Sundyne LMV-802 Instruction manual

SA-07-11-37 Rev Orig Jan 2009
Installation, Operation
& Maintenance Manual
Sundyne Pumps
Model:
LMV-802
SA-07-11-37, Rev Orig.
Jan 2009

http://www.sundyne.com
Copyright
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior permission of
Sundyne Corporation.
© 2009 Sundyne Corporation
Warranty
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the date of being placed in service
(but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will
be free from defects of design, material and workmanship. If any defects or malperformance occur during the
warranty period, Sundyne’s sole obligation shall be limited to alteration, repair or replacement at Sundyne’s
expense, F.O.B. Factory, of parts or equipment, which upon return to Sundyne and upon Sundyne’s examination
prove to be defective. Equipment and accessories not manufactured by Sundyne are warranted only to the extent of
and by the original manufacturers’ warranty. Sundyne shall not be liable for damage or wear to equipment caused by
abnormal conditions, vibration, failure to properly prime or to operate equipment without flow or caused by
corrosives, abrasives or foreign objects. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no event shall Sundyne be liable
for consequential or incidental damages

SA-07-11-37 Rev Orig Jan 2009
i
Contents
CONTENTS ..........................................I
INTRODUCTION & SAFETY...............1
Sundyne Centrifugal Pumps............... 1
Text Symbols........................................... 1
Equipment and Safety Precautions .. 1
Wearing Personal Protective
Equipment............................................. 2
Using Forklifts....................................... 2
Ensuring Electrical Safety................... 2
Testing Equipment............................... 2
Using Chemicals................................... 2
Protection from Falling......................... 2
Preventative Machine Guards............ 3
EXPLOSION/FIRE HAZARD...3
Pre-Commission Checklist.................. 4
Familiarizing Yourself with the Pump 4
Driver Instructions................................ 4
Verifying Auxiliaries.............................. 4
Installing a Seal Environmental
Control System..................................... 4
Checking Driver Rotation.................... 4
Piping Connections.............................. 4
Start Up Checklist.................................. 5
Pressurizing the Fluid Loop................ 5
Servicing the Gearbox......................... 5
Auxiliary Lube Pump............................ 5
Setting the Valves................................ 5
Control Checklist ................................... 5
Process Conditions.............................. 5
Adjusting the Cooling Flow................. 5
Verifying Operating Conditions.......... 5
INSTALLATION...................................6
Inspection................................................. 6
Suction and Discharge Piping............ 6
Seal Environmental Control System. 7
START UP ...........................................8
Starting the LMV–802............................ 8
Controlling the Pump During Startup8
Single Operation................................... 8
Parallel Operation ................................ 8
NPSH - (Net Positive Suction Head
and Cavitation)........................................ 9
Recirculation........................................... 9
Prevention................................................ 9
Temperature Rise................................... 9
Suction and Discharge Gauges ......... 9
OPERATION & CONTROL................10
Operation of Sundyne Pumps.......... 10
Suction Conditions............................. 10
Minimum Flow Conditions................. 10
Entrained Gases................................. 10
System Head Curve........................... 10
Parallel Operation .............................. 11
MAINTENANCE.................................12
Disassembling the LMV-802.............. 12
Reassembling the LMV-802............... 17
TROUBLESHOOTING.......................25
Troubleshooting the Sundyne LMV-
802 PUMP............................................... 25
Pump Mechanical Seals..................... 27

SA-07-11-37 Rev Orig Jan 2009
ii
SPECIFICATIONS.............................29
Gearbox and Pump Torque Values..
..............................................................29-30
Pump Spare Parts List........................ 31
Inducer and Stud.................................. 32
Pump Exploded View.......................... 35
Single Seal Arrangement................... 36
Double Seal Arrangement.................. 37
Tandem Seal Arrangement................ 38
INDEX................................................39

Instruction and Operation Manual
SA-07-11-37 Rev Orig 1 Jan 2009
INTRODUCTION & SAFETY
Sundyne Centrifugal Pumps
Sundyne pumps provide high-energy
performance and competitive efficiencies in an
industrial quality, compact unit that is simple to
maintain. Sundyne pumps are single stage that
utilize an integral gearbox. Designed to to
increase the pressure of a continuous flow of
fluid by applying centrifugal action, Sundyne
pumps are most commonly used in HPI, CPI,
and Boiler Feed applications. Commonly applied
in refineries, petrochemical plants, and power
generation plants, Sundyne pumps are used in
high-head, low-to-medium flow processes.
This manual presents installation, servicing,
troubleshooting, maintenance and spare parts
information for the latest configuration of
Sundyne centrifugal pumps.
Note: Parenthetical numbers included in the
text correspond to item numbers on the
illustrated figures. The correct spare
part can be ordered for any generation
pump by referencing the item and serial
numbers.
Text Symbols
The following symbols may be found in the text
of this manual.
They have the following meanings:
WARNING: Text accompanied by this
symbol indicates that failure to follow
directions could result in bodily harm or
death.
ELECTRICAL HAZARD: Text
accompanied by this symbol indicates
that failure to follow directions could result
in electrical damage to equipment or
electrical shock.
RECOMMENDED: Text accompanied by
this symbol indicates recommended
usage.
REMINDER: Text accompanied by this
symbol indicates a reminder to perform
an action.
EQUIPMENT USE ALERT: Text
accompanied by this symbol indicates
that failure to follow directions could result
in damage to equipment.
Equipment and Safety Precautions
Sundyne Corporation manufactures centrifugal
pumps to exacting International Quality
Management System Standards (ISO 9001) as
certified and audited by Lloyd’s Register Quality
Assurance Limited. Genuine parts and
accessories are specifically designed and tested
for use with these products to ensure continued
product quality and performance. Sundyne
cannot test all parts and accessories sourced
from other vendors; incorrect design and/or
fabrication of such parts and accessories may
adversely affect the performance and safety
features of these products. Failure to properly
select, install or use authorized Sundyne pump
parts and accessories is considered misuse and
damage or failure caused by misuse is not

Instruction and Operation Manual
SA-07-11-37 Rev Orig 2 Jan 2009
covered by Sundyne’s warranty. Additionally,
modification of Sundyne products or removal of
original components may impair the safety of
these products and their effective operation.
CAUTION
Sundyne pumps may handle hazardous,
flammable, and/or toxic fluids. Proper personal
protective equipment should be worn.
Precautions must be taken to prevent physical
injury. Pumpage must be handled and disposed
of in accordance with applicable environmental
regulations.
Note: Safety procedures must be applied
prior to any installation, maintenance,
or repair of a Sundyne pump. Failure to
follow safety precautions may lead to
injury!
Wearing Personal Protective
Equipment
To ensure safety, protective equipment must be
worn at all times when installing, performing
maintenance, or repairing equipment. The
following safety recommendations must be
adhered to for optimum safety:
•Safety glasses, with the minimum
requirement of side shields, must be
worn at all times.
•Steel-toed shoes must be worn when
lifting equipment greater than 15 pounds
(7 kg) or if pallet jacks or forklifts are
operated.
•Hearing protection is strongly
recommended at all times when noise
levels exceed 85 dB during an eight
(8.0) hour period.
Note: Chemical resistant gloves must be used
if chemicals are utilized (refer to Using
Chemicals for additional information).
Note: A dust mask respirator must be worn if
chemicals have warning labels
regarding fumes, dust, or mists.
When using more than one piece of protective
equipment, consider their compatibility. For
example, safety glasses will not interfere with
hearing protection equipment. Be sure to clean
all pieces of personal protective equipment
immediately after each use.
Using Forklifts
Any persons operating a forklift must have an
active recognized operator license.
Note: Before initializing forklift operation,
verify that the lift is in a safe operating
position.
Ensuring Electrical Safety
All electrical sources must be powered-off
before installation, service, or repair of
equipment occurs.
Note: Sundyne recommends that a Lock-
out/Tag-out program be followed prior
to altering the equipment. Locks or
tags must be provided to warn
employees that equipment is
temporarily unavailable.
Once all work has been completed, the person
installing the lock or tag must remove it
according to company procedure.
Testing Equipment
Prior to performing a test on newly installed,
maintained, or repaired equipment; all personnel
in the immediate area must be warned.
Note: Follow company procedures prior to
equipment testing at all times.
Using Chemicals
Any chemicals to be used must be accompanied
by a relevant material safety data sheet (MSDS),
in accordance with government legislation. If
applicable, use chemical proof gloves.
Note: An eye wash station (or equivalent)
should be available in the event of
injury. If any hazardous or flammable
chemicals pass through the equipment,
a complete decontamination of the
equipment is required.
Protection from Falling
Fall protection and associated preventative
measures are required when working on
equipment located six feet or higher from the
ground.
Note: Follow company fall prevention
procedures prior to working on
equipment.

Instruction and Operation Manual
SA-07-11-37 Rev Orig 3 Jan 2009
Preventative Machine Guards
Preventative guards must remain in place on all
equipment.
Note: Only remove the guards while
performing maintenance or repair.
Replace the guards immediately after working
on the equipment and prior to start up.
EXPLOSION/FIRE HAZARD
Note: Never use an acetylene torch, open
flame, or heat to attempt to remove
parts that have seized together in
Sundyne equipment. Any residual
process gas or liquid that is flammable
can result in an explosion or fire with
potential for serious injury or death.

Instruction and Operation Manual
SA-07-11-37 Rev Orig 4 Jan 2009
Pre-Commission Checklist
Familiarizing Yourself with the Pump
Before servicing and starting up the Sundyne
pump, carefully review all information on the
product, including:
•Specification sheets
•Outline drawings
•Performance curves
•Instruction and related manuals.
•System P&ID/Process Flow Diagram
(Clients equipment).
•Control system and operational
philosophy/narrative (client).
Familiarize yourself with the pump configuration
before starting and operating the pump.
Driver Instructions
Carefully follow all installation and starting
instructions provided by the driver manufacturer.
This information is included in the final data
package.
Verifying Auxiliaries
Before start up, verify that the following
auxiliaries are met:
•Check the utility connections.
•Verify that the auxiliary piping conforms
to Sundyne standards, as indicated in
the detailed specifications.
•Verify all switch and instrument
connections
•Verify that all switch and instrument
settings are set to normal operating
standards.
•Calibrate all measurement equipment,
such as Flow meters, ampere meters,
and pressure meters,ect.
Installing a Seal Environmental Control
System
Install a system to control the seal environment.
Also, verify that port 1 is properly vented.
If required, install drain piping overhead to
ensure that the environment operates under
normal conditions. For more information,
contact Sundyne Corporation.
Checking Driver Rotation
Verify that the direction of the driver rotates in
the same direction as the arrow stamped or cast
on the pump casing.
*Un-coupled
Piping Connections
Verify that the following bolted or threaded
connections are tight:
Pump flange bolts
Seal environment piping and port
connections
Cooling water connections to heat
exchanger (if applicable)
Gearbox oil drain plug
Pump case drain plug

Instruction and Operation Manual
SA-07-11-37 Rev Orig 5 Jan 2009
Start Up Checklist
Pressurizing the Fluid Loop
Pressurize the double seal buffer loop or
external seal flush, if required, prior to admitting
fluid into the pump casing.
Servicing the Gearbox
Fill the gearbox with lube oil up to a quarter inch
(¼) or 6 mm from the top of the oil level sight
glass.
Note: Prior to using lube oil, verify that it
conforms to acceptable lube oil
specification standards. Refer to the
SPECIFICATIONS section in this
manual for more information.
Under normal operation, the lube oil level will
lower about a quarter inch than when idle.
Additionally bubbles will appear at the top of the
sight glass.
Note: Sundyne recommends that gearbox lube
oil be changed at least every six
months.
For requirement information about priming the
lube oil system, refer to Starting the Pump in this
manual.
Auxiliary Lube Pump
If your pump includes an auxiliary lubrication
pump, unlock the electrical circuit and move it to
the “hand” position. Check for oil leaks and
recheck the oil level.
Setting the Valves
To set the pump to the designated operating
point, start the pump with the suction valve in
the open position while throttling the discharge
valve.
Control Checklist
Process Conditions
Verify the following process conditions against
the specifications in this manual:
•Process conditions
•Suction pressure
•Suction temperature
•Discharge pressure
Check with your Sundyne representative if the
operation conditions of your pump must run
under different parameters than indicated by the
specifications in this manual.
Adjusting the Cooling Flow
If your model pump includes an installed heat
exchanger for the gearbox, adjust the cooling
flow to keep the temperature of the gearbox
sump at 140°-180°F (60°-82°C).
Verifying Operating Conditions
Verify the following parameters against the
specifications included in this manual:
•Total head
•Flow rate
•Power consumption
•Specific gravity
•Viscosity
•Net Positive Suction Head (NPSH)
The status of these conditions will significantly
alter performance of the pump if they are not in
accordance with the specification sheet.

Instruction and Operation Manual
SA-07-11-37 Rev Orig 6 Jan 2009
INSTALLATION
Inspection
Immediately inspect your Sundyne product upon
receipt of the equipment. Check for any
damage, which may have occurred during
shipment. Notify the carrier and Sundyne
immediately if damage is evident.
Note: The input shaft on the pump may not
turn freely due to seal drag and speed
increasing gear meshes. If the input
shaft does turn freely, and if rotation is
“not smooth,” damage may have
occurred during shipping.
Suction and Discharge Piping
Please adhere to the following best practices for
installing and maintaining suction and discharge
piping:
Install a suction strainer (12 mesh - .062" or
1.6mm opening) and clean the suction line
prior to starting the pump. This procedure
will protect the impeller from damage by mill
scale, welding slag, or other foreign particles
during initial startup.
Note: Sundyne Recommends installation of a
differential pressure instrument across
strainer to indicate strainer condition.
When installing piping to the pump, ensure that
all piping is supported independently from
the pump.
All piping must always line up with the pump
flanges.
Note: Never use force to position piping into
place at the flanged suction and
discharge connection locations. Failure
to do so may impose excessive strains
on the unit.
Avoid using elbow fittings near the suction
flange. When necessary, use long radius
elbow fittings. Sundyne recommends using
a straight pipe assembly of at least three
times the length of the pipe diameter
between an elbow and suction flange.
Note: Carefully select the size of pipe and
fittings to be installed so that friction
losses will remain low.
Never use a suction pipe that is smaller in
diameter than the pump suction inlet.
Sundyne recommends installation of a discharge
check valve to prevent reverse rotation.
Use block valves (both suction and discharge)
when isolating the pump during shutdown.
This practice will minimize process leakage
and prevent possible reverse rotation from
pump back-flow.