Andritz FP Series Manual

Fan Pump, FP series
Erection Work, Operating and Maintenance Instructions
Rev.0, Printed: 2002.03.04 TITLE PAGE #455857 v1 - DECKBLATT
Erection Work, Operating and Maintenance Instructions
Machine: Fan Pump, FP series
Issued: PFe/Subosits, 2002-01 Revision:
Checked: HPp/Hartl Checked:

Fan Pump, FP series
Erection Work, Operating and Maintenance Instructions
Rev.0, Printed: 2002.03.04 TABLE OF CONTENTS Page 1 of 4
#455856 v1 - INHALTSVERZEICHNIS
Table of contents
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Warranty and guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Manufacturer’s name and address. . . . . . . . . . . . . . . . . 4
1.6 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1
2.2 Danger and warning signs . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 General remarks on machine/plant safety . . . . . . . . . . 2
2.5 User’s obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 General obligations of personnel . . . . . . . . . . . . . . . . . . 5
2.7 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.8 Personal protective apparel . . . . . . . . . . . . . . . . . . . . . . 7
2.9 Safety at the machine installation site . . . . . . . . . . . . . 7
2.10 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.11 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.12 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.13 Steam and fumes/smoke . . . . . . . . . . . . . . . . . . . . . . . . 8
2.14 Oils and greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . 1
3.1 Data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2 Characteristic curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.3 Dimensioned drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.4 Principal section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.5 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Erection Work, Operating and Maintenance Instructions
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4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.1 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.2 Main components of fan pump . . . . . . . . . . . . . . . . . . . . 2
4.3 Type specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3.1 Applicable standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3.2 Model designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Application limiting values . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Technological Description. . . . . . . . . . . . . . . . . . . . . . . 12
5 ERECTION WORK and TRANSPORT . . . . . . . 1
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Haulage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.5.1 Erection of the fan pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5.2 Pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.6 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.7 Cold test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3 Prerequisites for start-up. . . . . . . . . . . . . . . . . . . . . . . . . 2
6.4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.5 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.3 Control via DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7.4 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7.5 Checks after initial start-up . . . . . . . . . . . . . . . . . . . . . . 3
7.6 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.7 Fan pump requirements
(delivery head and flow rate) 5
7.8 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.9 Operating malfunctions and troubleshooting . . . . . . . . 7

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Erection Work, Operating and Maintenance Instructions
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8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 2
8.4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8.5 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.6 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.6.1 Oil lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
8.6.2 Grease lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8.7 Aligning the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.8 Removing and installing the rotor unit . . . . . . . . . . . . . 12
8.9 Changing the bearing assembly . . . . . . . . . . . . . . . . . . 16
8.10 Changing the stuffing box packing . . . . . . . . . . . . . . . . 19
8.11 Changing the mechanical seal. . . . . . . . . . . . . . . . . . . . 22
8.12 Removing and installing the impeller . . . . . . . . . . . . . . 23
8.13 Turning and balancing the impeller. . . . . . . . . . . . . . . . 27

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Erection Work, Operating and Maintenance Instructions
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Fan Pump, FP series
Erection Work, Operating and Maintenance Instructions
Rev.0, Printed: 2002.03.04 INTRODUCTION Chapter 1, Page 1 of 4
#704713 v1 - EINF‹HRUNG
1 INTRODUCTION
This manual is part of the technical documentation of Andritz AG. It is
intended as a supplement to the training provided, to supply the basic
knowledge required for proper, safe and economical use of the plant and
machinery delivered by Andritz AG. Observing these instructions helps
avoid hazards and reduce repair and downtime costs, as well as
increasing the reliability and useful life of machines.
1.1 Use
Target group This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator of the
mill and his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This refers
in particular to the following tasks:
•Handling, starting and stopping
•Troubleshooting
•Maintenance and upkeep
•Haulage
•Maintenance and disposal of process materials, cleaning of machine
and area around the machine.
The following sections are especially important:
•the Chapter on SAFETY,
•the safety instructions contained in various other chapters
Supplementary
instructions
The mill operator shall complete this manual by adding national
regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned to
the job shall also be added. This also includes instructions on supervising
and reporting obligations.
Safekeeping Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2 Standards and guidelines
The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. The equipment conforms with
the equivalent appropriate standards.

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1.3 How to use the manual
Presentation • Chapter and paragraph headings are printed in capitals in the
continuous text.
SAFETY
•Designations of indicating and handling elements are written in
inverted commas in the continuous text.
Operate switch "xxx"
•Lists without numbering do not require operations to be carried out in a
certain order.
Pictograms The following pictograms are used in the manual:
Work steps
(operations)
Work steps are presented in tables. Work steps are numbered and must
be carried out in the order specified.
Warning signs
Warning signs are shown with an explanation of the
type of the hazard.
The meaning of the different graduations of hazards
are described in the Chapter on SAFETY.
Marks an instruction on handling of the machine or
system.
Marks a useful piece of information
!Marks a cross-reference to another Chapter with
absolute path indication.
e.g. ! /FAN PUMP/SAFETY

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Erection Work, Operating and Maintenance Instructions
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Item numbers
Numbering of
pages, tables and
figures
Abbreviations
1.4 Warranty and guarantee
Andritz AG’s general terms of delivery and sale shall apply.
Guarantee and liability claims on Andritz AG shall become void if personal
injury or material damage is caused by one or several of the following:
•Use of the machine/system for any purpose other than its designated
use.
•Non-conformity of erection work, start-up and handling of the
machine/system.
•Non-observance of the safety instructions in the manual.
•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.
411.2 The item numbers shown in this format refer to the
assembly drawing and the parts list.
Pages Consecutive numbering of Chapters 2-1
Tables Tab.+ Continuous numbering of Chapters Tab. 2-1
Figures Fig. + Consecutive numbering of Chapters Fig. 2-1
Tab. Table
Fig. Figure

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1.5 Manufacturer’s name and address
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our service department will be pleased to help you and can be contacted
at:
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Service department for pumps
Tel.: [phone]
Fax: [phone]
email: [e-mail]
In case of emergency outside working hours
Tel.: [phone]
1.6 Copyright
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.
2002 Andritz AG

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Erection Work, Operating and Maintenance Instructions
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#455859 v1 - SICHERHEIT
2SAFETY
2.1 General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
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 (!/FAN
PUMP/SUPPLIER DOCUMENTATION). The safety instructions
supplement ANDRITZ AG’s operating instructions.
All safety instructions must be observed. Disregarding the safety
instructions may cause a risk to life and limb, environmental pollution
hazards and damage to property.
2.2 Danger and warning signs
The entire SAFETY chapter is of extreme importance and relevant to
safety. The information in this chapter, therefore, is not marked with
special danger symbols.
The Chapters on ERECTION WORK, START-UP, OPERATION and
MAINTENANCE in this Manual are marked by a pictogram. The following
warning signs are used:
DANGER
This symbol indicates there may be a risk to life and limb.
Non-compliance with the warning signs may lead to serious health
problems or even fatal injuries, and can cause extensive damage to
property.
WARNING
This symbol points to an imminent health risk, as well as a risk of
environmental pollution and of damage to property.
Non-compliance with the warning sign may cause moderate health
problems and/or extensive environmental pollution and damage to
property.
CAUTION
This symbol points to a dangerous situation.
Non-observance of these signs may cause environmental pollution and
damage to property.

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Further symbols and pictograms used are described under
INTRODUCTION.
2.3 Designated use
The fan pump should only be used according to the specifications forming
part of the purchase order.
Any change in the application must be checked by the operator and, if
necessary, approved by Andritz AG.
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.
2.4 General remarks on machine/plant safety
The fan pump has been built in accordance with state-of-the-art standards
and the recognized safety rules. Nevertheless, its use may constitute a
risk to life and limb of the user or of third parties, or cause damage to the
machine/plant and to other material property.
The fan pump may only be operated when in perfect condition and with
due consideration to safety and the risks involved. All protective devices
and the emergency cut-out devices must be in place and fully functional.
Malfunctions and unforeseen changes in the fan pump must be remedied
immediately.

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2.5 User’s obligations
Designated use The user of the fan 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.
Qualification of
assigned
personnel
The fan pump may only be operated, maintained and serviced by
authorized, skilled personnel with hands-on training.
Personnel must not be below the legal minimum age.
Any person undergoing training, serving an apprenticeship or being
instructed must not work on the fan pump except under the supervision of
an experienced person.
Instructions The user’s operating and maintenance personnel will be instructed by
manufacturer personnel or his contractual distributor upon completion of
installation work.
The user undertakes to have new, additional operating and maintenance
personnel instructed in machine operation and maintenance of the fan
pump to the same extent and applying the same care, and with due
consideration to the safety instructions.
Workers entrusted with the transportation, erection work and start-up of
the fan pump must have read and understood the operating instructions,
especially the chapter on SAFETY, the safety instructions concerning a
certain activity, as well as the safety instructions issued by sub-suppliers.
Definition of areas
of responsibility
The user shall be responsible for:
•definition of the machine operator's responsibility and his right to give
instructions
•definition of the contents and responsibility for keeping the records on
functioning and any failure of the monitoring equipment (log book)
•personnel areas of responsibility in terms of operating, tooling,
maintenance and upkeep.

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Inspections The operator undertakes
•to check at regular intervals whether the safety instructions and
regulations governing work on the fan pump are observed.
•to carry out regular training to confirm the level of knowledge of the
operating and maintenance personnel.
Attaching safety
devices
The user shall ensure that the following equipment, regulations, symbols
and instructions are mounted in the production area:
•Safety devices and regulations (see Chapter 2.7)
•Fire prevention regulations
•Markings on the floor for driveways, protective fencing and danger
areas (yellow)
•Fencings and covers
•Railings (foot, centre and chest height)
•Emergency lighting
•Emergency-off switch
•Repair switch for drive motors
•Signs on fire-fighting equipment
•Signs for emergency calls
•Direction arrows to exits
•Direction arrows to escape routes
•Signs to first-aid post

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2.6 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
fan pump.
•stop and secure the fan pump in case of a safety-relevant functional
disorder. Report the disorder and have it repaired immediately.
•not perform any work in a manner disregarding safety considerations.
•use only the machine accesses, paths and passages foreseen for this
purpose.
•not touch rotating parts and/or reach out beyond them.
•keep the machine and the work place clean, not place tools or other
objects on the fan pump.
•not wear any garments/pieces of jewellery which might get stuck on
rotating/moving pump parts, including ties, scarves, rings and
necklaces.
•not wear long hair hanging down.
•familiarize themselves before starting work with the function and any
failure of machine monitoring equipment (log book).
•refrain from smoking in the vicinity of the fan pump.
•Personal protective apparel must be worn when working on the fan
pump. (see Section 2.8).
•Due to the high temperatures and humidity, people wearing glasses
may find that their glasses steam up, thus exposing the wearer to a
risk of injury.
•The operating personnel must be acquainted with the safety data
sheets in order to be able to recognise how dangerous the chemicals
can be.

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2.7 Safety devices
The fan pump must not be operated without effective safety equipment.
Safety equipment must not be circumvented, dismantled or made
unserviceable. The safety equipment is here to protect operating
personnel.
Safety equipment and access thereto must be kept free.
Safety covers The fan pump must not be operated without safety covers mounted.
Fig. 2-1 shows the protective covers for the fan pump.
Fig. 2-1 Protective covers for the fan pump
Safety covers Coupling guard

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2.8 Personal protective apparel
General
safety equipment
The following must always be worn when performing work on the fan
pump:
•protective clothing to prevent the pulp from coming into contact with
the skin.
•gloves to prevent hand injuries
•goggles to prevent eye injuries
•safety shoes as protection against crushing
•the required personal ear protection to avoid hearing defects
•standard hard hat as protection against head injuries
2.9 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 fan
pump. Customer will be provided with a load plan.
Area around machine and marked escapes to be kept free. Area around
machine must be marked as danger zone.
Make sure machine and surrounding area are kept clean. In particular, oil
and grease on the floor and on machine elements may cause slipping.
This is therefore a considerable source of injuries, as are tools.
The floor around the fan pump must be provided with a non-slip finish.
Ramps, platforms and lifts must be used to avoid injury or excessive
physical effort.
2.10 Temperature
The fan pump is designed for a stock temperature of 55°C. If pulp at
temperatures higher than 65°C is to be used, the operator must take the
necessary safety measures (e.g. protective gloves, training of operating
staff, etc.).
2.11 Noise
The total noise emissions from all machines in the production room can
restrict spoken communication and impair hearing.

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The machine is designed such that no operator is required in the
immediate vicinity of the machine. Appropriate hearing protection should
be worn throughout maintenance and adjusting work while the machine is
running.
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.
Employees performing work on live parts should be accompanied by an
assistant who can operate the emergency switch if necessary.
Users of medical electronic equipment, such as pacemakers, must not
enter the electric danger zone.
Machine must be earthed to avoid electrostatic loading.
2.13 Steam and fumes/smoke
Unusual chemical reactions may take place in the fibre stock during a
prolonged standstill and hazardous fumes may be produced.
The machine must be thoroughly cleaned if shut down for longer than 2
hours.
The area must be sufficiently ventilated.
2.14 Oils and greases
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' information for the type of skin protection required.
Also observe relevant requirements for disposal.

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Erection Work, Operating and Maintenance Instructions
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#455860 v1 - TECHNISCHE DATEN
3 TECHNICAL DATA
3.1 Data sheet
3.2 Characteristic curve
3.3 Dimensioned drawing
3.4 Principal section
3.5 Parts list

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Erection Work, Operating and Maintenance Instructions
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Fan Pump, FP series
Erection Work, Operating and Maintenance Instructions
Rev.0, Printed: 2002.03.04 DESCRIPTION Chapter 4, Page 1 of 12
#762847 v1 - BESCHREIBUNG
4DESCRIPTION
4.1 Field of application
The fan pump is used in continuous operation to pump clean liquids and
various pulps in the paper industry.
Fig. 4-1 Fan pump