Pumpiran Cpkn Installation instructions

Standardised

Chemical Pump

Installation

Operating Manual

Bearings UP02 to UP06 and P08s

CPKN

1.1

1.2

1.3

1.4

1.5

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

3.1

3.2

3.3

3.4

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

5.1

5.2

5.3

5.4

Contents Page

Glossary

General

Principles

Installation of partly completed machinery

Target group

other applicable documents.

.Only operate pumps/pump sets which are in perfect technical condition.

.Do not operate partially assembled pumps/pump sets.

!DANGER

Symbol Description

!DANGER DANGER

This signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.

!WARNING WARNING

This signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.

CAUTION CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

Explosion protection

This symbol identies information about avoiding explosions in

potentially explosive atmospheres in accordance with EC Directive

94/9/EC (ATEX).

General hazard

In conjunction with one of the signal words this symbol indicates a

hazard which will or could result in death or serious injury.

Electrical hazard

In conjunction with one of the signal words this symbol indicates a

hazard involving electrical voltage and identies information

about protection against electrical voltage.

M achine damage

In conjunction with the signal word CAUTION this symbol indicates

a hazard for the machine and its functions.

2 Safety

.Only use the pump to handle the uids specied in the data sheet or product literature of the

respective design variant.

.Never operate the pump without the uid to be handled.

.Observe the minimum ow rates indicated in the data sheet or product literature

(to prevent overheating, bearing damage, etc).

.Observe the maximum ow rates indicated in the data sheet or product literature (to prevent

overheating, mechanical seal damage, cavitation damage, bearing damage, etc).

.Do not throttle the ow rate on the suction side of the pump (to prevent cavitation damage).

.Consult the manufacturer about any use or mode of operation not described in the dat

a sheet or product literature.

Prevention of foreseeable misuse

.Never open discharge-side shut-o elements further than permitted.

– The maximum ow rate specied in the data sheet or product literature would be exceeded.

– Risk of cavitation damage

.Never exceed the permissible operating limits specied in the data sheet or product literature

regarding pressure, temperature, etc.

.Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualied to install, operate, maintain and inspect the

machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in installation,

operation, maintenance and inspection must be clearly dened by the operator.

Decits in knowledge must be rectied by suciently trained specialist personnel training

and instructing the personnel who will carry out the respective tasks. If required, the operator

can commission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialist personnel.

2.5 Consequences and risks caused by non-compliance with these operating instructions

. Non-compliance with these operating instructions will lead to forfeiture of warranty cover

and of any and all rights to claims for damages.

. Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemical eects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use, the

following safety regulations shall be complied with:

.Accident prevention, health and safety regulations

.Explosion protection regulations

2 Safety

.Safety regulations for handling hazardous substances

.Applicable standards and laws

2.7 Safety information for the operator/user

.The operator shall t contact guards for hot, cold or moving parts and check that the guard

s function properly.

.Do not remove any contact guards while the pump is running.

.Connect an earth conductor to the metal jacket if the uid handled is

electrostatically charged.

.Provide the personnel with protective equipment and make sure it is used.

.Contain leakages (e.g at the shaft seal) of hazardous uids handled (e.g. explosive, toxic, hot)

so as to avoid any danger to persons and the environment. Adhere to all relevant laws.

.Eliminate all electrical hazards. (In this respect refer to the applicable national safety

regulations and/or regulations issued by the local energy supply companies.)

2.8 Safety information for maintenance, inspection and installation work

.Modications or alterations of the pump are only permitted with the manufacturer,s prior

consent.

.Use only original spare parts or parts authorised by the manufacturer. The use of other parts

can invalidate any liability of the manufacturer for resulting damage.

.The operator ensures that all maintenance, inspection and installation work is performed by

authorised, qualied specialist personnel who are thoroughly familiar with the manual.

.Carry out work on the pump (set) during standstill only.

.The pump casing must have cooled down to ambient temperature.

.Pump pressure must have been released and the pump must have been drained.

.When taking the pump set out of service always adhere to the procedure described in the

manual. ( Section 6.1.12 Page 37)

.Decontaminate pumps which handle uids posing a health hazard. ( Section 7.3 Page 47)

.As soon as the work is completed, re-install and/or re-activate any safety-relevant and

protective devices. Before returning the product to service, observe all instructions on

commissioning. ( Section 6.1 Page 31)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this manual.

The warranty relating to the operating reliability and safety of the supplied pump (set) is only

valid if the equipment is used in accordance with its intended use. ( Section 2.3 Page 8)

2.10 Explosion protection

Always observe the information on explosion protection given in this section when operating

the pump in potentially explosive atmospheres.

Only pumps/pump sets marked as explosion-proof and identied as such in the data sheet

may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to EC Directive

94/9/EC (ATEX).

Especially adhere to the sections in this manual marked with the Ex symbol and the following

sections. ( Section 2.10.1 Page 11) to ( Section 2.10.4 Page 12)

!DANGER

2 Safety

The explosion-proof status of the pump set is only assured if the pump set is used in

accordance with its intended use.

Never operate the pump (set) outside the limits stated in the data sheet and on the name

plate.

Prevent impermissible modes of operation at all times.

2.10.1 Marking

The marking on the pump refers to the pump part only.

Example of such marking: II 2 G c TX

Refer to theTemperature limits table for the temperatures permitted for the individual pump

variants. ( Section 2.10.2 Page 11)

An EC manufacturer,s declaration is required for the shaft coupling; the shaft coupling must

be marked accordingly.

The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the surface of

the pump casing, at the shaft seal and in the bearing areas.

The surface temperature at the pump casing corresponds to the temperature of the uid

handled. If the pump is heated in addition, the operator of the system is responsible for

observing the specied temperature classes and uid temperature (operating temperature).

The table below lists the temperature classes and the resulting theoretical temperature limits

of the uid handled (a possible temperature rise in the shaft seal area has already been taken

into account).

The temperature class species the maximum permissible temperature at the surface of

the pump set during operation. For the permissible operating temperature of the pump in

question refer to the data sheet.

Table 4: Temperature limits

Based on an ambient temperature of 40 °C and proper maintenance and operation, compliance

with temperature class T5is warranted in the area of the rolling element bearings. If the

ambient temperature exceeds 40 °C, contact the manufacturer.

A special design is required to comply with the requirements of temperature class T6in the

bearing area.

Misuse, malfunctions or non-compliance with the instructions may result in substantially

higher temperatures.

If the pump is to be operated at a higher temperature, the data sheet is missing or if the

pump is part of a pool of pumps, contact PUMPIRAN for the maximum permissible operating

temperature.

Temperature class as per EN 13463-1 M aximum permissible fluid

temperature

T1 Maximum 400 °C 2)

T2 280 °C

T3 185 °C

T4 120 °C

T5 85 °C

T6 Only after consultation

with the manufacturer

2) Depending on the material variant

Pump

Shaft coupling

Motor

Temperature class T5

Temperature class T6

2 Safety

2.10.3 Monitoring equipment

The pump (set) must only be operated within the limits specied in the data sheet and on the

name plate.

If the system operator cannot warrant compliance with these operating limits, appropriate

monitoring devices must be used.

Check whether monitoring equipment is required to ensure that the pump set functions

properly.

Contact PUMPIRAN for further information on monitoring equipment.

2.10.4 Operating limits

The minimum ows indicated in ( Section 6.2.3 Page 38) refer to water and water- like uids.

Longer operating periods with these uids and at the ow rates indicated will not cause an

additionalincreaseinthe temperaturesatthe pump surface.However, if thephysical properties

of the uids handled are dierent from water, it is essential to check whether an additional heat

build-up may occur and if the minimum ow rate must therefore be increased. The calculation

formula in ( Section 6.2.3 Page 38) can be used to check whether an additional heat build-up

may lead to a hazardous temperature increase at the pump surface.

2 Safety

3 Transport/Temporary Storage/Disposal

3.1 Transport

To transport the pump/pump set suspend it from the lifting tackle as shown below.

3.2 Storage and preservation

If commissioning is to take place some time after delivery, we recommend that the

following measures be taken for pump (set) storage.

The pump (set) could slip out of the suspension arrangement

Danger to life from falling parts!

Always transport the pump (set) in horizontal position.

Never attach the suspension arrangement to the free shaft end or the motor

eyebolt.

Refer to the weights given in the general arrangement drawing.

Observe the local accident prevention regulations.

Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.

C AUTION

Damage during storage by humidity, dirt, or vermin

Corrosion/contamination of the pump (set)!

For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

Fig. 1: Transporting the pump

max. 90 °

Fig. 2: Transporting the complete pump set

max. 90 °

Fig. 3: Transporting the pump on the baseplate

3Transport/Temporary Storage/Disposal

C AUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump set!

Only remove caps/covers from the openings of the pump set at the time of

installation.

1. Dismantle the pump (set).

Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlled manner.

NOT E

If required, a blank Certicate of Decontamination can be downloaded on the internet

under: www.pumpiran.com

3.4 Disposal

WAR NING

Fluids posing a health hazard

Hazardous to persons and the environment!

Collect and properly dispose of ushing liquid and any uid residues.

Wear safety clothing and a protective mask, if required.

Observe all legal regulations on the disposal of uids posing a health hazard.

Store the pump (set) in a dry, protected room where the atmospheric humidity is as constant

as possible.

Rotate the shaft by hand once a month, e.g. via the motor fan.

If properly stored indoors, the pump set is protected for a maximum of 12 months. New

pumps/pump sets are supplied by our factory duly prepared for storage.

For storing a pump (set) which has already been operated, observe the instructions in

( Section 6.3.1 Page 39) .

3.3 Return to supplier

1. Drain the pump as described in the manual. ( Section 7.3 Page 47)

2. Always ush and clean the pump, particularly if it has been used for handling noxious,

explosive, hot or other hazardous uids.

3. If the uids handled by the pump leave residues which might lead to corrosion damage

when coming into contact with atmospheric humidity, or which might ignite when coming

into contact with oxygen, the pump set must also be neutralised, and anhydrous gas must

be blown through the pump for drying purposes.

4.The pump (set) must always be accompanied by a completed certicate of decontamination.

( Section 11 Page 64)

It is imperative to indicate any safety and decontamination measures taken.

3Transport/Temporary Storage/Disposal

mm Year

Type:

Ser.No.

m /h

min

PUMPIRAN

6026411905

Type series, pump size

1Speed

Flow rate

3Head

Power

5Impeller Dia.

Ser.No.

7Year of construction

4 Description of the Pump (Set)

4.1 General description

. Standardised chemical pump with shaft seal

Pump for handling aggressive liquids in the chemical and petrochemical industries.

4.2 Designation

Example:

Table 5: Key to the designation

4.4 Design details

Design

.Volute casing pump

.Horizontal installation

.Back pull-out design

.Single-stage

.Meets technical requirements to ISO 5199:2002

.Dimensions and ratings to EN 22 858/ISO 2858

complemented by pumps of nominal diameters DN 25, DN 200 and above

Pump casing

.Single or double volute, depending on the pump size

. Radially split volute casing

.Volute casing with integrally cast pump feet

.Volute casing (partly with casing wear ring) and casing cover

4.3 Name plate

Fig. 4: Name plate

Code Description

CPKN Type series

150 Nominal discharge nozzle diameter [mm]

400

Nominal impeller diameter [mm]

Material variant

Type of sealing

4 Description of the Pump (Set)

CPKN 150-400(04)-SS-1

Impeller type

.Closed radial impeller with multiply curved vanes

.Back vanes reduce axial thrust

Shaft seal

.Stung box packing

.Commercial single and double acting mechanical seals

Preferable:

.Standardised mechanical seals to EN 12756 variant K

Possible:

.Commercial cartridge seals

Alternative:

.Version without shaft protecting sleeve with ,,wet shaft,,

Table 6: Seal chamber with dierent shaft seals (examples)

Bearings

Motor-end bearing:

.Fixed bearing

.Paired angular contact ball bearing

.Axial movement of the rotor limited to maximum 0.5 mm

.Oil lubrication

.Optional: grease lubrication

Conversion from stung box packing to mechanical seal and vice versa is possible without any

rework on the casing cover by using the relevant replacement parts.

ustration

Type of seal

Cylindrical seal chamber

Standardised mechanical seal

Double-acting mechanical seal

(back-to-back)

both sides unbalanced

4 Description of the Pump (Set)

Design specications

Pump-end bearing:

.Radial bearing

.Cylindrical roller bearing

.Absorbs radial loads only

.Oil lubrication

. Optional: grease lubrication

Example: UP03

Table 7: Bearing bracket designation

Refer to the data sheet to nd your bearing design.

Table 8: Bearing design

Table 9: Standard bearing assembly

4. 5 Design and function

Bearing bracket

designation

Bearings used

Code Description

UP Bearing bracket

03 Size code (based on dimensions of seal chamber and shaft

end)

Bearing bracket Rolling element bearing

Pump end M otor end

UP02 NU307 2 x 7307 B.G

UP03 NU311 2 x 7311 B.G.8

UP04 NU311 2 x 7311 B.G.8

UP05 NU313 2 x 7313 B.G.8

UP06 NU416 2 x 7319 B.G

P08s NU416 2 x 7319 B.G

designation F A G designation SKF designation

B.G B-TVP-UA BECBP

B.G.8 B-TVP-UA 80 BEC86P

PUMPIRAN

Fig. 5: Sectional drawing

4 Description of the Pump (Set)

1 Clearance gap 2 Discharge nozzle

3 Casing cover 4 Drive shaft

5 Bearing bracket 6 Suction nozzle

7 Impeller 8 Shaft seal

9 Rolling element bearing, pump end 10 Rolling element bearing, motor end

The pump is designed with an axial uid inlet and a radial or tangential outlet. The hydraulic

system runs in its own bearings and is connected to the motor by a shaft coupling.

The uid enters the pump axially via the suction nozzle (6) and is accelerated outward in a

cylindrical ow by the rotating impeller (7). In the ow passage of the pump casing the kinetic

energy of the uid is converted into pressure energy. The uid is pumped to the discharge

nozzle (2), where it leaves the pump. The clearance gap (1) prevents any uid from owing

back from the casing into the inlet. At the rear side of the impeller, the shaft (4) enters the

casing via the casing cover (3). The shaft passage through the cover is sealed towards the

atmosphere by a shaft seal (8). The shaft runs in rolling element bearings (9and 10), which are

supported by a bearing bracket (5) linked with the pump casing and/or casing cover.

The pump is sealed by a shaft seal.

Standardised mechanical seal or stung box packing

4.6 Noise characteristics

Table 10: Surface sound pressure level LpA3)4)

Design

Function

Sealing

Rated

power

input

PN[kW ]

Pump Pump set

2900 rpm

[dB]

1450 rpm

[dB]

960 rpm

760 rpm

[dB]

2900 rpm

[dB]

1450 rpm

[dB]

960 rpm

760 rpm

[dB]

1 54 53 52 63 58 56

2 56 55 53 66 60 58

3 57 56 55 68 62 60

4 59 58 56 69 63 61

6 61 59 58 71 65 62

8 62 61 59 72 66 64

11 64 63 61 74 68 65

15 66 65 63 75 69 67

19 67 66 64 76 70 68

22 68 67 65 77 71 68

30 70 68 66 78 72 70

37 71 70 67 79 73 70

45 72 71 68 80 74 71

55 73 72 69 80 74 72

75 75 73 71 81 76 73

90 76 74 71 82 76 73

110 77 75 72 82 77 74

132 78 76 73 83 77 75

160 79 77 74 84 78 75

200 80 78 75 84 79 76

250 81 79 - 85 80 -

3) Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.8 - 1.1 and non-cavitating pump

operation. If noise levels are to be guaranteed: Add + 3 dB for measuring and constructional tolerance.

4) Increase for 60 Hz operation: 3500 rpm+ 3 dB; 1750 rpm + 1 dB; 1160 rpm:± 0 dB

4 Description of the Pump (Set)

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

.Pump

.Surface-cooled IEC three-phase current squirrel-cage motor

.Flexible coupling with or without spacer

.Coupling guard to EN 294

.Baseplate (to ISO 3661), cast or welded, for pump and motor, in torsion-resistant design

.Channel section steel or folded steel plate

.As required

4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline drawing

of the pump (set).

Drive

Shaft coupling

Contact guard

Baseplate

Special accessories

4 Description of the Pump (Set)

5 Installation at Site

5.1 Safety regulations

5.2 Checking the site before installation

Place of installation

5.3.1 Installation on the foundation

Fig. 6: Fitting the shims

5.3 Installing the pump set

Always install the pump set in horizontal position.

DANG E R

Improper installation in potentially explosive atmospheres

Explosion hazard!

Damage to the pump set!

Comply with the applicable local explosion protection regulations.

Observe the information in the data sheet and on the name plates of pump and

motor.

WAR NING

Installation on foundations which are unsecured and cannot support the load

Personal injury and damage to property!

Make sure the foundation concrete is of sucient strength (min. X0 to

DIN 1045).

Only place the pump set on a foundation whose concrete has set rmly.

Only place the pump set on a horizontal and level surface.

Refer to the weights given in the general arrangement drawing.

1. Check the structural requirements.

All structural work required must have been prepared in accordance with the dimensions

stated in the outline drawing/general arrangement drawing.

The foundation has the required strength and characteristics.

DANG E R

E xcessive temperatures due to improper installation

Explosion hazard!

Install the pump in horizontal position to ensure self-venting of the pump.

1 Bolt-to-bolt clearance 2 Shim

3 Shim for bolt-to-bolt clearance >

800 mm

4 Foundation bolt

5 Installation at Site

This manual suits for next models

Table of contents

Other PUMPIRAN Water Pump manuals

PUMPIRAN

PUMPIRAN PB3 Installation instructions

Popular Water Pump manuals by other brands

K2 Pumps

K2 Pumps SPP03301K owner's manual

Salus

Salus AKL01P Wiring guide

Graco

Graco Fast-Flo Instructions and parts list

Blue-White

Blue-White C3 Series operating manual

Agora-Tec

Agora-Tec AT 001 008 003 operating instructions

Waterous

Waterous HL Series OVERHAUL INSTRUCTIONS

eta

eta K CL PLUS Series operating manual

Grundfos

Grundfos HYDRO SOLO-E instructions

Edwards

Edwards EXT70 Series instruction manual

SKF

SKF KFG Assembly instructions

Grundfos

Grundfos MAGNA3 25-100 (N) Installation and operating instructions

Aquatop

Aquatop BREZA AC/DC-PLUS owner's manual

Stoelting

Stoelting U3-02A Owner's service manual

ITT

ITT GOULDS PUMPS 3316 Installation, operation and maintenance instructions

Samoa

Samoa DF30 Operation and maintenance manual

Schmalz

Schmalz EVE-TR 4 DC operating instructions

Becker

Becker DVX Series operating instructions

Tuthill

Tuthill 1012 Installation and service instructions

PUMPIRAN CPKN Installation instructions

Popular Water Pump manuals by other brands