PUMPIRAN CPKN Installation instructions

Standardised
Chemical Pump
Installation
Operating Manual
Bearings UP02 to UP06 and P08s
CPKN

2
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5
5.1
5.2
5.3
5.4
Contents Page
Glossary
General
Principles
Installation of partly completed machinery
Target group
Other applicable documents
Symbols
Safety
Key to safety symbols/markings
General
Intended use
Personnel qualification and training
Consequences and risks caused by non-compliance with these
operating instructions
Safety awareness
Safety information for the operator/user
Safety information for maintenance, inspection and installation work
Unauthorised modes of operation
Explosion protection
Transport/Temporary Storage/Disposal
Transport
Storage and preservation
Return to supplier
Disposal
Description of the Pump (Set)
General description
Designation
Name plate
Design details
Design and function
Noise characteristics
Scope of supply
Dimensions and weights
Installation at Site
Safety regulations
Checking the site before installation
Installing the pump set
Piping
5
6
6
6
6
6
6
8
8
8
8
9
9
9
10
10
10
10
13
13
13
14
14
15
15
15
15
15
17
18
19
19
20
20
20
20
20
PagePage
ContentsContents
Legal information
Installation/Operating Manual CPKN Original operating manual
subject to technical modification without prior notice.

3
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5
5.1
5.2
5.3
5.4
Contents Page
Glossary
General
Principles
Installation of partly completed machinery
Target group
Other applicable documents
Symbols
Safety
Key to safety symbols/markings
General
Intended use
Personnel qualification and training
Consequences and risks caused by non-compliance with these
operating instructions
Safety awareness
Safety information for the operator/user
Safety information for maintenance, inspection and installation work
Unauthorised modes of operation
Explosion protection
Transport/Temporary Storage/Disposal
Transport
Storage and preservation
Return to supplier
Disposal
Description of the Pump (Set)
General description
Designation
Name plate
Design details
Design and function
Noise characteristics
Scope of supply
Dimensions and weights
Installation at Site
Safety regulations
Checking the site before installation
Installing the pump set
Piping
5
6
6
6
6
6
6
8
8
8
8
9
9
9
10
10
10
10
13
13
13
14
14
15
15
15
15
15
17
18
19
19
20
20
20
20
20
PagePage
ContentsContents

4
25
26
26
28
29
31
31
37
39
40
41
41
41
47
47
50
54
55
58
60
60
63
64
65
5.5
5.6
5.7
5.8
5.9
6
6.1
6.2
6.3
6.4
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
8
9
9.1
10
11
Protective equipment
Checking the coupling alignment
Aligning the pump and motor
Electrical connection
Checking the direction of rotation
Commissioning/Start-up/Shutdown
Commissioning/start-up
Operating limits
Shutdown/storage/preservation
Returning to service after storage
Servicing/Maintenance
Safety regulations
Servicing/inspection
Drainage/disposal
Dismantling the pump set
Reassembling the pump set
Tightening torques
Spare parts stock
Trouble-shooting
Related Documents
General assembly drawing with list of components
EC Declaration of Conformity
Certificate of Decontamination
Index
Page
Contents

5
Glossary
Back pull-out design Pool of pumps
Back pull-out unit Pump
The complete back pull-out unit can be pulled out
without having to remove the pump casing from
the piping.
Pumps which are purchased and stored
independently of their later use
Pump without pump casing; partly completed
machinery
Machine without drive, additional components or
accessories
A certicate of decontamination certies that
the pump (set) has been properly drained to
eliminate any environmental and health hazards
arising from components in contact with the uid
handled.
Complete pump set consisting of pump, drive,
additional components and accessories
The line which is connected to the suction nozzle
The line which is connected to the discharge
nozzle
The part of the pump in which the kinetic energy
is converted into pressure energy
Certificate of decontamination Pump set
Suction lift line/suction head line
Discharge line
Hydraulic system
Glossary

6
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated on the
front cover. It describes the proper and safe use of this equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order number
and the order item number. The order number and order item number clearly identify the
pump (set) and serve as identication for all further business processes.
In the event of damage, contact your nearest PUMPIRAN service centre immediately to
maintain the right to claim under warranty.
Noise characteristics ( Section 4.6 Page 18)
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by PUMPIRAN, refer to the sub-sections under
Servicing/Maintenance. ( Section 7.5.5 Page 54)
1.3 Target group
This manual is aimed at the target group of trained and qualied specialist technical
personnel. ( Section 2.4 Page9)
1.4 Other applicable documents
Table 1: Overview of other applicable documents
1 General
Document Contents
Data sheet Description of the technical data of the pump
(set)
General arrangement drawing/
Outline drawing
Description of mating and installation dimensions
for the pump (set)
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, eciency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature 1) Operating manuals and other product literature
of accessories and integrated machinery
components
Spare parts lists 1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
Symbol Description
Conditions which need to be fullled before proceeding with the
step-by-step instructions
Safety instructions
Cross-references
1) If agreed to be included in the scope of supply
1 General
1.5 Symbols
Table 2: Symbols used in this manual

7
Symbol
Description
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
Symbol
1 General

8
2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Denition of safety symbols/markings
2.2 General
This manual contains general installation, operating and maintenance instructions that must
be observed to ensure safe pump operation and prevent injury and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist personnel/
operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site at all times.
Information attached directly to the pump must always be complied with and be kept in a
perfectly legible condition at all times. This applies to, for example:
.Arrow indicating the direction of rotation
.Markings for connections
.Name plate
The operator is responsible for ensuring compliance with all local regulations which are not
taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits which are described in the
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

9
.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

10
.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