Gespasa BDP User manual

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BDP · HIGH FLOW PUMPS
INSTRUCTION MANUAL
1. INTRODUCTION
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The vane pumps use a rotor with sliding blades that push the liquid behind each blade from the inlet opening and move it to
the pumping chamber. When the rotor turns, the liquid is transferred among the vanes to the outlet opening being
discharged, while the pumping chamber is compressed. Each blade applies a positive mechanical thrust to the liquid it has.
The blade contact with the chamber walls is kept by three forces:
The centrifugal force of the rotor rotation.
Thrust rods that act between the opposed pairs of vanes.
The liquid pressure that gets in the slots of the vanes and acts in their top.
Each revolution of a pump displace a constant volume of fluid. The pressure variation has a minimum effect. The losses
and turbulences are reduced at minimum while the high volumetric output is guaranteed.
They are heavy duty pumps, made of cast iron and stainless steel, with single-race grease-lubricated ball bearings and
isolated from the pumping product by mechanical seals with nitrile or Viton joints, according their needs.
All the pumps has built in a safety valve. They are perfectly adapted to the truck service and transport, in general,
tank load and unload, storage of fuel or any other non-corrosive liquid free of particles in suspension.
TECHNICAL DATA
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BDP
MODELS PUMP SIZE
Maximum pump speed ( rpm) 1” 1.5” 2.5” 3” 4”
1,400 740 640 640 520
Maximum viscosity¹ 20,000 (4250)
Maximum temperature² 356 ºF (180 ºC)
Ma
x
imum differential
p
ressure 125 psi (862 kPa)
Maximum working pressure 175 psi (1207 kPa)
(1) The viscosity shown is in SSU (cP). cP= cSt for a fluid with a density of 1 kg/dm³.
(2) The maximum surface temperature of the pump in potentially explosive atmospheres is 135 ºC.

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SAFETY INFORMATION
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Serious or fatal injuries may be caused if the power supply is not disconnected and cut
before undertaking maintenance.
Serious injuries to people, damage to property or even the death may be caused by
operating the pump without the protections properly installed.
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Injury to people or damage to property may be caused by operating the pump with a
closed valve, causing the breaking of the system components.
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Note:
The pump must not work empty since this would increase its superficial temperature, causing component wear and
damages and not correct operation. Check all the valves of the system, verifying they are in their correct position
(please, refer to the next section 4.5).

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2. WARNINGS
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When choosing a pump, first decide its flow (l/min) you required and then the pump series for the specific application.
2 .1. SUCTION HOSE
The pump is thought to give its capacity, but according to the load suction there may be restrictions because the suction
pipe is too long or its diameter is too small. This restriction could even restrict the pump liquid demand, causing its
cavitation and breaking down the liquid into a mixture of liquid and vapour as it goes into the pump.
Not only does the result of cavitation give less delivery, but also an increase of the noise, the vibration, the wear of the
pump and other parts.
The cavitation may be also caused because of the use of other components of inadequate size in the pipe, like valves,
elbows and suction emergency connections with the consequent flow reduction.
2.2. DELIVERY PIPE
The pipe, the hose, the meters and the other equipment in the installation must be selected for a minimum flow reduction. If
they are too small, the pump may work at low revolution in order to eliminate the excessive pressure in the system,
decreasing the delivery frequency.
It a system is designed for a larger sizes, remember the simplicity of the system also reduces its resistance.
It is advisable to consider the convenience of reducing the pipe length or the number of elbows or other couplings.

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3. INSTALLATION
Note:
The motorised pumps must be only installed in the systems designed by qualified technical personnel.
The system must comply with all the pertinent regulations and codes and must include warning signs for all the implicit
dangers.
 The installation, electrical connection and earthing must comply with the local
regulations and the national electrical code.
 Install a switch close to the pump to switch off all the phases.
 Disconnect and block the supply system before starting the installation or the
maintenance.
The power supply must match the specifications on the motors feature plate.
The motors with built-in heat protection automatically disconnect the electrical circuit of the motor in case of overloading. The
motor can start up unexpectedly and without any warning.
3.1. CLEANING BEFORE THE INSTALLATION
The foreign particles that can go into the pump will cause important damages.
The tank and the suction pipe must be cleaned and washed before their installation start-up.
3.2. LOCATION AND PIPES
If the pipe system or the pump is not well-installed, it will reduce the pump output and its useful life.
It is recommended to follow the below instructions for the best pipe and pump installation:
1. To reduce at minimum the losses in the suction pipe, install the pump as close as possible to the power supply.
2. The diameter of the suction pipe and its couplings must be at least equal to the inlet diameter of the pump
3. Reduce at minimum the element number (valves, elbows, etc.) in the suction pipe and also the pipe direction changes. When
used, they must be located at a minimum distance from the pump inlet equal to 5-10 times the pipe diameter.
4. It is advisable to install a filter at a distance from the pump inlet equal to 5-10 times the pipe diameter. With viscosities
lower than 1000 SSU, the filter should have a net open surface equal to 4 times the suction pipe surface. With
viscosities higher than 1000 SSU, refer to the instructions of the filter manufacturer. The filters must be cleaned
periodically in order to prevent the lack of supply to the pumps.
5. The suction and delivery pipes must be free of leaks.
6. To make easier the expansion and contraction of the pipes, the expansion joints should be installed 0.9 m from the
pump inlet and outlet.
7. All the pipes and their elements must be properly supported so that the pipe loads are not transmitted to the pump.
3.3. PUMP ASSEMBLY
It is advisable to assemble the pump fixing its base with anchoring bolts with the suitable size to a concrete floor, correctly
levelled according to the recommended industrial regulations.
Strong foundations will reduce the noise and vibration of the system and improve the pump output.
Please, check the ANSI standards or a suitable pump instruction manual for the correct assembly and founding of the pumps.

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Please also check the coupling alignment after fixing the pump set and the base to the foundations.
3.4. COUPLING ALIGNMENT
The pump must be connected directly to the gear box and or the transmission system through a flexible coupling.
The coupling alignment (both angular and parallel) MUST BE KEPT among the pump, the box gear, the motor etc. according
to the manufacturer's instructions.
To check the parallel alignment, it is advisable to use a dial gauge (if none is available, use a ruler). Turn both shafts with the
hand, checking the gauge readings in a whole turn. The maximum deviation should be lower than 0.005 “ (0.127 mm).
To check the angular alignment, insert the thickness gauge between the both halves of the coupling. Check the spacing
every 90º around the coupling (four check points). The maximum variation should not be higher than 0.005 “ ( 0.127 mm).
Alignment check:
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DIAL GAUGE FXED TO
THE SHAFT
RULER THICKNESS GAUGE

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3.5. PUMP ROTATION
To set the pump turn sense:
 If the pump opening inlet and the safety valve are on the right, with the shaft drive side pointing to the observer, the
pump turns to the right, i.e. clockwise
 If the pump opening inlet and the safety valve are on the left, with the shaft drive side pointing to the observer, the pump
turns to the left, i.e. anticlockwise.
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4. OPERATION
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Serious injuries to people, damage to property or even the death may be caused by
operating the pump without the protections properly installed.
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Injury to people or damage to property may be caused by operating the pump with a
closed valve, causing the breaking of the system components.
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4.1. CHECKINGS BEFORE THE START-UP
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- Inspection of the pipe system and the supports in order to ensure the pipe loads are not transmitted to the pump.
- Check all the valves and other elements installed in the pipeline are switched on or working.
- Briefly start the motor in order to see if the pump turns the correct sense.
4.2. START-UP PROCEDURE
1. Start the motor up, the priming is made in one minute.
2. Check the manometer and the gauge to ensure the system is working in the planned parameters.
3. Check the pipes, the joints and the equipment associated with the system for leaks, noise, vibrations or
overheating.
4. If possible, also check the flow to ensure the pump is working within the planned parameters.
5. Check the safety valve set, by closing the valve in the discharge pipe and reading the pressure. The pressure
should be 10-20 psi (69 –138 kPa), above the maximum working pressure or the setting value of the external
bypass valve (if there is any installed).
Do not let the pump work with a closed valve in the discharge pipe more than 15 seconds. If necessary to set,
please refer to next 4.4.1. "Safety valve Setting" section of this instruction manual.
4.3. REVERSE TURN
The pump can turn in the reverse sense that is currently turning, but taking into account the safety valve of the pump
stops working.
It is advisable to install an individual safety valve in order to protect the pump against an excessive pressure.
The pump will work at a less output level.

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4.4. PUMP SAFETY VALVE
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NOTE: The internal safety valve of the pump has been designed to protect the pump against an excessive pressure and
it must not be used as a control valve of the system pressure.
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The volatile liquid pumping in adverse suction conditions can cause cavitation. The partial closing of the discharge
valve will cause vibrations to the internal safety valve, that is why is not recommended. For this type of use, install
an external control valve of the system pressure and the required bypass up to the storage tank.
It is also advisable to install a control valve of the system pressure when the pump is going to work during periods
longer than 1 minute with the discharge valve closed.
4.4.1. Safety valve setting
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The value of the safety valve setting set in factory it is marked in the metallic sheet in the valve cover.
It is advisable to adjust the safety valve as minimum 10-20 psi (69-138 kPa) above the working pressure or the
value of the control valve setting of the system pressure.
Safety valve setting instructions:
1. To increase the value of the pressure setting:
Disassemble the cap of the valve (no. 17) and the gasket.
Loosen the nut, if there is any.
Turn the tensor stud (no. 9) inwards or clockwise.
Check the gasket and replace it if required.
Reassemble the gasket and the cap of the safety valve.
2. To reduce the value of the pressure setting:
Disassemble the cap of the valve (no. 17) and the gasket.
Loosen the nut, if there is any.
Turn the tensor stud (no. 9) outwards or anticlockwise.
Check the gasket and replace it if required.
Reassemble the gasket and the cap of the safety valve.
The cap of the safety valve is exposed to the pumping fluid and may contain some fo
this fluid.
An incorrect setting of the safety valve can cause the breaking of some system
components, injury to people or damages to property.
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4.5. HEATING CHAMBER
The heating or cooling chamber is heated or cooled connecting it to an external circuit with hot liquids like oil or steam with the
aim of heating very viscous liquids or freezing liquid into the pumping chamber. The chamber covers are equipped with some
connections from 3/8" to 1/2" GAS, depending on the different models, through which the hot oil or the steam is entered.
Note:
The liquid used in the heating chamber must have an ignition temperature at least of 50 ºC / 122 ºF above the maximum
superficial pump temperature.
The pressure in the heating chamber must not exceed than 10 bar / 145 psi.
Note:
When the pump works with hot liquids that create a high superficial temperature, it is advisable to place a signal, warning
about the danger in order to avoid the users burn themselves.
All the pumps with heating chamber working in an explosive atmosphere will have always built in a mechanical locking.
4.6. SURFACE TEMPERATURE OF THE PUMP
The surface temperature of the pump mainly depends on the pumping liquid temperature, the working conditions, the liquid
temperature that there is into the heating chamber (the models with heating chamber) as well as its design.
When determining the maximum surface temperature, choose the following minimum values:
Apart of depending on the pumping liquid temperature, the maximum surface temperature of the pump is determined by the
used manufacturing materials. The used elastomer can work in different temperature ranges.
According to the pumping liquid, the used elastomer depends on its chemical compatibility with the fluid.
In presence of potentially explosive gases, the surface Tª of the pump must be equal to or less than 80% of the gas ignition
temperature.
In presence of potentially explosive powder, the temperature must be equal to or less than 2/3 of the powder ignition
temperature.
The maximum surface temperature will be the minimum value of these possible values:
MINIMUM/MAXIMUM TEMPERATURE OFDIFFERENT ELASTOMERS
ELASTOMER TYPE ELASTOMER MARK MIN/MAX Tª
FPM VITON -25 ºC/+205 ºC
NBR NITRILE -30 ºC/+115 ºC
PTFE TEFLON -45 ºC/+260 ºC
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A badly projected installation (refer to the above section 3.2. of this manual) where the pump works empty (without liquid)
or the fluid is recirculating into the pump without being delivered to the discharge tank could cause the increase of the
surface temperature of the pump.
The pump must be freely exposed to the atmosphere, allowing its own cooling.
4.7. ATEX MARK OF THE EQUIPMENT
Equipment description: High flow blade pumps · Series: BDP-300 · BDP-400 · BDP-500 · BDP-600 · BDP-800
Marked: II 2G DT *

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Serial number:
The ATEX plate is placed along with the pump identification plate.
*All the pumps are classified as Group II category 2. The maximum surface temperature is different for each model, as
shown in the below table:
TEMPERATURE CLASS PUMP MODEL
T4 ( 135 ºC) BAL- 2R
T2 (230 ºC) BAL- C (with heating chamber)
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4.8. NOISE EMISSION OF THE PUMPS
Declared disassociated noise emission values as per the International Standard: ISO 4871/1996 · Acoustics - Declaration
and verification of noise emission values of machinery and equipment “A”,LWA (re. 1pW in dB) 83 dB (A).
Values determined from the results of the AAC 091850 essay report (ENAC 88/LE 229), according to the UNE EN ISO
3744:1996 Basic Standard.

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5. PUMP MAINTENANCE
Note:
The maintenance of the pump only must be made by qualified technicians following the correct procedures and warning
according to this instruction manual.
Electric shocks, burns or even death may be caused if the power supply is not
disconnected before starting the pump maintenance.
When pumping dangerous or toxic liquids, the system must be cleaned or
decontaminated, both externally and internally, before its maintenance.
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Injury to people or damage to property may be caused if the system is not
depressurised before starting the pump maintenance.
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5.1. PLANNED MAINTENANCE
Filters
The filters must be cleaned regularly in order to prevent the lack of fluid supply to the pump. The frequency will
depend on the application and the working conditions.
Pump lubrication
It is advisable to grease the ball bearings each 3 months as minimum. The frequency will depend on the
application and the working conditions.
Recommended grease
Repsol Molibgras EP-2 grease
Greasing procedure:
1. Remove the grease nipple (no. 41) of the bearing covers (no. 13).
2. Apply the grease slowly with a gun until the grease goes out.
3. Remove the excess of grease according to the relevant standards.
4. Reassemble the grease nipple in the greasing holes.
DO NOT EXCESSIVELY GREASE the pump bearings. Although it is perfectly normal a bit of grease in the
greasing nipple hole, an excessive leak in the pumps with mechanical gaskets can cause the gasket breaking
(the greasing indicator hole is in the cylinder head, between the gasket and the bearing).

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5.2. VANE REPLACING
To change the vanes (no. 6) is very easy. In a few seconds the pump is working again.
1. Just disassemble the external head set.
2. Remove the old vanes.
3. Insert the new ones.
4. Reassemble the head again.
The routine checks are also easy. In fact, most of the maintenance can be made without disconnecting the pump from its pipe
or drive shaft. Changing the vanes does not require any special tool.
5.2.1. Vane position
The vanes have only one position for the correct operation of the pump. Its surface has some channels for which the liquid
makes the enough pressure along with the bars and the centrifugal force action to help the vane to slide. these channels must
be facing the pump turn sense (clockwise) (engraved arrow in the pump body).
The rounded edge must touch the body inner.

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6. PUMP TROUBLESHOOTING
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DESCRIPTION POSSIBLE CAUSE
The pump does not prime.
- The pump is not wet
- Worn banes
- Closed suction valve
- Air inlet in the suction pipe
- Blocked filter
- Blocked or too restrictive suction pipe or valves
- Blocked pump by the steam
- Pump speed not enough for the priming
- Safety valve partially open or worn or with a non-proper seat.
Reduced capacity
- Too low pump speed
- Suction valves not totally opened
- Excessive restriction in the suction pipe
- Damaged or worn parts
- Excessive restriction in the delivery pipe
- The safety valve is worn or tare at low value or does not
correctly close.
- Vanes incorrectly installed
Noise
- Excessive vacuum because of:
Undersized adapters or with restrictions in the suction pipe
- Excessive speed of the pump for the liquid viscosity or
volatility
- Pump far away of the fluid source.
- The pump has been working too much with the delivery pipe
blocked.
- The pump is not firmly assembled.
- Worn or damaged bearings
- Vibrations because of non-correct fixed pipes
- Bent shaft or misaligned motor coupling
- Error of the system valve
- The safety valve is tare at a too low value
- Damaged vanes
- Vanes incorrectly installed
Damaged vanes
- Entry of foreign particles in the pump
- The safety valve does not open.
- Hammer blow · pressure peak
- Misaligned motor / pump
- Worn or cracked vanes
- Accumulated or solidified material in the pump during the start-up.
Mechanical leaks
- O-rings not compatible with the pumping liquids
- O-rings with notches, cuts or damaged
- Damaged, worn or filthy shaft
- Excessively lubricated ball bearings
- Excessive cavitation
- Mechanical joint faces with grooves, scratches or dirt

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7. PUMP ASSEMBLY INSTRUCTIONS
Assembly:
First fit the rotary mechanical seal no. 39/2 in the pump rotor/shaft no. 5 & 11 respectively. Lubricate the shaft
no. 11 of the pump and turn inwards the rotary mechanical seal no. 39/2 until it touches the rotor base no. 5.
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Carefully fit the cover no. 2 D until its face is seated on the rotor no. 5.
Then fit the fixed race of the rotary mechanical seal no. 39/1 with its corresponding O-ring no. 39/3.
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Then fit the bearing no. 18 and the blocking washer no. 18/1 & no. 18/2, adjusting them without tightening them so
much.
The next step is to place upwards this assembly and seated it in the assembly pipe; fit the axial joint no. 27 in the
cover no 2D.
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Before fitting the pump body no. 1, put the rods no. 7 in their corresponding hole and grease them to prevent they fall.
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Insert the vanes no. 6 in their corresponding slots.
The vanes no. 6 must be placed clockwise in the channels and the rounded edge looking outwards the motor.
Fit the body no. 1. Tighten the bolts that joint the body no. 1 with the cover no. 2D.
Then put the body no. 1 in horizontal position and start assembling the other part of the pump.
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Fit the rotary mechanical seal no. 39/2 as above explained and then the cover no. 2D, the fixed seal race no.
39/1 with its joint no. 39/3 and then the bearing no. 18.

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Then use two bolts to fix the cover no. 2D to the pump body no.1 without tightening it so much. Then place the
blocking washer no. 18/1 along with the blocking nut no. 18/2 and find the correct gap between the parts of the
rotor no. 5 with the body no. 1, by slowly tightening the washer no. 18/1 & the nut no. 18/2 of one side of the
pump and then the other one.
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Cuando la bomba este promediada y gire correctamente trincaremos las dos tuercas de bloqueo nº18/2 opuestas y
amarraremos los tornillos.
Grease the bearings, fit and tighten the two covers of the bearings no. 13 with their corresponding klinger joints no. 13/1.
BYPASS ASSEMBLY
The bypass is composed of:
The tensor cover no. 8 with its corresponding klinger gasket no. 8/1, the tensor stud no. 9, the grille no. 10, the valve no. 14,
the spring no. 16, the tap nut no. 17 with its corresponding klinger gasket no. 17/1.
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To assembly the bypass start fitting the valve no. 14 in the body nº 1 hole of the pump that is on the suction hole (for a
standard assembly).
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Then insert the spring no. 16 until it is seated in the valve no. 14.
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Then put the grille no. 10 as it is shown in the below image:
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Then fit the gasket for the tensor cap no. 8/1.
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Tighten the tensor cap no. 8 with the fixing bolts
and fit the tensor stud no. 9.

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Then fit the joint of the cap nut no. 17/1.
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Finally, thread the cap nut no. 17 in the tensor stud.
DISASSEMBLY:
Remove the bolts of the bearing cap (no.13) to start to disassemble the pump.
Remove the bearing cap and remove the blocking nut (no. 18/1) and the blocking washer (no. 18/2).
Then, carefully remove the bolts of the cover (no. 2D) avoiding damaging the piece. use two screwdrivers to lever it out of
the body (no. 1). Carefully do not damage the O-ring joing (no. 27), which is in the cover (no. 2D).
In the shaft (no. 11), there is the rotary mechanical seal (no. 39/2), which must be removed by turning it with the hand.
Then remove the vanes (no. 6). Now it is possible to start the disassembly of the other part of the pump.
Remove the bolts (no. 40) of the cover (no. 2D) and place the rods (no. 7) such a way they do not fall when removing the
set and damage the body no. 1).
Then grasp the shaft (no.11) and tap the other part with a plastic mallet carefully not to hit the rotor (no. 5) against the
body).
In such a way the other part will be out of the pump body. Then remove the bolts of the bearing cover no. 13, loosing and