pipes must be free of stress and vibration when installed! • The pipes must be installed so that they do not cause stress on the machine dur- ing operation (e.g.
Page 70: Coupling
Optional accessor- Optional accessories (for temperature monitoring, vibration measurements, etc.) are to be connected up to the centrifugal pump according to the manufacturer's instructions. Please contact ANDRITZ if you have special requirements. Installation Rev. 2.9...
Page 71: Electrical Equipment
Centrifugal pump ACP STANDARD, C-01-000000 5.5.5 Electrical equipment The complete electrical installation must be set up and carried out in accordance with valid standards. The motor and the instruments must be connected in accordance with the operating instructions of the suppliers. >>...
Page 72 Centrifugal pump ACP STANDARD, C-01-000000 After laying: -40 °C to +70 °C Nominal voltage (U0/U) 0.6/1.0 kV Test voltage 4 kV Identification code of the conductor VDE 0293 Installation Rev. 2.9...
Page 73: Cold Test
Centrifugal pump ACP STANDARD, C-01-000000 Cold test Requirements • The shaft seal has been adjusted. • Sealing water line is flushed and sealing water of specified quality is available. • Motor for main drive is electrically connected. • Safety covers have been correctly installed. •...
Page 74: Disassembly And Disposal
Centrifugal pump ACP STANDARD, C-01-000000 Disassembly and disposal DANGER Electric voltage Electric voltage at the machine results in a potentially life-threatening hazard. • The machine must be de-energised before disassembly and secured against be- ing switched on again! • Disassembly may only be performed by qualified and authorised personnel! If the machine/system is to be shut down, the following must be taken into account for subsequent disposal: Machine parts...
Page 75: Commissioning
Centrifugal pump ACP STANDARD, C-01-000000 Commissioning General This chapter describes the preparations and steps required for initial start-up of the machine. Safety regulations Follow safety instructions Disregarding the safety instructions can lead to dangerous situations. All measures to prevent hazards must be strictly obeyed! General safety reg- All applicable accident prevention rules must be observed.
Page 76: Prerequisites For Commissioning
Centrifugal pump ACP STANDARD, C-01-000000 Prerequisites for commissioning 6.3.1 General prerequisites Before commissioning begins, the following conditions must be met: • Before commissioning, ensure that all the necessary measures mentioned in the engineering documents supplied with the equipment have been duly implemented. •...
Page 77 Centrifugal pump ACP STANDARD, C-01-000000 WARNING Improper lubrication of the pump Incorrect or no lubrication of the pump can result in hazardous situations for personnel and damage to the machine • Under no circumstances may the pump be operated without suitable lubricant!! If the pump is stored for a prolonged period of time prior to commissioning, dirt and water can penetrate.
Page 78: Start-Up
Centrifugal pump ACP STANDARD, C-01-000000 Start-up NOTICE Incorrect start-up procedure Machine may be damaged if incorrect start-up procedures are used. • All electric interlocks must be functional and checked! Before commissioning is started, the procedure for starting the machine is determined together with our commissioning engineer.
Page 79: Reports
Centrifugal pump ACP STANDARD, C-01-000000 First trial run Functioning of the pump must be monitored carefully during the first few hours in oper- ation. Particular attention must be paid to the following: • Temperature of the shaft seal • Required amount of seal water to the shaft seal •...
Page 80 Centrifugal pump ACP STANDARD, C-01-000000 Commissioning Rev. 2.9...
Page 81: Operation
Centrifugal pump ACP STANDARD, C-01-000000 Operation General This chapter describes the activities required for starting, operating and stopping the machine. Possible malfunctions and troubleshooting methods are also presented. Safety regulations General safety reg- The applicable accident prevention regulations must be observed. ulations Operating the machine/system is permissible only with all the required protective devices installed.
Page 82: Checks After Initial Commissioning
Centrifugal pump ACP STANDARD, C-01-000000 NOTICE! If the operating pressure (see instruments) is not obtained within a short time, the pump must be stopped and the cause of the problem found! Checks after initial commissioning The pump function must be monitored carefully during the first few hours in operation. Particular attention must be paid to the following: •...
Page 83: Bearing Temperatures
Centrifugal pump ACP STANDARD, C-01-000000 • Design flow rate exceeded by 10% (overload operation). • Design flow rate undershot by 35% (partial-load operation). • Rotating parts are unbalanced due to corrosion or mechanical damage. • The bearings have reached the end of their service life and should be replaced. Vibration measurements are carried out at the manufacturer/supplier's facility in accordance with ISO5199: Horizontal pumps...
Page 84 Centrifugal pump ACP STANDARD, C-01-000000 • For continuous operation, a minimum flow rate is required. The curve shown in the performance diagram for the required suction pressure (set NPSH pump) begins at the point of the permitted continuous minimum flow rate. •...
Page 85: Shutdown
Centrifugal pump ACP STANDARD, C-01-000000 7.10 Shutdown Automatic shutdown In an automatic shutdown, all the required steps will be carried out automatically by the process control system. Manual shutdown Manual short-term shutdown For a manual short-term shutdown of the machine, the following steps must be carried out: Steps 1) Stop the pump motor.
Page 86: Operating Malfunctions And Troubleshooting
Check the pipe resistance, check and/ than the delivery head of the pump or correct the valve setting Unexpectedly high density and/or vis- Contact ANDRITZ for further instruc- cosity of the medium being conveyed tions Deformed or eccentric pump shaft...
Page 87 NPSH System medium too low Unexpected air/gas proportion in the Contact ANDRITZ for further instruc- medium being conveyed tions Air ingress into suction line or shaft Check the suction line and shaft seal seal...
Page 88 Centrifugal pump ACP STANDARD, C-01-000000 Malfunction Possible cause Rectification Overheating or blocking of Pressure-side valve closed Open valve the pump Pump insufficiently pre-filled Repeat pre-filling of the system The output of the pump is below the The requirements of the pump system permitted minimum flow rate must be checked Pump and motor not flush with each...
Page 89: Maintenance And Inspection
Maintenance and inspection General information This chapter describes the maintenance and repair which is the responsibility of the operating company. The ANDRITZ service department is available for troubleshooting and comprehensive maintenance and repair work. >> Service address [} 9] Safety regulations Follow safety instructions Disregarding the safety instructions can lead to dangerous situations.
Page 90 Centrifugal pump ACP STANDARD, C-01-000000 Chemicals If chemicals are used, proceed as follows in order to avoid corrosion or chemical burns: • Secure closure of the inlet pipe (interlocking, manual valve, etc.) • Interlocking the chemicals feed so that no more chemicals can flow into the ma- chine when it is shut down.
Page 91: Regular Maintenance
Centrifugal pump ACP STANDARD, C-01-000000 Regular maintenance NOTICE Regular monitoring of the operation and performance of the pump en- ables early detection of any necessary servicing. This ensures excellent efficiency, a malfunction-free workflow and minimises servicing costs! The outlet pressure, flow rate and power consumption must be monitored continu- ously.
Page 92: Maintenance Schedule
Centrifugal pump ACP STANDARD, C-01-000000 NOTICE Incorrect cleaning Damage due to incorrect cleaning agent. • Only the permitted cleaning agents may be used for cleaning! • Water, steam or other cleaning agents must not be allowed to ingress into any electrical machine parts.
Page 93: Fasteners
Centrifugal pump ACP STANDARD, C-01-000000 Fasteners The specified installation values are valid for standard screwed connections on the machine and must be used only if no special installation values are specified on the assembly drawings or in the instructions! The specifications of the following table ap- ply to commercially available hexagon-head screws and cap screws with metric ISO threads.
Page 94: Checks
Centrifugal pump ACP STANDARD, C-01-000000 Coefficients of fric- Refer to the following table, depending on the lubrication, for the coefficient of friction: tion and lubrication μ Lubrication 5.6 / 8.8 / 10.9 / C3-80 A4-50/A4-70/A4-80 MoS2 0.125 dry or oiled - 0.14 -...
Page 95: Lubrication
Centrifugal pump ACP STANDARD, C-01-000000 Lubrication Before start-up, check whether all lubrication points have been filled with the appropri- ate lubricants. Please also observe maintenance instructions on the maintenance signs and rating plates attached to the machine and components. NOTICE Improper disposal of lubricants Improper disposal of lubricants is hazardous to the environment.
Page 96: Lubrication With Grease
Manufacturer Type Exxon EXXON Beacon 2 Mobil Mobilux EP2 Shell SHELL Alvania RL3 SKF LGMT2 FAG Arcanol MULTI 3 Tab. 44: Lubricant NOTICE If the surface temperature of the bearing housing exceeds 80°C, please contact ANDRITZ. Maintenance and inspection Rev. 2.9...
Page 97 Centrifugal pump ACP STANDARD, C-01-000000 8.7.1.2 Lubricating schedule NOTICE The bearings are filled with grease during assembly at the factory. Prior to initial commissioning, the grease quantity stated in the table “Re- lubrication” must be added to the bearings. WARNING Improper lubrication of the pump Incorrect or no lubrication of the pump can result in hazardous situations for personnel and damage to the machine...
Page 98 Centrifugal pump ACP STANDARD, C-01-000000 8.7.1.3 Grease change The grease should be changed after approx. 24000 operating hours as described in the following table. Steps 1) Remove the screw plug (903.1). 2) Extract the old grease through the bore hole (903.1) by applying suction. 3) Insert plug screw (903.1) again with new sealing ring (411.1).
Page 99: Oil Lubrication
Viscosity: 64 cST at 40 °C (ISO VG68) Manufacturer Type Mobil SHC626 Shell Tellus S4 ME68 Castrol Alphasyn T68 Tab. 47: Lubricant NOTICE If the surface temperature of the bearing housing exceeds 80°C, please contact ANDRITZ. Rev. 2.9 Maintenance and inspection...
Page 100 Centrifugal pump ACP STANDARD, C-01-000000 8.7.2.2 Lubricating schedule NOTICE During works assembly, the bearings and the oil chamber are filled with a preserving oil providing protection for approximately 6 months. Before start-up, oil according to the table must be filled up to the middle of the oil inspection glass.
Page 101 Centrifugal pump ACP STANDARD, C-01-000000 The oil change intervals listed above are recommended reference values. During the oil change, we recommend carrying out an oil analysis to adapt the oil change interval to actual circumstances and ensure safe and efficient operation. Rev.
Page 102 Centrifugal pump ACP STANDARD, C-01-000000 8.7.2.3 Oil change Oil change The oil change should be performed in the following manner at operating temperature and while the machine is at a standstill: Steps 1) Open the screw plug (903.1) and drain the used oil into a prepared container (note the quantity of oil).
Page 103: Pump
Centrifugal pump ACP STANDARD, C-01-000000 Pump The item numbers in the following chapters refer to the arrangement, dimensioned and sectional drawings included in the full documentation. The illustrations in the present chapter only show a detail of the pump in order to explain the work steps in more detail.
Page 104 Centrifugal pump ACP STANDARD, C-01-000000 8.8.1.2 Removing the pull-out unit The removable unit consists of a bearing support (330), impeller (230), housing cap (161) and shaft seal (430). Steps 1) Attach lifting slings as shown in the figure. ð Through the bearing support windows and between the coupling half and bear- ing cap ð...
Page 105 Centrifugal pump ACP STANDARD, C-01-000000 901.12 902.3 554.3 Fig. 33: Pump Rev. 2.9 Maintenance and inspection...
Page 106 Centrifugal pump ACP STANDARD, C-01-000000 8.8.1.3 Mounting the pull-out unit Steps 1) Visually check the impeller (230) and front insert (135.1) for defects. 2) Manually rotate the shaft to check how easily it moves. 3) Clean the sealing surfaces of the bearing housing (350) and of the spiral casing (102).
Page 107: Installing And Dismounting The Impeller And The Front Lining
Centrifugal pump ACP STANDARD, C-01-000000 8.8.2 Installing and dismounting the impeller and the front lining DANGER Improper lifting of the impeller Hazard due to suspended load. • According on the size and weight of the impeller, use suitable lifting gear! •...
Page 108 Centrifugal pump ACP STANDARD, C-01-000000 3) Screw the stud bolts (902.1) into the lining and mount the required spacer wash- ers. 4) Insert new O-ring (412.1) and grease well with silicone grease. 5) Remove the jackscrews and mount the front lining into the spiral casing (102). 6) Tighten the nuts (920.2) using the required torque.
Page 109: Turning Off (Machining) The Impeller
3) Machine the new impeller diameter according to the ANDRITZ turning specific- ation. 4) The new impellers must be balanced according to the ANDRITZ balancing spe- cification. If needed, the turning specification and balancing specification can be requested from ANDRITZ.
Page 110: Changing The Seal
Centrifugal pump ACP STANDARD, C-01-000000 Changing the seal DANGER Adjustment of the shaft seal During inspection and adjustment work on the shaft seal, there is a significant risk of crushing and being drawn in as well as a risk of scalding or chemical burns as a result of escaping medium.
Page 111: Andritz Cartridge Seal - Single-Action
ANDRITZ cartridge seal – single-action 551.1 412.5 551.2 551.3 433.1 902.5 920.5 554.5 Fig. 34: ANDRITZ – Cartridge seal BS42 – BS100 Pos. Designation Pos. Designation 433.1 Shaft seal 412.5 O-ring 902.4/ 902.5 Stud bolt 551.1 Spacer plate 554.4/ 554.5 Washer 551.2 Spacer plate 920.4/ 920.5 Hexagon nut...
Page 112 7) Secure seal in casing cover (161) with the bolts (902.4, 902.5). 8) Mount the impeller. 9) Mount the pull-out unit. 551.1 902.4 551.2 433.1 920.4 551.3 554.4 Fig. 35: ANDRITZ – Cartridge seal BS24 – BS32 Maintenance and inspection Rev. 2.9...
Page 113: Andritz Cartridge Seal - Double-Action
ANDRITZ cartridge seal – double-action 551.1 412.5 551.2 551.3 433.1 902.5 920.5 554.5 Fig. 36: ANDRITZ – Cartridge seal BS42 – BS100 Pos. Designation Pos. Designation 433.1 Shaft seal 412.5 O-ring 902.4/ 902.5 Stud bolt 551.1 Spacer plate 554.4/ 554.5 Washer 551.2 Spacer plate 920.4/ 920.5 Hexagon nut...
Page 114 7) Secure seal in casing cover (161) with the bolts (902.4, 902.5). 8) Mount the impeller. 9) Mount the pull-out unit. 551.1 902.4 433.1 551.2 920.4 551.3 554.4 Fig. 37: ANDRITZ – Cartridge seal BS24 – BS32 Maintenance and inspection Rev. 2.9...
Page 115: Mechanical Seal - Single-Action
Centrifugal pump ACP STANDARD, C-01-000000 8.9.3 Mechanical seal – single-action 551.1 551.2 433.1 412.5 551.3 902.5 920.5 554.5 Fig. 38: Mechanical seal – single-action (BS42 – BS100) Pos. Designation Pos. Designation 433.1 Shaft seal 412.5 O-ring 902.4/ 902.5 Stud bolt 504 Spacer ring 554.5/ 554.5 Washer 551.1 Spacer plate 920.4/ 920.5 Hexagon nut...
Page 116 Centrifugal pump ACP STANDARD, C-01-000000 Changing the seal Changing the seal Steps 1) Dismounting the pull-out unit >> Installing and removing the pull-out unit 2) Dismounting the impeller >> Installing and dismounting the impeller and the front lining [} 107] 3) Remove the mechanical seal (433.1). (>> Follow the seal manufacturer's instruc- tions) ð...
Page 117: Standard Cartridge Seal - Single-Action
Centrifugal pump ACP STANDARD, C-01-000000 8.9.4 STANDARD cartridge seal – single-action 551.1 902.4 412.5 551.2 920.4 551.3 554.4 433.1 902.5 920.5 554.5 Fig. 40: STANDARD Cartridge seal BS42 – BS100 Pos. Designation Pos. Designation 433.1 Shaft seal 412.5 O-ring 145 Adapter 504 Spacer ring 902.4 Stud bolt 551.1 Spacer plate...
Page 118 Centrifugal pump ACP STANDARD, C-01-000000 Changing the seal Changing the seal Steps 1) Dismounting the pull-out unit >> Installing and removing the pull-out unit 2) Dismounting the impeller >> Installing and dismounting the impeller and the front lining [} 107] 3) Detach the nuts (920.4) and remove the washers (554.4). 4) Separate the shaft seal (433.1) from the adapter (145).
Page 119: Standard Cartridge Seal - Double-Action
Centrifugal pump ACP STANDARD, C-01-000000 8.9.5 STANDARD cartridge seal – double-action 551.1 902.4 412.5 551.2 920.4 551.3 554.4 433.1 902.5 920.5 554.5 Fig. 42: STANDARD Cartridge seal BS42 – BS100 Pos. Designation Pos. Designation 433.1 Shaft seal 412.5 O-ring 145 Adapter 504 Spacer ring 902.4 Stud bolt 551.1 Spacer plate...
Page 120 Centrifugal pump ACP STANDARD, C-01-000000 Changing the seal Changing the seal Steps 1) Dismounting the pull-out unit >> Installing and removing the pull-out unit 2) Dismounting the impeller >> Installing and dismounting the impeller and the front lining [} 107] 3) Detach the nuts (920.4) and remove the washers (554.4). 4) Separate the shaft seal (433.1) from the adapter (145).
Page 121: Stuffing Box
Centrifugal pump ACP STANDARD, C-01-000000 8.9.6 Stuffing box Fig. 44: Stuffing box BS42 – BS100 Pos. Designation Pos. Designation 451 Stuffing box body 412.5 O-ring 452 Stuffing box gland 412.8 O-ring 458 Sealing water ring 524 Shaft protection sleeve 461 Packing cord 551.1 Spacer plate 902.5 Stud bolt 551.2 Spacer plate...
Page 122 Centrifugal pump ACP STANDARD, C-01-000000 Fig. 45: Stuffing box BS24 – BS32 8.9.6.1 Removing the stuffing box Steps 1) Removal of the removable unit >> Installing and removing the pull-out unit 2) Removal of the impeller >> Installing and dismounting the impeller and the front lining [} 107] 3) Loosen nuts (920) and remove the washers (554).
Page 123 Centrifugal pump ACP STANDARD, C-01-000000 8.9.6.2 Installing the stuffing box Steps 1) Mark stuffing box packing (>> Marking the stuffing box packing [} 123]) and cut to the appropriate length. ð Keep stuffing box clean, do not stretch or squash stuffing box when measuring and cutting.
Page 124 Centrifugal pump ACP STANDARD, C-01-000000 8.9.6.3 Setting the stuffing box DANGER Setting the stuffing box There is a considerable risk of crushing and being drawn into the machine when set- ting the stuffing box. • The stuffing box may only be set by trained and authorized personnel! Steps 1) Tighten the screw fitting slightly at the stuffing box gland.
Page 125: Bearing Change - Bearing With Grease Lubrication
Centrifugal pump ACP STANDARD, C-01-000000 8.10 Bearing change – bearing with grease lubrication The bearings are designed for continuous operation at full load for about 50000 oper- ating hours. An increased bearing temperature and vibrations on the bearing support are a sign of imminent bearing damage. If these symptoms occur, the bearings have to be replaced.
Page 126 Centrifugal pump ACP STANDARD, C-01-000000 636.1 321.1 931.1 636.2 321.2 423.2 901.1 507.2 940.2 901.3 507.3 412.14 904.2 412.1 903.1 411.1 904.1 903.2 411.2 Fig. 47: Bearing support with grease lubrication Maintenance and inspection Rev. 2.9...
Page 127: Bearing Change - Bearing With Oil Lubrication
Centrifugal pump ACP STANDARD, C-01-000000 8.11 Bearing change – bearing with oil lubrication The bearings are designed for continuous operation at full load for about 50000 oper- ating hours. An increased bearing temperature and vibrations on the bearing support are a sign of imminent bearing damage. If these symptoms occur, the bearings have to be replaced.
Page 128 Centrifugal pump ACP STANDARD, C-01-000000 903.4 903.3 321.1 931.1 411.4 411.3 321.2 423.2 901.1 507.4 940.2 901.3 507.3 412.14 914.10 411.10 412.1 903.1 411.1 914.11 411.11 Fig. 48: Bearing support with oil lubrication Maintenance and inspection Rev. 2.9...
Page 129: Supplier Documentation
Centrifugal pump ACP STANDARD, C-01-000000 Supplier documentation COUPLING SHAFT SEAL MOTOR FOUNDATION WORK See also 2 Adhesive anchor capsule - HVU (HILTI) - Instruction [} 130] Rev. 2.9 Supplier documentation...
Page 130 Centrifugal pump ACP STANDARD, C-01-000000 10 Certificates See also 2 Declaration of Conformity [} 142] 2 ANDRITZ Certificate ISO9001 [} 143] Rev. 2.9 Certificates...
Page 133 Centrifugal pump ACP STANDARD, C-01-000000 Rev. 2.9...
Page 134 Centrifugal pump ACP STANDARD, C-01-000000...

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