Veolia AS Series Guide

INSTALLATION, OPERATIONS, &
MAINTENANCE DOCUMENTATIONPACKAGE
Project No.: N/A
TONKAFLO AS400, AS1600, AS2500, AS4000
TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing
frame
SYSTEM PART NO.: 1123174
*Trademark of Veolia; may be registered in one or more countries.

This page has been
left blank
intentionally

Installation, Operations, & Maintenance Documentation Package
Preface
1123174-WTS-OM-SYS-EN41-MA-100 | REV A I
About the installation, operations,
and maintenance manuals
The Installation, Operations & Maintenance Documentation Package
(“IOM Package”), includes a set of instruction manuals that contain
warnings and guidance required to safely install, operate, and
maintain the Veolia TONKAFLO pump. Before installing,
maintaining, and operating the TONKAFLO pump, the owner and its
employees, contractors and agents (collectively, the “Owner”) must
read and fully understand the IOM Package and any supplemental
supporting materials or additions/modifications of the IOM Package
that were provided separately.
If the Owner does not fully understand the information provided in the
IOM Package, or if the Owner perceives there to be ambiguities or
uncertainties with any part of the installation, operation, or
maintenance of the TONKAFLO pump, do not proceed with
installation, operation, or maintenance until you have contacted
Veolia for additional information and clarification. Contact
information can be found on the following Project Information page or
in the Maintenance Manual.
FAILURE TO READ AND FULLY UNDERSTAND THE
IOM PACKAGE AND TO SEEK ADDITIONAL
INFORMATION FROM Veolia WHEN QUESTIONS OR
UNCERTAINTIES ARE PERCEIVED TO ARISE
BEFORE INSTALLATION, OPERATION, AND
MAINTENANCE COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH, BROKEN OR
DAMAGED PARTS/EQUIPMENT, AND/OR WATER
QUALITY ISSUES AND RESULTING HARM.
Deviations or modifications of the IOM Package suggested by Veolia
field personnel or other employees do not supersede the IOM
Package unless stated in writing by Veolia.
If owners are interested in requesting and purchasing professional
installation, operation, maintenance, inspections and training
services for its products, contact their Veolia representative.

Installation, Operations, & Maintenance Documentation Package
Preface
II 1123174-WTS-OM-SYS-EN41-MA-100 | REV A
This IOM Package applies generally to all TONKAFLO pumps and,
as a result, could contain instructions, statements and information
about installations, uses, operations or other features that may not
apply to all TONKAFLO pumps. To purchase a customized package
applicable to your product, contact Veolia.
Proprietary information
The information contained in these manuals is Veolia proprietary
information and is disclosed in confidence. It is to be used solely for
the purpose for which it is furnished and returned upon request. This
manual and such information is not to be reproduced, transmitted,
disclosed or used otherwise in whole or in part without the written
authorization of Veolia. The information contained in these
documents may also be controlled by export control laws in
applicable countries. Unauthorized export or re-export is prohibited.
ISO safety symbols are used under license. When printed in black
and white, these images represent modified versions of the symbols.
Veolia and Veolia Water Technologies &Solutions are trademarks of
Veolia.
Disclaimer
This IOM Package is not intended to modify, amend or
otherwise change the terms and conditions pursuant to which
TONKAFLO pump were purchased, nor be construed as
containing or otherwise giving rise to express or implies
warranties, each of which are hereby disclaimed. Refer to the
warranty information in the contract pursuant to which the
Veolia product was purchased.

Installation, Operations, & Maintenance Documentation Package
Service information
1123174-WTS-OM-SYS-EN41-MA-100 | REV A III
Service information
It is recommended that owners complete the following fields upon
receiving the system. This information will be helpful when
requesting service and support.
System provider information
System provider
Contact
Phone
Fax
Email
System information
Installation date
Model number*
Serial number*
* Model and serial number information can be found on the nameplate located on
the system's electrical panel.
Internal Ref No: V23.1

This page has been
left blank
intentionally

Installation, Operations, & Maintenance Documentation Package
Contents
1123174-WTS-OM-SYS-EN41-MA-100 | REV A V
Contents
Service information III
System provider information III
System information III
BOOK 1: Overview &Design
1.1 Design and theory of operation 2
1.2 System design parameters 3
1.2.1 Pump nomenclature 5
1.2.2 Standard construction materials 5
BOOK2: Safety Manual
2.1 Personal safety 3
2.1.1 Personal protective equipment 3
2.1.2 Walking and working surfaces 4
2.1.3 Temperature extremes 4
2.2 Safety on site 5
2.2.1 General precautions 5
2.2.2 Safety inspections 7
2.2.3 Electrical and thermal hazards 8
2.2.4 Mechanical hazards 9
2.2.5 Chemical hazards 10
2.2.6 Pinch and fall hazards 12
2.2.7 Noise hazards 13
2.2.8 Pressure and rupture hazards 14
2.2.9 Environmental hazards 14
2.3 High-risk procedures 15
2.3.1 Locking out components 16
2.3.2 Entering confined spaces 16
2.4 Safety Data Sheets (SDS) 18
BOOK 3: Installation Manual
3.1 Initial requirements 3

Installation, Operations, & Maintenance Documentation Package
Contents
VI 1123174-WTS-OM-SYS-EN41-MA-100 | REV A
3.2 Initial setup 4
3.2.1 Location 4
3.2.2 Foundation 4
3.3 Installing the flexible coupling 6
3.3.1 Coupling guards 6
3.4 Installing the piping 7
3.4.1 Orient the inlet housing 7
3.4.2 Piping specifications 7
3.4.3 Suction screen (strainer) 10
3.4.4 Discharge screen (strainer) 11
3.4.5 Pump piping connections 11
3.5 Belt drive operation 13
BOOK 4: Operations Manual
4.1 Priming the pump 2
4.2 Pump rotation 3
4.2.1 Electrical grounding 3
4.2.2 Three-phase power imbalance 3
4.3 Pre-start checks 5
4.4 Initial operation 6
BOOK 5: Maintenance Manual 1
5.1 Preparing for maintenance or service 3
5.1.1 Locking out and tagging out equipment 3
5.1.2 Securing the electrical cabinet 4
5.2 TONKAFLO pumps field maintenance 5
5.2.1 Mechanical seal leakage 5
5.2.2 Replacing the mechanical seal on D, G, H bearing
frames 6
5.2.3 High-pressure mechanical seal replacement 9
5.2.4 D, G and H-bearing frame maintenance 9
5.2.5 Maintenance during long-term storage 21
5.3 Service and support 23

Installation, Operations, & Maintenance Documentation Package
Contents
1123174-WTS-OM-SYS-EN41-MA-100 | REV A VII
5.3.1 Available services 23
5.3.2 Contact information 24
5.3.3 TONKAFLO service policy - liquid ends 25
5.3.4 TONKAFLO pump repair procedure 26
5.3.5 Motor warranty 26
BOOK 6: Troubleshooting Manual
6.1 General precautions 2
6.2 Troubleshooting guidelines 4
6.2.1 Bearing frame temperature 4
6.2.2 Troubleshooting possible issues 4
BOOK 7: Project Documents 1
Standard Model Parts List - 1123174 12
Pump Cutaway drawing D G frames - 1123174 14
Pump Cutaway drawing H frames 1123174 15

This page has been
left blank
intentionally

TONKAFLO AS400, AS1600, AS2500, AS4000
TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing
frame
1123174-WTS-OM-SYS-EN41-MA-001 | REV A
SYSTEM PART NO.: 1123174
BOOK 1: Overview &Design
*Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.

This page has been
left blank
intentionally

Installation, Operations, &Maintenance Documentation Package
BOOK 1: Overview &Design
1123174-WTS-OM-SYS-EN41-MA-001 | REV A 1-1
About this manual
This manual provides an overview of the system and its design. It
describes how the system works, how water flows through the
system, and what the system parameters are.
Use this manual in conjunction with the other manuals in the
Installation, Operations, &Maintenance Documentation Package
(IOMPackage).
WARNING
Read the manual
The operator must read and fully understand all
instructions in this IOM Package before using this
system. Failure to follow safety guidelines or
instructions could result in severe personal injury or
death, broken or damaged parts/equipment, and/or
water quality issues and resulting harm.
Topics in this manual
1.1 Design and theory of operation 2
1.2 System design parameters 3
1.2.1 Pump nomenclature 5
1.2.2 Standard construction materials 5

Installation, Operations, &Maintenance Documentation Package
BOOK 1: Overview &Design
1-2 1123174-WTS-OM-SYS-EN41-MA-001 | REV A
1.1 Design and theory of operation
This section provides a general description of the TONKAFLO pump,
including its primary components, design, and theory of operation.
NOTICE
Operating this system in a manner that deviates
substantively from the Veolia instructions and best
practices may render the warranty null and void. If an
alternate mode of operation (example: revised
cleaning frequency) is being considered, contact
Veolia to request warranty approval before making
any changes. (See 5.3 Service and support)

Installation, Operations, &Maintenance Documentation Package
BOOK 1: Overview &Design
1123174-WTS-OM-SYS-EN41-MA-001 | REV A 1-3
1.2 System design parameters
The instructions provided in this manual refer to the lower and
medium capacity 400, 1600, 2500, and 4000 series pumps with D, G,
and H bearing frames.
The TONKAFLO Pumps AS Series has been designed for reliable
service in many types of pumping applications. The materials of
construction make these pumps suitable for many chemical,
corrosive and pure water applications. Their unique modular design
allows the user to choose the number of stages that most closely
match the desired performance and, thereby, achieve the highest
pumping efficiency.
The TONKAFLO Pumps AS Series covers a flow range of 4 to 700
gpm (0.9 to 159 m3/hr) with single unit pressures up to 630 psig (43.5
barg).
The capacity and discharge pressures can be increased by
operating pumps in parallel or series. When operating in series, a
maximum discharge pressure of 1,000 psig (69 barg) may be
achieved with high pressure construction on the downstream pump.
With inlet pressure greater than 200 psig (13.8 barg), optional high-
pressure mechanical seals should be used.
AS Series 60 Hz 3450 rpm 50 Hz 2875 rpm
Model Range gpm (m3/h) Range gpm (m3/h) Max.
efficiency
400 1.5 to 6 (0.3 to 1.4) 1 to 5 (0.2 to 1.1) 34%
1600 5 to 22 (1.1 to 5.0) 4 to 18 (0.9 to 4.1) 61%
2500 10 to 32 (2.3 to 7.3) 8 to 35 (1.8 to 7.9) 60%
Table 1.1 - Pump design capacities

Installation, Operations, &Maintenance Documentation Package
BOOK 1: Overview &Design
1-4 1123174-WTS-OM-SYS-EN41-MA-001 | REV A
AS Series 60 Hz 3450 rpm 50 Hz 2875 rpm
Model Range gpm (m3/h) Range gpm (m3/h) Max.
efficiency
4000 0 to 55 (4.5 to 12.5) 15 to 45 (3.4 to
10.2) 58%
Operating temperature for standard steel stages Note
Maximum recommended operating tem-
perature 200 F (93 C)
Table 1.1 - Pump design capacities
Note
lFor high temperature applications, contact Veolia.
lThe temperature stated in this table is for design flow and pressure. The
maximum recommended temperature is stated on the pump case.
NOTICE
To prevent excessive heat buildup, ensure adequate
flow through the pump at all times.
AS series 60 Hz 60 Hz 3500/3565 rpm 50 Hz 50 Hz 2900/2950 rpm
Model Stages Developed pressure Stages Developed pressure
400 45 500 psi (34 bar) 67 400 psi (31 bar)
1600 45 520 psi (36 bar) 57 450 psi (31 bar)
2500 45 500 psi (34 bar) 57 450 psi (31 bar)
4000 42 420 psi (29 bar) 48 340 psi (23 bar)
Table 1.2 - Maximum developed boost pressure

Installation, Operations, &Maintenance Documentation Package
BOOK 1: Overview &Design
1123174-WTS-OM-SYS-EN41-MA-001 | REV A 1-5
1.2.1 Pump nomenclature
Example model AS9022KZC Example model AS40415KTF-50
AS = all stainless steel AS = all stainless steel
90 = series 9000 40 = series 40000
22 = number of stages 4 = inlet size (4 in. Victaulic)
KZ = bearing frame 15 = number of stages
C = motor adapter KT = high thrust bearing frame
F = motor adapter
-50 = 50 Hz operation only
Table 1.3 - Pump name definitions
1.2.2 Standard construction materials
Impellers, diffusers, wetted casting, pump shaft, and casing are 304
stainless steel. The standard mechanical seal has a carbon rotating
face and a ceramic stationary face. The secondary sealing element
of the mechanical seal is Buna-N. The mechanical seal is a Crane
type 21, 5/8 inch diameter, with a material code of BF501C1. The
shaft bearings, diffuser bearings, discharge bearings, O-rings, and
mechanical seal elastomers are Buna-N.

This page has been
left blank
intentionally

TONKAFLO AS400, AS1600, AS2500, AS4000
TONKAFLO pumps with D, DM, G, GM, HT, HU, HW, HY, HZ-Bearing
frame
[Project Number]-WTS-OM-SYS-EN41-MA-002 | REV A
SYSTEM PART NO.: 1123174
BOOK2: Safety Manual
*Trademark of Veolia; may be registered in one or more countries. Information in this manual is Veolia proprietary and confidential.

This page has been
left blank
intentionally