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Andritz ACP Series Erection Work, Operating And Maintenance Instructions

Centrifugal pump
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Centrifugal Pump, ACP series
Erection Work, Operating and Maintenance Instructions
Erection Work, Operating and Maintenance Instructions
Machine:
Issued:
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Rev.0, Printed: 2010.08
Centrifugal Pump, ACP series
Revision:
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  • Page 1 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Erection Work, Operating and Maintenance Instructions Centrifugal Pump, ACP series Machine: Issued: Revision: Checked: Checked: Rev.0, Printed: 2010.08...
  • Page 2 The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or partly reproduced without authorization by Andritz AG. Contraventions shall entail damage claims and may have penal consequences. 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 ............................ 26 3.2.3 Bearing support ............................27 Type of seal ............................29 3.3.1 Andritz cartridge mechanical seal - single ....................31 3.3.2 Andritz cartridge mechanical seal - double .................... 32 3.3.3 Standard cartridge mechanical seal - single .................... 34 3.3.4...
  • Page 4 Trimming the impeller ........................99 7.11 Changing the shaft seals ....................... 100 7.11.1 Changing the Andritz cartridge mechanical seal-single and double ............. 100 7.11.2 Changing the standard cartridge mechanical seal-single and double ........... 102 7.11.3 Changing the single standard mechanical seal ..................104 7.11.4...
  • Page 5 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Rev.0, Printed: 2010.08 Page 5 of 117...

  • Page 6: Introduction

    Erection Work, Operating and Maintenance Instructions INTRODUCTION This manual is part of the ANDRITZ AG technical documentation for the pump. It is intended to provide the operator with the basic knowledge required for proper, safe and economical use of the equipment delivered by ANDRITZ AG.

  • Page 7: How To Use The Manual

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions How to use the manual Chapter and paragraph headings are printed in capitals in the Presentation  continuous test SAFETY Designations of indicating and handling elements are written in inverted ...

  • Page 8: Warranty And Guarantee

    Non-authorized structural changes to the machine/system.  Non-observance of the maintenance and upkeep instructions.  In the event of a claim for repair under guarantee, ANDRITZ AG reserves the right to assess the damage to the machine/system. Rev.0, Printed: 2010.08 Page 8 of 117...

  • Page 9: Manufacturer's Name And Address

    Copyright The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or partly reproduced without authorization by Andritz. All rights shall also be reserved for any patents granted, registration of trade marks and technical modifications without prior notification.

  • Page 10: Safety

    In addition, the chapters in the operating manual contain further safety regulations. These are marked by DANGER SIGNS. Safety instructions on components not supplied by Andritz AG are contained in the descriptions of the components ( /ACP-PUMP/SUPPLIER DOCUMENTATION). The safety instructions supplement ANDRITZ AG’s operating instructions.

  • Page 11: Designated Use

    Non-observance of the application can lead to environmental or property damage, or to personal injury. Any modifications to the scope of supply made without the agreement of Andritz AG are considered contrary to the designated use. The term designated use shall also include adherence to the operating instructions, observance of the operating, inspection and maintenance conditions and of the regulations on cleaning and upkeep.

  • Page 12: User's Obligations

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions User’s obligations Designated use The user of the centrifugal pump is responsible for its designated use. Work instructions In addition to the operating instructions, applicable legal stipulations and other rules governing the safety at work, health and environmental protection must be observed and personnel instructed in them.
  • Page 13 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Inspections The operator undertakes To check at regular interval whether the safety instructions and  regulations governing work on the centrifugal pump are observed. To carry out regular training to confirm the level of knowledge of the ...

  • Page 14: General Obligations Of Personnel

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions General obligations of personnel To avoid personal and material damage anybody working on the machine shall Observe the safety instructions in the operating regulations and on the  centrifugal pump itself.

  • Page 15: Safety Devices

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Safety devices The centrifugal pump must not be operated without effective safety equipment. Safety equipment must not be circumvented, dismantled or made unserviceable during operations. The safety equipment is there to protect operating personnel.
  • Page 16 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Indicative, warning Indicative, warning and prohibiting signs must be observed. They must be and prohibiting Checked regularly for legibility and completeness and they must not be signs removed or obstructed.

  • Page 17: Personal Protective Apparel

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Personal protective apparel General protective Operating personnel must use and carry personal protective equipment along with them in accordance with the national regulations or as specified by the apparel plant operator.

  • Page 18: Safety At The Machine Installation Site

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Safety at the machine installation site Adequate lighting must be provided (industrial lighting). The foundations must be sized to withstand the loads caused by the centrifugal pump. The customer will be provided with a load plan.

  • Page 19: Noise Levels (Db(A))

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 2.11.1 Noise levels (dB(A)) 990 u/min 1180 u/min 1450 u/min 1780 u/min 3000 u/min 3560 u/min ACP 65-315 ACP 100-500 ACP 65-250 ACP 100-315 ACP 125-400 ACP 150-500 ACP 100-250...

  • Page 20: Electrical Equipment

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 2.12 Electrical equipment All work on the electrical equipment, without exception, must be carried out by skilled electricians. Any form of contact with electrical equipment may cause fatal injuries. Before beginning any maintenance or repair work, the operator must disconnect the energy supply to all drives securely.

  • Page 21: Oils And Greases And Cleaning Agents

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 2.14 Oils and greases and cleaning agents The safety instructions for the products concerned must be observed when handling oil, grease and other chemical substances. Suitable skin protection is required when handling aggressive media. See manufacturers’...
  • Page 22 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions clean the pump from aggressive media. Interlocking the chemical feed so that no more chemicals can flow into the  pump when pump is shut down. Emptying the vent line safely to prevent from possible contact with ...

  • Page 23: Technical Description

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Technical Description General description 3.1.1 Field of application The centrifugal pump is used in continuous operation to pump specified liquids and various pulps in the paper industry. (See chapter headed Technical Data) Fig.

  • Page 24: Design

    ) with steel cage. 321.2 Depending on operating requirements, there is a choice of eight different Shaft seal shaft seals: Andritz cartridge mechanical seal - single  Andritz cartridge mechanical seal - double  Standard cartridge mechanical seal - single ...

  • Page 25: Main Components Of The Centrifugal Pump

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Main components of the centrifugal pump 3.2.1 Centrifugal pump with base frame Fig. 3-2 Main components of the centrifugal pump Item Component Item Component Centrifugal pump, complete Motor ( Coupling (...

  • Page 26: Centrifugal Pump

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 3.2.2 Centrifugal pump 135.1 554.1, 920.1, 902.1 Fig. 4-3 Main section - centrifugal pump Item Component Item Component Volute casing Bearing support Front lining Safety guard for sealing chamber 135.1...

  • Page 27: Bearing Support

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 3.2.3 Bearing support 636.1 321.1 321.2 636.1 550.2 421.2 550.1 507.2 421.1 507.1 904.2 904.1 903.2 Fig. 4-4 Grease lubrication Item Component Item Component Rotary shaft seals ( Bearing housing 421.1, 421.2...
  • Page 28 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 903.3 321.1 321.2 903.4 423.2 914.10 411.10 423.1 914.11 411.11 Fig. 3-5 Oil lubrication Item Component Item Component Bearing housing Plug Shaft Vent screw Angular contact ball bearing Socket head cap screw 321.1...

  • Page 29: Type Of Seal

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Type of seal Fig. 3-6 Fig. 3-7 Andritz cartridge mechanical seal - single Andritz cartridge mechanical seal - double Fig. 3-8 Fig. 3-9 Standard cartridge mechanical seal - single Standard cartridge mechanical seal - Double...
  • Page 30 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Not available yet Fig. 3-14 Fig. 3-15 Stuffing box packing Dynamic shaft seal Rev.0, Printed: 2010.08 Page 30 of 117...

  • Page 31: Andritz Cartridge Mechanical Seal - Single

    ..... . 3000 r.p.m. (3600 r.p.m. at 60 Hz) Bearing suppport size Shaft diameter D[mm] Seal diameter D1[mm] Sizes - Andritz cartridge mechanical seal – single Tab. 3-6 Rev.0, Printed: 2010.08 Page 31 of 117...

  • Page 32: Andritz Cartridge Mechanical Seal - Double

    ..... . 3000 r.p.m. (3600 r.p.m. at 60 Hz) Bearing suppport size Shaft diameter D[mm] Seal diameter D1[mm] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12 Sealing water pressure [bar] Sealing water quantity [1/min] Sizes - Andritz cartridge mechanical seal – single Tab. 3-7 Rev.0, Printed: 2010.08 Page 32 of 117...
  • Page 33 Temperature 2 mg/l max. Solids content Tab. 3-8 Sealing water data for Andritz cartridge mechanical seal Monitoring In order to guarantee proper operation the sealing water must be monitored with suitable monitoring units according to the diagrams (Fig. 4-18, Fig. 4-19).

  • Page 34: Standard Cartridge Mechanical Seal - Single

    Function: Seal between medium and the atmosphere. The mechanical seal is lubricated by the medium to be pumped. 412.5 902.4, 920.4, 554.4 551.2 Atmosphere Medium 914.1 Fig. 3-20 Andritz cartridge mechanical seal - single Item Component Item Component Adapter 412.5 O-ring 433.1 Mechanical seal 914.1 Screw Spacer 902.4 Bolt...
  • Page 35 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Bearing suppport size Shaft diameter D[mm] Seal diameter D1[mm] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12 Sealing water pressure [bar] Sealing water quantity [1/min] Sizes - Standard cartridge mechanical seal – single Tab.

  • Page 36: Standard Cartridge Mechanical Seal - Double

    902.4,920.4, 554.4 433.1 551.2 Atmosphere Medium 914.1 412.5 Fig. 3-23 Andritz cartridge mechanical seal - double Item Component Item Component Adapter 412.5 O-ring 433.1 Mechanical seal 914.1 Screw Spacer 902.4 Bolt Tab.
  • Page 37 Shaft diameter D[mm] Seal diameter D1[mm] 0.5-12 0.5-12 0.5-12 0.5-12 0.5-12 Sealing water pressure [bar] Sealing water quantity [1/min] Sizes - Andritz cartridge mechanical seal – single Tab. 3-13 Sealing water data: 0.5 bar min. - 12 bar max. Pressure...

  • Page 38: Single Standard Mechanical Seal

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 3.3.5 Single standard mechanical seal Function: Seal between medium and the atmosphere. The mechanical seal is lubricated by the medium to be pumped. Type: A1 551.2 433.1 Atmosphere Medium Type: A2 914.1...
  • Page 39 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Item Component Item Component Adapter 412.5 O-ring 433.1 Mechanical seal (MG12) 914.1 Screw Spacer Single standard mechanical seal – type A1-MG12S14 Tab. 3-15 Item Component Item Component Adapter 412.5 O-ring 433.1 Mechanical seal (MG12)

  • Page 40: Stuffing Box Packing

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 3.3.6 Stuffing box packing Function: Seal between medium to be conveyed and the atmosphere formed by packing rings and sealing water. 902.4 920.4 554.4 412.8 914.1 Fig. 3-30 Stuffing box packing 412.5...
  • Page 41 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Sealing water data: 3 - 5 bar +inlet pressure Sealing water pressure Pure water Quality Mechanical contamination: 80 microns max. 10°C min. - 30°C max. Temperature 2 mg/l max. Solids content Tab.

  • Page 42: Type Specification

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Type specification 3.4.1 Applicable standards Dimensions ........ISO 2858 Design .

  • Page 43: Application Limiting Values

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Application limiting values The limit values shown in the present Chapter should not be exceeded under any circumstances! CAUTION The limit values shown for the centrifugal pump Series “ACP” stated in the present Chapter should not be exceeded under any circumstances.
  • Page 44 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions The application limit for the appropriate shaft seal (Andritz cartridge Shaft seal mechanical seal – single / double, Standard cartridge mechanical seal – single / double, Single standard mechanical seal, Tandem standard...
  • Page 45 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions The permitted forces and torques according to Table (Tab.3-27) should Permitted forces not be exceeded. and torques As a general principle, the suction and delivery pipes must be connected up stress-free. We recommend checking this item before initial start-up.
  • Page 46 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Force N Torque N.m Diameter ΣFb ΣMb 1 300 1 300 1 050 1 650 1 100 1 600 1 100 1 000 1 250 1 950 1 050 1 300...
  • Page 47 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions F ...Vector sum of forces from: and 0.47 * F at the delivery flange and F and 1.0 * F at the suction flange M ...Vector sum of torques: and M Fig.

  • Page 48: Performance Limits For Bearing Supports For Different Shaft Material

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Performance limits for bearing supports for different shaft material The performance limit shown in the table for different shaft materials must be observed! Shaft performance limits (kW) Bearing support n = 1000 rpm...

  • Page 49: Technological Description

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Technological description Definition The centrifugal pump is to be used for an application according to the purchase order specification to convey specified media observing the manufacturer’s instructions. If any changes are made and the pump is to be used for an application not specified, the manufacturer must be contacted beforehand.

  • Page 50: Erection And Transport

    This chapter describes certain steps for transport, storage and installation of the centrifugal pump which may be the responsibility of the user. Activities which are carried out by ANDRITZ AG, including works assembly, are not the subject of this description.

  • Page 51: Haulage

    In the event of transport damage or short supply, do not accept  goods but notify forwarder and ANDRITZ AG’s shipping department. If there is a hidden defect, notify forwarder and ANDRITZ AG’s  shipping department within two weeks. Rev.0, Printed: 2010.08...
  • Page 52 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Lifting the entire The complete centrifugal pump should only be raised as follows after centrifugal pump unpacking: The complete centrifugal pump should only be raised if the lifting devices have been attached under the suction and delivery flanges. The lifting devices must be short enough to prevent the centrifugal pump from tilting (Fig.
  • Page 53 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Lifting the The centrifugal pump with free shaft should only be raised as follows: centrifugal pump The pump should only be lifted if the lifting devices have been mounted ...
  • Page 54 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Lifting the pull-out Attach lifting slings at the points marked in Fig.5-3 unit Through the bearing support windows  Between the coupling half and the bearing cover  Secure sling to lifting hook and tension slightly.

  • Page 55: Storage

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Storage Short-term storage If the pump is to be stored for less than three months before erection work begins, please observe the following storage instructions. Store the centrifugal pump in a dry place, with suitable protection ...

  • Page 56: Installation

     Space requirement for erection work, operation and maintenance will be defined Together with the ANDRITZ AG representative in charge before the beginning of erection work. Ambient temperature during erection work should not be less than 10-15˚ Rev.0, Printed: 2010.08...

  • Page 57: Erection Of The Centrifugal Pump

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 4.5.1 Erection of the centrifugal pump The foundation should be made according to ANDRITZ AG’s foundation Foundation plan. The following preparations have to be made prior to placing the centrifugal pump on the foundation: Mark axes and levels on the foundation.
  • Page 58 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Step Activity Mounting the motor: Draw the drilling coupling half flush onto the motor stub and secure on the feather key with a set screw. Mount motor on motor base frame (893).
  • Page 59 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Fig. 4-4 Lifting the pull – out unit Item Component Item Component Cast concrete according to Threaded rod EN206-1, C16/20 Foundation Fastening nuts Fastening nuts Flush anchor Adjusting nut Rev.0, Printed: 2010.08...

  • Page 60: Pipework

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 4.5.2 Pipework If pipework is not mounted professionally. This can result in risks to life and limb and in damage to the machine. Under no circumstances should the centrifugal pump be used to...

  • Page 61: Aligning The Coupling

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 4.5.3 Aligning the coupling Data on the coupling used (tolerances, application limits, aligning information, etc.) can be found in the manufacturer's operating instructions. /CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER DOCUMENTATION/COUPLING) Fig. 4-5 Fig.

  • Page 62: Instruments

    Special accessories (temperature monitoring, vibration measurements,  etc.) are to be connected up to the centrifugal pump according to the manufacturer's instructions. Please contact Andritz AG if you have special requirements. Rev.0, Printed: 2010.08 Page 62 of 117...

  • Page 63: Electrical Equipment

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Electrical equipment Motor and instruments are to be connected up according to the operating instructions provided by the appropriate supplier. /CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER DOCUMENTATION/... The electrical equipment must be installed such that there is no risk of injury to personnel, nor of damage to machines.

  • Page 64: Cold Test

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Cold test Prerequisites The following utilities must be available: Electric power  Water  Lubrication First filling of lubricant and recording of all further lubrication  procedures according to the section headed “Lubrication” in the MAINTENANCE chapter.
  • Page 65 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Step Activity Check direction of rotation without medium: Remove the intermediate sleeve of the coupling (see section  4.5.3). Switch the motor and off briefly in order to check the direction ...

  • Page 66: Start-Up

    Disregarding the safety regulations may cause a risk to life and limb and damage to the machine or its components. All safety instructions in this Chapter must be strictly observed. DANGER Start-up shall be carried out under the control of ANDRITZ AG’s start-up General safety instructions supervisor or by the Buyer.

  • Page 67: Prerequisites For Start-Up

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Prerequisites for start-up The following must be checked before start-up: Motor may be started up unintentionally. Risk to life and limb and risk of damaging the machine or its DANGER components.
  • Page 68 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Aligning the A further check should be performed to ensure that the coupling is properly coupling aligned. Coupling alignment should then be verified in writing. For assembly and disassembly of the coupling, as well as the tolerances to be observed here, please see: /CENTRIFUGAL PUMP/SUPPLIER DOCUMENTATION/COUPLING...

  • Page 69: Start-Up

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Start-up Machine may be damaged by inappropriate starting. All electric interlocks must be functional and checked. CAUTION Starting up the If all preliminary requirements (see Chapter 5.3) have been fulfilled, the...

  • Page 70: Certificates

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Fist trial run Functioning of the pump must be monitored carefully during the first few Hours in operation. Particular attention must be paid to the following: Temperature of the shaft seal ...

  • Page 71: Operation

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions OPERATION General This chapter describes the activities required for starting, operating and stopping the centrifugal pump. Possible malfunctions and troubleshooting methods are also presented. Safety regulations Disregarding the safety regulations may cause a risk to life and limb and damage to the machine or its components.

  • Page 72: Control Via Dcs

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Control via DCS The centrifugal pump can be started up and operated entirely from the DCS. There is no permanent workspace provided at the pump. Starting Prerequisites All preliminary requirements for start-up must be fulfilled before switching on the pump.

  • Page 73: Checks After Initial Start-Up

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Automatic starting When using the group start, all of the steps required are implemented automatically by the DCS. Carry out the following steps for manual start. Manual start Step Activity...

  • Page 74: Normal Operation

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Normal operation Do not operate without all safety devices ON. DANGER While the pump is in operation the operating personnel should record the relevant data (shift record and data sheets).

  • Page 75: Centrifugal Pump Requirements (Delivery Head And Flow Rate)

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Centrifugal pump requirements (delivery head and flow rate) Sizing The pump sizing (delivery head/flow rate0 refers to the values shown on the pump’s type plate. The values obtainable for head and flow rate can be read off the impeller diameter and the defined operating speed is shown in the performance diagram.

  • Page 76: Shutdown

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Shutdown Automatic When using the group stop, all necessary steps are carried out shutdown automatically with the DCS. Brief manual Carry out the following steps to shut the centrifugal pump down manually...

  • Page 77: Operating Malfunctions And Troubleshooting

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Operating malfunctions and troubleshooting Malfunction Possible cause Remedy Pump is not pumping Insufficient pre-filling of pump Repeat pre-filling of the pump medium Steam bubbles forming in and suction pipe suction pipe (NPSH...
  • Page 78 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Malfunction Possible cause Remedy Steam bubbles forming in the Repeat pre-filling of the pump and Inadequate or irregular flow rate suction pipe suction pipe Wrong direction of rotation Change sense of rotation of the motor...
  • Page 79 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Malfunction Possible cause Remedy Pressure difference between Check the suction pipe Excessive noise and/or vibration NPSH and NPSH plant pump too low Unexpected air/gas content in Contact Andritz AG for further...
  • Page 80 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Malfunction Possible cause Remedy Excessive wear on Pump and motor are not in true Check pump/motor alignment or bearing alignment re-align Broken or eccentric pump shaft Replace the pump shaft and bearing...

  • Page 81: Maintenance

    The ANDRITZ AG service department is at your disposal for troubleshooting, as well as for extensive maintenance and repair work. (/CENTRIFUGAL PUMP/INTRODUCTION) Workers trained and authorized by Andritz AG may also carry out repairs on site after obtaining consent from AAG. Safety regulations Disregarding the safety regulations may cause a risk to life and limb and damage to the machine or its components.

  • Page 82: Regular Maintenance

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Personal protective The following protective equipment must be worn when carrying out apparel cleaning and maintenance: Hard hat  Protective gloves  Protective shoes  Goggles  Lighting The operator shall ensure that adequate lighting is provided (with extra-low voltage bulbs) during service and repair work.
  • Page 83 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions In the course of general machine checks all additional units should also be checked to guarantee that the entire plant functions satisfactorily. For these checks, the attached manufacturer’s maintenance and upkeep instructions must be observed.

  • Page 84: Maintenance Schedule

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Maintenance schedule In addition to the work outlined below, maintenance and word required for normal operations (/CENTRIFUGAL PUMP/OPERATION/NORMAL OPEATION) must also be carried out. Monthly The following maintenance work is to be carried out at monthly intervals.

  • Page 85: Fasteners

    Pre-stressing forces and tightening torques in the table apply to normal screw connections. Please contact Andritz AG in the event of special requirements. The thread and screw head should be lubricated with an appropriate lubricant (for example Molyslide Plus from Loctite).
  • Page 86 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Wrong torque tightening may cause machine damage and hazards leading to personal injury. The above pre-stressing forces and tightening torques must be CAUTION observed. Rev.0, Printed: 2010.08 Page 86 of 117...

  • Page 87: Lubrication

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Lubrication 7.6.1 Oil lubrication During works assembly the bearings and the oil chamber are filled with a preserving oil providing protection for approximately 6 months. CAUTION Before start-up, oil must be filled up to the middle of the oil inspection glass according to the table (Tab.7-6)
  • Page 88 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Oil change The first oil change should be carried out after approximately 200 operating hours. After this oil changes should be performed according to Tab. 8-7. Pump speed (n) Oil change interval...
  • Page 89 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Oil quantities The following oil quantities are required, depending on the pump size: Bearing size Pump type Oil quantity (litres) BS42 ACP 100-250 ACP 125-250 ACP 65-315 ACP 100-315 ACP 125-315...

  • Page 90: Grease Lubrication

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.6.2 Grease lubrication The bearings are filled with grease during works assembly. The bearings should be topped up with approx. 2 to 10 g of grease before being put into operation.
  • Page 91 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Grease change The old grease should be cleaned off the bearing housing after approximately 24,000 operating hours. Then fill the bearing with fresh grease. The grease in the bearings is to be changed according to the `following table.

  • Page 92: Aligning The Coupling

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Aligning the coupling The coupling alignment must be checked after each of the following assembly steps and corrected if necessary. In particular:  After mounting and before grouting in the pump ...

  • Page 93: Installing And Removing The Pull-Out Unit

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Installing and removing the pull-out unit Preparations The following parts must be prepared before starting to disassemble the pull-out unit: Tools  Lifting gear  Belts, ropes  Replacement parts ...

  • Page 94: Removing The Pull-Out Unit

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.8.1 Removing the pull-out unit The pull-out unit comprises the complete bearing support (330), casing cover (161), the shaft seal (430), and impeller (230). Remove the pull-out unit according to the following table:...

  • Page 95: Mounting The Pull-Out Unit

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.8.2 Mounting the pull-out unit Install the pull-out unit according to the following table: Step Activity Check the impeller ( ) and the front lining ( ) visually for any defects.

  • Page 96: Changing The Impeller And The Front Lining

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Changing the impeller and the front lining Danger of injury at the impeller! Impellers may have very sharp edges, particularly when they are worn. Wear protective clothing and gloves! GEFAHR...
  • Page 97 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Fig. 7-4 Gaps according to impeller diameter Rev.0, Printed: 2010.08 Page 97 of 117...
  • Page 98 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 412.2 412.1 902.2 901.4 551.2 Fig. 7-5 Impeller and location of gaps Rev.0, Printed: 2010.08 Page 98 of 117...

  • Page 99: Trimming The Impeller

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.10 Trimming the impeller The various pump service data are obtained with different impeller diameters. The required diameter for various service data can be found in the pump characteristic diagram or in the data sheet. Before changing an impeller, it must be turned down to the required impeller diameter first of all.

  • Page 100: Changing The Shaft Seals

    Mount impeller according to Section 7.9. Mount pull-out unit according to Section 7.8.2. Start up pump according to Chapter on “Operation”. Changing the Andritz cartridge mechanical seal – single and double Tab. 7-16 Rev.0, Printed: 2010.08 Page 100 of 117...
  • Page 101 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 433.1 551.2 Medium Atmosphere 914.1 Fig. 7-6 Changing the Andritz cartridge mechanical seal - single 551.2 433.1 Atmosphere Medium 914.1 Fig. 7-7 Changing the Andritz cartridge mechanical seal - double Rev.0, Printed: 2010.08...

  • Page 102: Changing The Standard Cartridge Mechanical Seal-Single And Double

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.11.2 Changing the standard cartridge mechanical seal-single and double To avoid greater damage the mechanical seal must be replaced immediately if there is leakage on the atmospheric side. The pump must always be shut down under the following conditions in...
  • Page 103 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 920.4 551.2 433.1 Medium Atmosphere Fig. 7-8 Changing the Standard cartridge mechanical seal - single 920.4 551.2 433.1 Medium Atmosphere Fig. 7-9 Changing the Standard cartridge mechanical seal - double Rev.0, Printed: 2010.08...

  • Page 104: Changing The Single Standard Mechanical Seal

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.11.3 Changing the single standard mechanical seal To avoid greater damage the mechanical seal must be replaced immediately if there is leakage on the atmospheric side. If hot and aggressive pumping medium leaks, this may cause a risk to life and limb and damage to the machine or its components.
  • Page 105 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 551.2 Type: A1 433.1 Type: A2 Medium Atmosphere 551.2 433.1 Type: A3 Medium Atmosphere 914.12 Fig. 7-10 Changing the Single standard mechanical seal Rev.0, Printed: 2010.08 Page 105 of 117...

  • Page 106: Changing The Tandem Standard Mechanical Seal

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.11.4 Changing the tandem standard mechanical seal To avoid greater damage the mechanical seal must be replaced immediately if there is leakage on the atmospheric side. The pump must always be shut down under the following conditions in...
  • Page 107 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 551.2 914.2 Type: B1 433.1 433.2 Type: B2 Medium Atmosphere 914.2 Type: B3 433.1 433.2 412.6 Medium Atmosphere Fig. 7-11 Changing the Tandem standard mechanical seal Rev.0, Printed: 2010.08 Page 107 of 117...

  • Page 108: Changing The Stuffing Box Packing And The Shaft Protection Sleeve

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.11.5 Changing the stuffing box packing and the shaft protection sleeve The stuffing box packing is a wear part. When the stuffing box gland (452) is approximately 5mm from the parallel surface of the stuffing box casing (451), the packing must be changed.
  • Page 109 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 412.6 920.4 551.2 912.6 Fig. 7-12 Changing the Stuffing box packing Rev.0, Printed: 2010.08 Page 109 of 117...
  • Page 110 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Installing the stuffing box Proceed according to the following table when installing the packing: packing Step Procedure Mark packing (see Fig.8-17) and cut to the appropriate length. Keep stuffing box clean, do not stretch or squash stuffing box when measuring and cutting.
  • Page 111 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions Setting the stuffing The following settings must be observed: Never tighten the stuffing box gland so far that drainage of sealing  water is brought to a complete halt. At least a few drops should drain off per minute in order to avoid excessive friction and wear on the shaft.

  • Page 112: Changing The Anti-Friction Bearings

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.12 Changing the anti-friction bearings The anti-friction bearings are designed for continuous operation under full load for approximately 50000 operating hours. Higher bearing temperature and vibration at the bearing support are a sign of impending bearing damage.
  • Page 113 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 321.1 636.1 412.1 931.1 321.2 636.2 550.1, 421.1, 507.1 550.1 421.1 507.1 904.2 904.1 Fig. 7-14 Bearing support-Grease lubrication 903.3, 411.3 903.4, 411.4 423.2 423.1 914.10 411.10 914.11 411.11 Fig. 7-15 Bearing support-Oil lubrication Rev.0, Printed: 2010.08...

  • Page 114: Disassembly And Disposal

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions 7.13 Disassembly and disposal The machine must be disconnected from the power source before disassembly! The machine should only be disassembled by qualified and DANGER authorized personnel. If the machine/plant is to be shut down, the following must be taken into account for subsequent disposal: •...
  • Page 115 Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions • Surface-treated sheet steel, such as powder-coated or wet-painted Other metal groups to be covers, etc. separated are: • Surface-coated construction steel, such as rotating parts, gratings, bolts, etc. • Copper (electrical grade copper or silver-coated electrical grade copper), such as bush bars, connecting straps, connections pieces, etc.

  • Page 116: Technical Data

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions TECHNICAL DATA Data sheet Characteristic curve Dimensional drawing Rev.0, Printed: 2010.08 Page 116 of 117...

  • Page 117: Coupling

    Centrifugal Pump, ACP series Erection Work, Operating and Maintenance Instructions SUPPLIER DOCUMENTATION Coupling Shaft seal Rev.0, Printed: 2010.08 Page 117 of 117...

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