Munsch NPC Series User manual

Standard Chemical Pump
Operating manual NPC series
Version BA-2005.07
Print-Nr. 02
VM-Nr. EN
Munsch Chemie-Pumpen GmbH
Im Staudchen
56235 Ransbach-Baumbach
Germany
Phone: [phone]
Fax: [phone]
E-mail: mun[email protected]
Internet: http://www.munsch.de
Technical alterations reserved.

Table of contents
Table of contents
1 About this document ............................... 6
1.1 Target groups ................................. 6
1.2 Other applicable documents . . . . . . . .. . . . . . . . 6
1.3 Warning labels and symbols ................ 7
1.4 Technical terms ............................... 7
2 Security .............................................. 8
2.1 Intended use .................................. 8
2.2 General safety instructions .................. 8
2.2.1 Product safety ................................ 8
2.2.2 Duties of the operating company . . . . . . . . . .. 9
2.2.3 Duties of the operating personnel . . . . . . . .. . . 9
2.3 Special hazards .............................. 9
2.3.1 Explosion hazard area ....................... 9
2.3.2 Hazardous pumped media . . . . . . .. . . . . . . .. . . 9
3 Layout and function ................................ 10
3.1 Labels ......................................... 10
3.1.1 Type plate ..................................... 10
3.1.2 ATEX plate .................................... 10
3.1.3 Pump type code . . . . . . . . . . .. . . . . . . .. . . . . . . .. . . 10
3.2 Layout ......................................... 11
3.3 Shaft seals .................................... 11
3.3.1 Mechanical seals ............................. 11
3.4 Auxiliary operating systems ................. 12
3.4.1 Sealing systems .............................. 12
4 Transport, storage and disposal .................. 13
4.1 Transport ...................................... 13
4.1.1 Unpacking and inspection on delivery .. .. . . 13
4.1.2 Lifting .......................................... 13
4.2 Preservation .................................. 14
4.3 Storage ....................................... 14
4.4 Disposal ....................................... 14
5 Setup and connection .............................. 15
5.1 Preparing the setup .......................... 15
5.1.1 Checking the ambient conditions . . . . . . . .. . . 15
5.1.2 Preparing the setup site ..................... 15
5.1.3 Preparing the foundation and setup
surface ........................................ 15
5.1.4 Installing the heat insulation . . . . .. . . . . . .. . . . . 15
5.2 Setup with foundation ........................ 16
5.2.1 Setting the pump aggregate on the
foundation .................................... 16
5.2.2 Fastening the pump aggregate . . . . . . .. . . . . . 16
5.3 Setup without foundation .................... 17
5.4 Mounting the motor .......................... 17
5.5 Planning the piping ........................... 17
5.5.1 Avoid contamination of the piping . . . . . . . . . . . 17
5.5.2 Specifying supports and flange
connections . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . 17
5.5.3 Specifying nominal widths ................... 18
5.5.4 Specifying pipe lengths ...................... 18
5.5.5 Optimizing cross-section and direction
changes ....................................... 18
5.5.6 Arranging for safety and control devices
(recommended) .............................. 18
5.6 Connecting the pipes ........................ 18
5.6.1 Installing auxiliary pipes ..................... 18
5.6.2 Installing the suction pipe . . . . . . . . .. . . . . . . .. . . 18
5.6.3 Installing the pressure pipe . . . . . . . . . . . .. . . . . . 18
5.6.4 Inspection for stress-free pipe
connections . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . 19
5.6.5 Inspecting the support foot for
distortion ...................................... 19
5.7 Electrical connection ......................... 19
5.7.1 Connecting the motor ........................ 19
5.7.2 Checking the direction of rotation . . . . . . . .. . . 19
5.8 Fine alignment of the coupling . . . . . .. . . . . . . . 20
5.9 Aligning the motor ............................ 20
5.9.1 Aligning the motor using sets of shims .. . . . 20
6Operation ............................................ 21
6.1 Preparations for the initial start-up . . . . . . . . .. 21
6.1.1 Identifying the pump type .................... 21
6.1.2 Lubricating the bearings ..................... 21
6.1.3 Preparing auxiliary operating systems (if
available) ..................................... 21
6.1.4 Filling and bleeding .......................... 21
6.2 Start up ....................................... 22
6.2.1 Switching on .................................. 22
6.2.2 Switching off .................................. 22
6.3 Shut-down .................................... 23
6.4 Start-up following a shutdown period . . .. . .. 23
6.5 Running the stand-by pump ................. 23
7 Maintenance ......................................... 24
7.1 Inspections . . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . 24
7.2 Maintenance .................................. 24
7.2.1 Roller bearings with grease lubrication .. . . . 24
7.2.2 Roller bearings with oil lubrication . . . . . . . . . . 25
7.2.3 Stationary seal rings ......................... 25
7.3 Disassembling . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . . 25
7.3.1 Returning the pump to the manufac-
turer ........................................... 26
7.3.2 Preparations for disassembling . . . . . . . . . . . . . 26
7.3.3 Loosening connectors (if available) . . .. . . . . . 27
7.3.4 Extracting the volute casing . . . . . . . .. . . . . . . .. 27
7.3.5 Disassembling the impeller . . . . . . . . . .. . . . . . . . 27
7.3.6 Disassembling a casing cover with
MUNSCH-REA-C mechanical seal . . . . . . . .. 28
7.3.7 Disassembling the atmosphere-side
stationary seal ring ........................... 28
7.3.8 Disassembling the bearing bracket . . . . . . . .. 29
7.3.9 Disassembling the pump shaft . . . . . . . .. . . . . . 29
7.4 Assembling ................................... 30
2 NPC series BA-2005.07 EN – 02

Table of contents
7.4.1 Preparations for assembling .. . . . . . . .. . . . . . . 30
7.4.2 Fitting the pump shaft ........................ 30
7.4.3 Fitting the bearing bracket . .. . . . . . . .. . . . . . . .. 30
7.4.4 Fitting the casing cover . . . . . . . . . . . .. . . . . . . .. . 30
7.4.5 Fitting the pump into the installation . . . . . ... 30
7.5 Ordering replacement parts ................. 30
8 Disturbance recovery .............................. 31
9 Appendix ............................................. 34
9.1 Sectional drawings ........................... 34
9.1.1 Part numbers and designations ............. 34
9.1.2 Overview sectional drawing . . . . . . . . . . .. . . . . . 36
9.1.3 Variants ....................................... 36
9.2 Technical specifications ...................... 40
9.2.1 Ambient conditions ........................... 40
9.2.2 Parameters for auxiliary operating
systems ....................................... 40
9.2.3 Noise pressure level . . . . .. . . . . . . .. . . . . . . .. . . . 40
9.2.4 Tightening torques ........................... 41
9.2.5 Lubricants . . . . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. . 42
9.2.6 Detergents .................................... 42
9.2.7 Socket loads according to ISO 5199 . . . . . . . 42
9.3 Replacement parts for 2 years of continuous
operation according to DIN 24296 . . . . . . . . . . 43
EN – 02 BA-2005.07 NPC series 3

Table of contents
List of figures
Fig. 1 Type plate (example) ........................ 10
Fig. 2 ATEX plate (example) ........................ 10
Fig. 3 Pump type code (example) . . . . . . . . . . . . .. . . . . 10
Fig. 4 Layout NPC ................................... 11
Fig. 5 Double mechanical seal with quench
(operating principle) .......................... 12
Fig. 6 Double mechanical seal with foreign blocking
(operating principle) .......................... 12
Fig. 7 Fastening the lifting gear to the pump
aggregate ..................................... 13
Fig. 8 Fastening the lifting gear to the pump . . . . . . 13
Fig. 11 Setup without foundation .................... 17
Fig. 12 Straight pipe lengths upstream and down-
stream of the pump (recommended) . . . . . . . 18
Fig. 16 Oil level in sight glass ........................ 21
Fig. 17 Loosening the flushing connector or supply
connectors REA-C/D . . . . . . . . . . . . .. . . . . . .. . . . . 27
Fig. 18 Extracting the volute casing . . . . . . . . . . .. . . . . . 27
Fig. 19 Disassembling the impeller . .. . . . . . . .. . . . . . . . 27
Fig. 20 Disassembling a casing cover with
MUNSCH-REA-C mechanical seal . . . . . . . .. 28
Fig. 21 Disassembling MUNSCH-REA-D stationary
seal ring ....................................... 28
Fig. 22 Disassembling the bearing bracket (grease
lubrication, L16A, L18B, L20A) . . . . . .. . . . . . . . 29
Fig. 23 Disassembling the pump shaft (no lifetime
lubrication) .................................... 29
Fig. 24 Disassembling the pump shaft (with lifetime
lubrication) .................................... 29
Fig. 25 Fitting the casing cover ...................... 30
Fig. 26 NPC – overview sectional drawing . . . . . . . . . 36
Fig. 27 NPC – casing foot ............................ 36
Fig. 28 Emptying (optional) .......................... 36
Fig. 29 MUNSCH-REA-C single mechanical
seal ............................................ 37
Fig. 30 MUNSCH-REA-C/D double mechanical
seal ............................................ 37
Fig. 31 Stationary seal ring holder (only for double
mechanical seal) ............................. 37
Fig. 32 Shutdown/continuous flushing (flushing of
pump interior) ................................. 37
Fig. 33 Single mechanical seal with spring chamber
flushing (supply connectors) . . . . . . . .. . . . . . . . 37
Fig. 34 MUNSCH-REA-C/D supply connec-
tors ............................................ 38
Fig. 35 Casing cover (split) .......................... 38
Fig. 36 Bearing bracket L16A (grease-lubricated
bearing) ....................................... 38
Fig. 37 Bearing bracket L16A (grease-lubricated
bearing, lifetime lubrication) ................. 38
Fig. 38 Bearing bracket L16A (oil-lubricated
bearing) ....................................... 39
Fig. 39 Bearing bracket L18B (grease-lubricated
bearing) ....................................... 39
Fig. 40 Bearing bracket L18B (oil-lubricated
bearing) ....................................... 39
Fig. 41 Blocking – pressure of sealing medium . . . .. 40
Fig. 42 Socket loads at the pump . . . . . . . .. . . . . . . .. . . 42
4 NPC series BA-2005.07 EN – 02

Table of contents
List of tables
Tab. 1 Target groups and their duties . . . . . . . . . . . .. . 6
Tab. 2 Other applicable documents and their
purpose ....................................... 6
Tab. 3 Warning labels and consequences of
disregarding them ............................ 7
Tab. 4 Symbols and their meaning ................. 7
Tab. 5 Technical terms and their meaning . . . . . . . .. 7
Tab. 6 Quenching – variants and characteris-
tics ............................................. 12
Tab. 7 Foreign blocking – variants and
characteristics ................................ 12
Tab. 8 Action to be taken for pump shutdowns .... . 23
Tab. 9 Measures depending on pumped medium
behavior ....................................... 23
Tab. 10 Actions to be taken after prolonged shutdown
periods ........................................ 23
Tab. 11 Actions for return ............................. 26
Tab. 12 Fault/number assignment . . . . . . . . . .. . . . . . . .. 31
Tab. 13 Troubleshooting list .......................... 33
Tab. 14 Designations of components listed with part
numbers ...................................... 35
Tab. 15 Ambient conditions ........................... 40
Tab. 16 Operating parameters for sealing medium in
open flow system ............................. 40
Tab. 17 Noise pressure level . . . . . . . . . . .. . . . . . . .. . . . . . 40
Tab. 18 Steel/cast pairing . . . . . .. . . . . . . .. . . . . . . .. . . . . . . 41
Tab. 19 Socket head cap screw 914.1 - steel/steel
pairing ......................................... 41
Tab. 20 Lubricating greases .......................... 42
Tab. 21 Minimum amounts for grease lubrica-
tion ............................................ 42
Tab. 22 Lubricating oils ............................... 42
Tab. 23 Minimum amounts for oil lubrication . . . . . . . . 42
Tab. 24 Detergents .................................... 42
Tab. 25 Socket loads – forces . . . . . . . . . .. . . . . . . .. . . . . . 42
Tab. 26 Socket loads – torques . . . . . . . .. . . . . . . .. . . . . . 42
Tab. 27 Replacement parts for 2 years' continuous
operation ...................................... 43
EN – 02 BA-2005.07 NPC series 5

About this document
1 About this document
This manual
• is part of the pump
• applies to the pump series mentioned above
• describes safe and appropriate operation during all oper-
ating phases
1.1 Target groups
Target group Duty
Operating company Keep this manual available at the site of operation of the
installation, including for later use.
Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
information and warnings.
Observe any additional rules and regulation referring to the
installation.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable
documents, especially all safety information and warnings.
Tab. 1 Target groups and their duties
1.2 Other applicable documents
Document Purpose
ATEX additional instructions Operation in explosion hazard areas
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions, etc.
Technical description Technical specifications, operating limits
Sectional drawing Sectional drawing, parts numbers, component designations
Supplier documentation Technical documentation for parts supplied by subcontractors
Replacement parts list Ordering replacement parts
Safety certificate Returning the pump to the manufacturer
Tab. 2 Other applicable documents and their purpose
6 NPC series BA-2005.07 EN – 02

About this document
1.3 Warning labels and symbols
Warning label Risk level Consequences of disregard
DANGER Immediate acute risk Death, grievous bodily harm
WARNING Potential acute risk Death, grievous bodily harm
CAUTION Potential hazardous situation Minor bodily harm
CAUTION Potential hazardous situation Material damage
Tab. 3 Warning labels and consequences of disregarding them
Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the respective instructions to avoid injury or death.
Safety instruction
1. , 2. , ... Step-by-step safety instructions
Precondition
→Cross reference
Information, hint
Tab. 4 Symbols and their meaning
1.4 Technical terms
Term Meaning
Sealing medium Medium for locking or quenching of shaft seals
Auxiliary operating systems Systems for operating the pump
Tab. 5 Technical terms and their meaning
EN – 02 BA-2005.07 NPC series 7

Security
2 Security
The manufacturer does not accept any liability for events
resulting from disregard of the entire documentation.
2.1 Intended use
• Only use the pump for pumping the agreed pumped media
(→ Order data sheet).
• Adhere to operating limits and size-dependent minimum
flow rate.
• Avoid dry running:
Initial damage such as destruction of mechanical seal and
plastic parts within only a few seconds.
– Make certain that the pump is never put into operation
and never operated without a pumped medium.
• To avoid cavitation:
– Fully open the suction-side armature and do not use
for adjusting the flow rate.
– Do not open the pressure-side armature beyond the
agreed operating point.
• To avoid overheating:
– Do not operate the pump while the pressure-side arma-
ture is closed.
– Observe the minimum flow rate (→ Order data sheet).
• To avoid damage to the motor:
– Do not open the pressure-side armature beyond the
agreed operating point.
– Observe the allowed number of motor switch-ons per
hour (→ Manufacturer's specifications).
• Consult with the manufacturer about any other use of the
pump.
Prevention of self-evident misuse (examples)
• Observe the operating limits of the pump regarding operat-
ing temperature, pressure, flow rate and speed (→ Order
data sheet).
• The power uptake of the pump will increase with increasing
density of the pumped medium. To avoid any overload for
the pump, the coupling and the motor, do not exceed the
allowable density (→ Order data sheet).
A lower density is allowed. Adapt auxiliary systems accord-
ingly.
• Adhere to limits on solids content and grit size when pump-
ing solids-carrying fluids (→ Order data sheet, technical
description).
• When using auxiliary operating systems, ensure that
there is a continuous supply of the appropriate operating
medium.
2.2 General safety instructions
Take note of the following instructions before carrying out
any work.
2.2.1 Product safety
The pump has been constructed according to up-to-date tech-
nology and established technical safety rules. Nevertheless,
operation of the pump can involve risks to life and health of the
user or of third parties, or risks of damaging the pump and other
property.
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would
expose personnel or third parties to any risk.
• Should there be any safety-relevant fault, deactivate the
pump immediately and have the fault corrected by appro-
priate personnel.
• In addition to the entire documentation for the product,
always comply with statutory or other safety and acci-
dent-prevention rules and with the applicable standards
and guidelines in the country where the pump is operated.
8 NPC series BA-2005.07 EN – 02

Security
2.2.2 Duties of the operating company
Safety-conscious operating
• Operate the pump only if it is in perfect technical condition,
according to its intended use, in awareness of safety and
risks and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– adherence to intended use
– statutory or other safety and accident-prevention rules
– safety regulations governing the handling of hazardous
substances
– applicable standards and guidelines in the country
where the pump is operated
• Make protective equipment available.
Qualified personnel
• Make certain that all personnel tasked with work on the
pump have read and understood this manual and all other
applicable documents, especially the safety, maintenance
and repair instructions, before they begin the job.
• Organize responsibilities, who is in charge of any specific
duty and how personnel is supervised.
• Ensure that all work is carried out by specialist technicians
only:
– fitting, repair and maintenance work
– work on the pump electrical system
• Make certain that trainee personnel is supervised by a spe-
cialist technician when performing tasks on the pump.
Safety installations
• Provide the following safety installations and verify their
integrity:
– for hot and moving parts: device-side contact protec-
tion on the pump
– in case of potential electrostatic charging: appropriate
grounding
Warranty
• Obtain the manufacturer's approval prior to carrying out
any modification, repair or alterations during the warranty
period.
• Only use original parts or parts that have been approved
by the manufacturer.
2.2.3 Duties of the operating personnel
• Observe and keep legible all directions given on the pump,
e.g. the arrow indicating the direction of rotation and the
markings for fluid connections.
• Do not remove the contact protection for hot, cold and mov-
ing parts during operation.
• Use protective equipment if necessary.
• Carry out work on the pump only while the pump is not
running.
• Isolate the motor from its supply voltage and keep it locked
in that state while carrying out any fitting or maintenance
work.
• Mount the safety installations on the pump according to
instructions after completion of work on the pump.
2.3 Special hazards
2.3.1 Explosion hazard area
• (→ ATEX additional instructions).
2.3.2 Hazardous pumped media
• Observe the safety regulations for the handling of haz-
ardous substances when working with hazardous pumped
media (e.g. hot, flammable, poisonous or potentially harm-
ful).
• Use protective equipment when carrying out any work on
the pump.
EN – 02 BA-2005.07 NPC series 9

Layout and function
3 Layout and function
3.1 Labels
3.1.1 Type plate
MUNSCH Chemie-Pumpen GmbH
D-56235 Ransbach-Baumbach
n
W.-Nr.
Lfrd.
impeller
serial-no.
P
Q
type
Typ
-1
Nm
M
kg/dm
Baujahr
H
kW
m /h
3
year
m
3
min
9
8
7
3
4
5
6
1
2
10
Fig. 1 Type plate (example)
1Pumptype
2 Serial number
3 Construction year
4 Total differential head
5 Density
6Torque
7 Speed
8 Power consumption
9Flowrate
10 Impeller diameter
3.1.2 ATEX plate
1
2
Fig. 2 ATEX plate (example)
1 Explosion protection mark
2 Reference to ATEX additional instructions
3.1.3 Pump type code
1
2
3
4
NPC 50 - -32 200
Fig. 3 Pump type code (example)
1 Pump series
2 Suction flange DN [mm]
3 Pressure flange DN [mm]
4 Impeller nominal diameter [mm]
10 NPC series BA-2005.07 EN – 02