Doc No.: 09035-00-OPM-VD-MR001-002 Job No.: 2009035 Installation, operation & maintenance(IOM) manuals PROJECT : DINH VU POLYESTER PLANT PROJECT LOCATION : DVIZ, HAI PHONG CITY, VIETNAM 09035-00-PPO-MR001 001 OWNER : PVTEX., JSC PO NO : 09035-00-PPO-MR001 DOCUMENT NO : 09035-00-OPM-VD-MR001-002 Document Class : Z 01 Jun 23, 2011 Issue for Approval J.H.YUN J.D.KIM J.W.LEE REV DATE DESCRIPTION PREPARED CHECKED APPROVED Young Poong Precision Corporation MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division I.O.M Installation, Operation and Maintenance Durco Mark III Alloy Pumps • ANSI Standard • Sealmatic • Unitized Self-Priming • Recessed Impeller • Lo-Flo • In-Line Bulletin P-10-502g (E) MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division TABLE OF CONTENTS 1.0 Introduction .1 2.0 Safety considerations .2 3.0 Overview 3.1 Warranty statement 3.2 Nameplate 3.3 Storage Short term Long term 3.4 Lifting pumps and assemblies 4.0 Mark III ANSI Standard Pump 4.1 General description of pump 4.2 Installation Protection of openings and threads .8 Rigid baseplates – overview Installation and Alignment Factory Alignment Procedure Recommended Procedure for Baseplate Installation and Final Field Alignment .9 New Grouted Baseplates Existing Grouted Baseplates 10 Stilt Mounted Baseplates 10 Zirconium Components 11 Piping connection – Suction/discharge 11 Mechanical Seal 12 Packing 13 Piping connection – Seal/packing support system .13 Piping connection – Bearing housing cooling system 13 Piping connection – Support leg cooling for centerline mounting option 13 Piping connection – Heating/cooling fluid for jacketed cover/casing .14 Piping connection – Oil mist lubrication system 14 Coupling .15 Coupling guard maintenance .15 C-flange motor adapter – Special considerations 15 4.3 Operation Rotation check .16 Pre start-up checks 16 (See Maintenance Section for details) Impeller setting .16 Shaft seal 16 Seal/packing support system 16 Bearing lubrication 16 Bearing housing cooling system 16 Support leg cooling for centerline mounting option .16 Heating/cooling fluid for jacketed cover/casing .16 4.4 Start-up considerations Ensuring proper NPSHA .17 Minimum flow 17 Starting the pump and adjusting flow 17 Operation in sub-freezing conditions 18 Shutdown considerations 18 Troubleshooting 18 4.5 Maintenance Preventive maintenance .22 Need for maintenance records .22 Need for cleanliness .22 Disassembly .22 Cleaning/inspection 25 Critical measurements and tolerances 25 Assembly .26 Power end assembly Bearing installation 27 Lip seals 29 Labyrinth seals 29 Magnetic seals 29 Bearing carrier/power end assembly 29 Wet end assembly Cartridge mechanical seals Seal installation 30 Rear cover plate installation .30 Impeller installation and clearance setting 30 Component-type mechanical seal Determination of seal location 30 Gland installation 30 Seal installation 30 Rear cover plate installation .31 Impeller installation and clearance setting 31 Packing with split gland Rear cover plate installation .31 Impeller installation and clearance setting 31 Packing/gland installation .31 Packing with one-piece gland Gland installation 31 Impeller installation and clearance setting 32 Packing installation 32 Bearing lubrication Oil bath 32 MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Grease Regreaseable bearings .33 Shielded bearings .33 Sealed bearings 33 Oil mist 33 Reinstallation .33 4.6 Spare parts 34 How to order spare parts .34 5.0 Mark III Sealmatic Pump 5.1 General description of pump 38 5.2 Overview Repeller function 39 Design difference 39 Seal options Packing - Option A 40 Checkmatic - Option B 40 Dry Running Seals - Option C 41 5.3 Operation General information 41 Start-Up .41 5.4 Maintenance Disassembly of Group Pumps 42 Disassembly of Group Pumps 42 Reassembly - Sealmatic with Packing 42 Reassembly - Sealmatic with Checkmatic Seal 42 Reassembly - Sealmatic with Dry Running Seal 42 5.5 Miscellaneous information 43 Repeller selection instructions .43 5.6 Spare parts 44 6.0 Mark III Unitized Self-Priming Pump 6.1 General description of pump 45 6.2 Pump installation and operation 46 6.3 Spare parts 48 7.0 Mark III Recessed Impeller Pump 7.1 General description of pump 49 7.2 Setting the impeller 50 7.3 Spare parts 50 8.0 Mark III Lo-Flo Pump 8.1 General description of pump 51 8.2 Setting the impeller 51 8.3 Spare parts 52 9.0 Mark III In-Line Pump .53 9.1 General Description of the Pump .53 9.2 Installation .53 9.3 Operation 55 9.4 Start-Up Considerations 55 9.5 Maintenance 57 9.6 Spare Parts 60 Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H Appendix I Appendix J Appendix K IOM for C-flange motors adapters Assembly of stilt and spring mounted baseplates Critical measurements and tolerances Installation/clearance setting of reverse vane impeller Installation/clearance setting of front vane open impeller Removal/installation of seals with SealSentry™ FMI seal chamber Bearing isolation maintenance instructions Installation of repeller cover, repeller, cover, impeller for Sealmatic Pump Part – Allowable nozzle loads Part – Mark IIIA In-Line allowable nozzle loads ClearGuard trimming and assembly instructions Sources of additional information MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 1.0 Section 1.0 INTRODUCTION This bulletin contains instructions and guidelines for the installation, operation, and maintenance of the Durco Mark III ANSI Standard Pump, the Mark III Sealmatic Pump, the Mark III Unitized Self-Priming Pump, the Mark III Recessed Impeller Pump and the Mark III Lo-Flo Pump These pumps all use the Mark IIIA standard power end, or the ANSI 3A™ upgraded power end The “A” designation signifies that both of these power ends are the new improved design that was released in 1995 Information concerning the older Mark III and ANSI power ends is also available in the IOM There are many factors affecting the successful installation, operation, and maintenance of a pump From one pump to the next there is typically significant variation in these factors This makes it impossible to create a bulletin that covers all situations Therefore, the information contained herein is meant to serve only as a general guideline If detailed questions or problems arise, contact the nearest Flowserve Regional Sales Office or Distributor/Representative It is extremely important that this entire bulletin be read prior to installation or start-up of the pump This is important for safety, for proper performance of the pump, and for maximum Mean Time Between Planned Maintenance (MTBPM) THE COMPANY Among Flowserve Corporation’s brands, Durco has long been recognized as the leading name in chemical process pumps Durco pumps are manufactured at Flowserve’s modern facilities, utilizing state-of-the-art equipment and sophisticated quality control techniques Flowserve provides technical support and special services specific to the needs of its customers Flowserve is proud of earning preferred supplier status with many of the world's leading processing companies Engineered and manufactured, sold and serviced to ISO 9001 quality certification, Durco process pumps are truly world class products And with more than 120 years of experience in serving the needs of the worldwide process industries, Flowserve has become the unchallenged leader in hydraulic design engineering, materials expertise, and application knowhow Committed to continuous quality improvement, Flowserve controls the complete product life cycle – from melting and casting, to cellular manufacturing to assembly and testing, to supply of aftermarket products, repair and diagnostic services The advanced design and precision manufacture of the rugged, heavy-duty Mark III chemical service pump significantly enhance bearing and seal life, thereby extending mean time between planned maintenance (MTBPM) Its exclusive features provide significant performance benefits for chemical pump users Most notable among these are: The exclusive reverse vane impeller offers important performance-enhancing, maintenance-reducing advantages The exclusive external micrometer shaft adjustment provides dead accurate setting of impeller clearance in seconds The ANSI 3A™ power end, SealSentry™ family of seal chambers, Ultralign™ pump/motor shaft alignment system and the BaseLine™ family of baseplates are building blocks for improved MTBPM A Flowserve Sales Engineer, Representative or Distributor will be happy to review the advanced product features that make the Mark III the leader in chemical pumping technology MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 2.0 Section 2.0 SAFETY CONSIDERATIONS The Durco Mark III process pump has been designed and manufactured for safe operation In order to ensure safe operation, it is very important that this manual be read in its entirety prior to installing or operating the pump Flowserve shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for installation, operation and maintenance contained in this manual Remember that every pump has the potential to be dangerous, because of the following factors: • parts are rotating at high speeds • high pressures may be present • high temperatures may be present • highly corrosive and/or toxic chemicals may be present Paying constant attention to safety is always extremely important However, there are often situations that require special attention These situations are indicated throughout this book by the following symbols: DANGER DANGER – Immediate hazards which WILL result in severe personal injury or death Several important general precautions are listed below: DO NOT RUN EQUIPMENT DRY OR START THE PUMP WITHOUT THE PROPER PRIME (Casing Flooded) DO NOT EXCEED THE MAXIMUM DESIGN PRESSURE (MDP) AT THE TEMPERATURE SHOWN ON PUMP NAMEPLATE See Figure for general pressure versus temperature ratings of common alloys ALWAYS LOCK OUT POWER TO THE DRIVER BEFORE PERFORMING PUMP MAINTENANCE NEVER OPERATE THE PUMP WITHOUT COUPLING GUARD AND ALL OTHER SAFETY DEVICES CORRECTLY INSTALLED DO NOT APPLY HEAT TO DISASSEMBLE THE PUMP OR TO REMOVE THE IMPELLER Entrapped liquid could cause an explosion NEVER OPERATE THE PUMP FOR MORE THAN A SHORT INTERVAL WITH THE DISCHARGE VALVE CLOSED The length of the interval depends on several factors including the nature of the fluid pumped and its temperature This interval must be determined by the customer’s Engineering personnel NEVER OPERATE THE PUMP WITH THE SUCTION VALVE CLOSED WARNING WARNING – Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION CAUTION – Hazards or unsafe practices which COULD result in minor personal injury or product or property damage EXCESSIVE PUMP NOISE OR VIBRATION may indicate a dangerous condition The pump must be shut down immediately DO NOT OPERATE THE PUMP FOR AN EXTENDED PERIOD BELOW THE RECOMMENDED MINIMUM FLOW (Figure 20) 10 THE PUMP SHAFT MUST TURN CLOCKWISE WHEN VIEWED FROM THE MOTOR END It is absolutely essential that the rotation of the motor be checked before installation of the coupling spacer and starting the pump Incorrect rotation of the pump for even a short period of time can unscrew the impeller, which can cause severe damage NOTE: ALWAYS COORDINATE REPAIR ACTIVITY WITH OPERATIONS PERSONNEL, AND FOLLOW ALL PLANT SAFETY REQUIREMENTS AND APPLICABLE SAFETY AND HEALTH LAWS/REGULATIONS MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 2.0 FIGURE – Pressure-Temperature Limits By Alloy 50 CD4M DS 300 100 DC2 DC3 MAX DISCHARGE PRESSURE - lbf /in2 200 250 300 1500 DINC D20 1250 DNI 150 1000 DS DCI LOW TEMPERATURE LIMIT 100 CLASS 150 MARK III PUMPS BASED ON ANSI B16.5 50 CR29 DCI UPPER LIMIT 100 300 400 500 700 Ductile Iron High Chrome Iron High Chrome Iron High Chrome Iron Carbon Steel Durco CF8 Durco CF3 Durco CF8M Durco CF3M Durcomet 100 Durimet 20 Durcomet Durco CY40 Durco M35 Nickel Chlorimet Chlorimet Duriron® Durichlor 51® Superchlor® Durco DC8 Titanium Titanium-Pd Zirconium DCI CR28 CR29 CR35 DS D2 D2L D4 D4L CD4M D20 DV DIN DM DNI DC2 DC3 D D51 SD51 DC8 Ti Ti-Pd Zr None None None None None CF8 CF3 CF8M CF3M CD4MCu CN7M None CY40 M351 CZ100 N7M CW6M None None None None None None None 300 DS DINC DC2 DC3 2250 2000 D2 D4 D2L D4L D20 CD4M UPPER LIMIT 200 1500 1250 GROUP I & II CLASS 300 MARK III PUMPS BASED ON ANSI B16.5 GROUP III CLASS 300 MARK III PUMPS LIMITED TO CLASS 150 RATINGS 150 CLASS 300 FLANGES -100 100 1000 TI TIP ZR 750 500 CURVE NO 2505-7 200 300 400 500 600 700 TEMPERATURES – °F Equivalent Wrought Designation ASTM Specifications None None None None Carbon Steel 304 304L 316 316L Ferralium® Alloy 20 None Inconel® 600 Monel® 400 Nickel 200 Hastelloy® B Hastelloy® C None None None None Titanium Titanium-Pd Zirconium A395 A532 class III None None A216 Gr WCB A744, Gr CF8 A744, Gr CF3 A744, Gr CF8M A744, Gr CF3M A744, Gr CD4MCu A744, Gr CN7M None A744, Gr CY40 A744, Gr M351 A744, Gr CZ100 A494, Gr N7M A494, Gr CW6M A518 A518 A518 None B367, Gr C3 B367, Gr C8A B752, Gr 702C ® Duriron, Durichlor 51 and Superchlor are registered trademarks of Flowserve Corporation ® Ferralium is a registered trademark of Langley Alloys ® Hastelloy is a registered trademark of Haynes International, Inc ® Inconel and Monel are registered trademarks of International Nickel Co Inc 350 1750 TEMPERATURES – °F FIGURE – Alloy Cross-Reference Chart Designation Symbol ACI Designation 250 D4 500 600 200 250 250 300 150 DS LOW TEMPERATURE LIMIT DNI CURVE NO 2505-7 200 100 CD4M 100 CLASS 150 FLANGES -100 750 CD4M UPPER LIMIT 50 DM 1750 D2 D2L 350 2000 DM 200 -50 350 D4 D4L DCI 250 150 TI TIP ZR MAX DISCHARGE PRESSURE - lbf /in2 MAX DISCHARGE PRESSURE - kPa -50 TEMPERATURES – °C MAX DISCHARGE PRESSURE - kPa TEMPERATURES – °C MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 3.0 Section 3.0 OVERVIEW 3.1 WARRANTY STATEMENT 3.3 STORAGE The warranty on a Durco pump is provided in a statement which was sent with the Order Acknowledgement Please call the Flowserve Regional Sales Office or Distributor/Representative for a copy of this warranty statement SHORT TERM STORAGE 3.2 NAMEPLATE An example of the nameplate used on the Mark III pump is shown below This nameplate, which is always mounted on the Mark III bearing housing, is shown in Figure FIGURE How To Identify Durco Mark III Process Pump Pump Division Serial No Equipment No Purchase Order Model Size 2K6X4M-13A/12.5RV MDP Material Date, DD/MMM/YY Flowserve’s pump size code is used to indicate the size of the pump For example, consider the following: K X M – A / 12.5 R V indicates a medium size pump frame - in this example, a Group 1=Group (small frame) 2=Group (medium frame) 3=Group (large frame) K = Mark style power end J = Mark style PE arranged for Mark wet end No letter and no preceding number indicates a Mark power end Nominal suction port size Nominal discharge port size Modifier for “specialty pumps” blank or no letter = Standard pump M = Sealmatic L = Non-metallic wet end R = Recessed impeller H = High silicon iron US = Unitized self-priming S = Old style self-priming V = Vertical in-line T = Teflon lined wet end LF = Lo-Flo E = Durcon wet end Nominal maximum impeller diameter 13 = 13 inch Pump design variation A = This pump has been redesigned from an earlier version The impeller and casing are no longer interchangeable with the earlier version H = This pump is designed for a higher flow capacity than another pump with the same basic designation Examples: 4X3-10 and 4X3-10H; 6X4-10 and 6X4-10H; 10X8-16 and 10X8-16H In each case the pump with the “H” is designed for a higher flow capacity HH = This pump is designed for a higher head than another pump with the same basic designation Example: 4X3-13 and 4X3-13HH Actual impeller size 12.5 = 121/2 in diameter; 8.13 = 81/8 in; 10.75 = 106/8 or 103/4 in Previous annotation: 124 = 124/8 or 121/2 in diameter; 83 = 83/8 in Impeller style RV = Reverse vane impeller; OP = Open impeller Normal packaging is designed to protect the pump during shipment and for dry, indoor storage for up to two months or less The procedure followed for this short term storage is summarized below: Standard Protection for Shipment : a Loose unmounted items, including, but not limited to, oilers, packing, coupling spacers, stilts, and mechanical seals are packaged in a water proof plastic bag and placed under the coupling guard Larger items are cartoned and metal banded to the baseplate For pumps not mounted on a baseplate, the bag and/or carton is placed inside the shipping carton All parts bags and cartons are identified with the Flowserve order number, the customer purchase order number, and the pump item number (if applicable) b Inner surfaces of the bearing housing, shaft (area through bearing housing), and bearings are coated with Cortec VCI-329 rust inhibitor, or equal Note: Bearing housings are not filled with oil prior to shipment c Regreasable bearings are packed with grease (Chevron SRI #2) d After a performance test, if required, the pump is tipped on the suction flange for drainage (some residual water may remain in the casing) Then, internal surfaces of ferrous casings, covers, flange faces, and the impeller surface are sprayed with Calgon Vestal Labs RP-743m, or equal Exposed shafts are taped with Polywrap e Flange faces are protected with plastic covers secured with plastic drive bolts 3/16 in (7.8 mm) steel, or 1/4 in (6.3 mm) wood covers with rubber gaskets, steel bolts, and nuts are available at extra cost f All assemblies are bolted to a wood skid which confines the assembly within the perimeter of the skid g Assemblies with special paint are protected with a plastic wrap h Group and Group bare pumps, when not mounted on baseplates, are packed in hard paper cartons mounted on wood skids i Group bare pumps, when not mounted on baseplates, are bolted to wood skids j All pump assemblies utilizing polycrete baseplates are mounted on wood skids k All assemblies having external piping (seal flush and cooling water plans), etc…are packaged and braced to withstand normal handling during shipment In some cases components may be disassembled for shipment The pump must be stored in a covered, dry location MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 3.4 LONG TERM STORAGE LIFTING Long term storage is defined as more than two months, but less than 12 months The procedure Flowserve follows for long term storage of pumps is given below These procedures are in addition to the short term procedure The following describes how to lift pump components, assembled pumps, or pump, motor and baseplate assemblies Do not attempt to lift a pump mounted on a baseplate by itself Only a pump-motor assembly may be lifted once installed on a baseplate Solid wood skids are utilized Holes are drilled in the skid to accommodate the anchor bolt holes in the baseplate, or the casing and bearing housing feet holes on assemblies less baseplate Tackwrap sheeting is then placed on top of the skid and the pump assembly is placed on top of the Tackwrap Metal bolts with washers and rubber bushings are inserted through the skid, the Tackwrap, and the assembly from the bottom of the skid and are then secured with hex nuts When the nuts are “snugged” down to the top of the baseplate or casing and bearing housing feet, the rubber bushing is expanded, sealing the hole from the atmosphere Desiccant bags are placed on the Tackwrap The Tackwrap is drawn up around the assembly and hermetically (heat) sealed across the top The assembly is completely sealed from the atmosphere and the desiccant will absorb any entrapped moisture A solid wood box is then used to cover the assembly to provide protection from the elements and handling This packaging will provide protection up to twelve months without damage to mechanical seals, bearings, lip seals, etc due to humidity, salt laden air, dust, etc After unpacking, protection will be the responsibility of the user Addition of oil to the bearing housing will remove the inhibitor If units are to be idle for extended periods after addition of lubricants, inhibitor oils and greases should be used Every three months, the shaft should be rotated approximately 10 revolutions 3.4 LIFTING PUMPS AND PUMP ASSEMBLIES Lifting should only be done by trained personnel Pumps and motors often have integral lifting eyes or eye bolts These are intended for use in lifting the individual piece of equipment CAUTION Do not use eye bolts or cast-in lifting lugs to lift pump, motor, and baseplate assemblies Before lifting the equipment refer to the pump data sheet for the complete assembly weight Pump Components: Casing (#100): Use a choker hitch pulled tight around the discharge nozzle Rear cover (#106): Insert an eye hook in the drilled and tapped hole at the top of the cover Use either a sling or hook through the eye bolt Bearing housing (#119): Group I Insert a sling between the upper and lower support ribs between the housing barrel and the casing attachment flange Use a choker hitch when slinging Caution, make sure there are no sharp edges on the bottom side of the ribs which could cut the sling Group and Insert either a sling or hook through the lifting lug located on the top of the housing Power end: Same as bearing housing Bare Pump: Sling around the pump discharge nozzle, and around the outboard end of the bearing housing with separate slings Choker hitches must be used at both attachment points and pulled tight Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in Figure The sling lengths should be adjusted to balance the load before attaching the lifting hook Pump, motor and baseplate assembly: If the baseplate has lifting holes cut in the sides at the end, (Type A Group 3, Type D, and Type E bases) insert lifting S hooks at the four corners and use slings or chains to connect to the lifting eye as shown in Figure Do not use slings through the lifting holes For other baseplates sling around the pump discharge nozzle, and around the outboard end of the motor frame using choker hitches pulled tight (Figure 6) The sling should be positioned so the weight is not carried through the motor fan housing Make sure the completion of the choker hitch on the discharge nozzle is toward the coupling end of the pump shaft as shown in Figure MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division Section 3.4 FIGURE FIGURE FIGURE 6 MK III PUMPS IOM - 11/8/02 10:36 AM Page 89 Dan K Snelson Clients:023-FLOWSERVE Pumps:023- Job Files:023-Closed Jobs:IOMs:1181-(P Hydraulic Engineering Mechanical Design Materials Science Intelligent Pumping Manufacturing Technology USA and Canada Flowserve Corporation Pump Division Millennium Center 222 Las Colinas Blvd., 15th Floor Irving, Texas 75039-5421 USA Telephone: 972 443 6500 Toll free: 800 728 PUMP Telefax: 972 443 6800 Europe, Middle East, Africa Worthington S.P.A Flowserve Corporation Pump Division Via Rossini 90/92 20033 Desio (Milan), Italy Telephone: 39 0362 6121 Telefax: 39 0362 303396 Pump Division Your local Flowserve representative: To find your local Flowserve representative please use the Sales Support Locator System found at www.flowserve.com Latin America & Caribbean Flowserve Corporation Pump Division 6840 Wynnwood Lane Houston, Texas 77008 USA Telephone: 713 803 4434 Telefax: 713 803 4497 Asia Pacific Flowserve Pte Ltd Pump Division 200 Pandan Loop #06-03/04 Pantech 21 Singapore 128388 Telephone: 65 6775 3003 Telefax: 65 6779 4607 Printed in U.S.A June 2002 © Flowserve Corporation Installation and maintenance for Polyphase AC Induction Motors All operations serving transport, installation, connection, operation and maintenance by skilled, qualified and responsible personnel ensures safe and proper use of motors Read instructions carefully before attempting to install, operate or service motors and retain for future reference and work with care Especially, safety precautions must be observed to protect personnel from possible injury which will be caused by high voltage, hot surface and rotating parts of 14 RECEIVING Check motor & nameplate data (HP, Pole, Voltage and etc.) Check any damage or loose parts during transportation and stop commissioning if necessary Turn shaft by hand to check smooth rotation If shaft is clamped by locking device to prevent axial movement of heavy rotor during transportation, please remove it to run motors and retain it for future transport CAUTION If the motor is supplied with eyebolts for lifting purposes, make certain that these tightened securely Use these for lifting the motor only Do not use these for lifting any equipment mounted to the motor Note that the direction of lift should not exceed 15 degrees form the shank of the eyebolt WARNING High voltage, hot surfaces and rotating parts of electrical machinery can cause serious or fatal personal injury and damage to property Qualified personnel should perform proper installation, operation and maintenance Recommendations to be familiarized are NEMA MG2, the National Electric Code, IEC364(prEN50110-1) and all sound local safety practices Before attempting maintenance or repair, avoid contact with energized circuits and disconnect and de-energize all power sources to the motor and to the necessary devices to avoid electrical shock Before motor is energized, avoid contact with rotating parts and ensure that shaft key is fully captive or removed When working near machinery with high noise levels, suitable protection must be used Automatic-reset thermal protection should not be used where unexpected automatic starting will be hazardous to personnel Proper safeguards or protective devices against possible failure of motor-mounted brake, especially on overhauling load applications should be provided and should not be by-passed And a suitable enclosure should be provided against access to the motor or other un-authorized personnel of 14 Grounding of motor against fatal injury to personnel should be in accordance with the National Electrical Code and applicable local practice Grounding cable and terminal should be securely crimped with proper crimping tools for safe grounding Repair of Explosion-proof motors should be made by Hyundai, U/L,CSA or other listed authorized service center to maintain those listings, safety and special feature in hazardous area The use of non-explosion-proof motors in hazardous area is prohibited unless they are expressly intended for such use STORAGE When storing motors without immediate installation, to keep motors in best condition, make sure of dry, clean, dust-free and low-vibration environment to avoid danger of bearing damage at rest Precautions should be taken to prevent the entrance of moisture, dust or dirt during storage especially for winding and bearing Before commissioning, make sure insulation resistance of winding In case of resistance values≤1㏁, the windings should be dried LOCATION Drip-proof motors (IEC protection degree ≤IP23) are intended for use in well ventilated areas where the atmosphere is reasonably free of dirt, moisture and corrosion and not intended for use in outdoor Enclosed motors (IEC protection degree ≥IP44) are intended for operation where they are exposed to dirt, moisture, dust and most outdoor conditions Explosion-proof motors are designed for operation in hazardous areas classified by Underwriters' Laboratories, National Electrical Code, Canadian Standard Association and IEC79 Chemical heavy duty enclosed motors are designed for use in highly corrosive or excessively moisture locations Standard ambient condition of motors are rated for ambient temperatures of -20℃∼ +40℃ (-40℃ with low temperature grease such as Beacon325) and altitudes below 1000m(3300feet) above sea level of 14 MOUNTING Mount motors securely on a firm and flat base and make sure of solid foot or flange solid foot or flange mounting All ball bearing normal thrust motors can be side wall or can be side wall or ceiling mounted and can be vertically mounted for motors up to and including 326frame(IEC200L) size For the recommendations of other applications, check nearest Hyundai office or sales agents Align motors accurately using flexible coupling for direct drive if possible Because the balance of motors is made by half-key, the coupling or pulley must be half-key balanced Mount or remove belt pulley or coupling only using appropriate means and cover them with a safety guard and avoid excessive belt tensions Consult drive or equipment manufacturer or Hyundai for drive recommendations The bolts for motor mounting and base assembly must be carefully tightened to prevent change in alignment and possible damage to the equipment applying the recommended tightening torques shown in table Use the recommended torques for medium carbon steel bolts identified by three radial lines at 120 degrees on the head and use 50% of the recommended torques for low carbon steel bolts with no ID marks In case of motors with holes in feet, these holes are used for the application of dual frame sizes Only holes are used for mounting in accordance with outline drawing Recommended Bolt Size Torque Inch Metric Ft.-lb N-M 1/4 M6 7-11 9-15 5/16 M8 14-21 19-28 3/8 M10 25-37 34-50 1/2 M12 60-90 81-122 5/8 M16 120-180 163-244 3/4 M20 210-320 285-433 If bases are removed from enclosed motors having bolt-on base, the enclosure must be maintained by plugging or closing the bolt holes and not replace the base bolts in the frame with the base removed In case of enclosed motors having drain plugs, remove them from the end shields or frame in the bottom side for the use in outdoors or in other high moisture area Because low voltage motors per IEC are components for installation of 14 in machinery as defined in Machinery Directive89/392/EEC, commissioning is prohibited until conformity of the end product with this directive has been established per EN60204-1 for European country The application of pulleys, sheaves, sprockets and gears on motor shaft is described in NEMA standard MG1-14.07 The application of V-belt sheave dimensions to AC motors is shown in NEMA MG1-14.41 The V-belt sheave diameters should not be less than the values in Table below and the sheave width should not be wider than the maximum width per equation below Horsepower Synchronous Speed, RPM 3600 1800 1200 1.5 2-3 7.5-10 15 20-25 - 1.5-2 5-7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 0.75 1.5 3-5 7.5 10 15 20 25 30-40 50 60 75 100 125 - V-belt Sheave(inch) Conventional Narrow A,B,C,D,E 3V,5V,8V Minimum Minimum 900 Pitch Outside Diameter▶ Diameter◀ 0.5 2.2 2.2 0.75 2.4 2.4 2.4 2.4 1.5 2.4 2.4 2.6 2.4 2-3 3.0 3.0 3.8 3.8 7.5 4.4 4.4 10 4.6 4.4 5.0 4.4 15 5.4 5.2 20 6.0 6.0 25-30 6.8 6.8 7.4 7.4 40 8.2 8.2 9.0 8.6 9.0 8.0 50 9.0 8.4 10.0 8.6 60 10.0 10.0 11.5 10.5 11.0 10.0 75 10.5 9.5 10.5 100 12.5 12.0 13.2 of 14 z Maximum sheave width = 2(N-W) – 1/4” z Maximum sheave width = (N-W) # N-W (E for IEC) = the usable shaft length Sheave ratios greater than 5:1 & center to center distances less than the diameter of large sheave should be referred to Hyundai Make necessary ventilation passage for the best operation of motors In case of belt pulley, ventilation opening of rim of pulley is essential for motors The ventilation must not be obstructed The distance between ventilation openings of motors and wall or obstacle should be maintained by minimum 25mm(1inch) and ventilation diameter divided by Motors with shaft ends pointing upward are to be provided with a cover by the customer to prevent foreign materials from falling into the ventilation or openings CAUTION In all cases, no surrounding structure should obstruct normal flow of ventilation air throught or over the motor of 14 POWER SUPPLY and CONNECTIONS Wiring of motor, control, grounding and overload protection should be in accordance with the National Electric Code and all sound local building codes or practices only by qualified technical personnel Power supply should agree with nameplate voltage and frequency and permissible variations of power supply are ±5% for frequency, ±10% for line voltage and ±10% for combined variation to avoid elevated temperatures and effects on the electromagnetic compatibility (IEC motors :±2% for frequency, ±5% for line voltage per IEC34-1, EN60034-1 for multi-voltage motors) Thermally-protected motors to prevent excessive temperature rise or overload have two terminals of protectors (P1,P2) and should be connected to the control panel according to the connection diagram inside of the conduit box CAUTION All explosion proof motors are equipped with thermostats These must be connected to the motor control in order to maintain the factory warranty , and for the install to comply with CSA, UL, NFPA, WCE, and other governing regulations Manual-reset protectors can be reset after motor cooled by pressing reset button and Automatic-reset protectors(no external button) reset automatically after motor cooled Do not use Automatic-reset protectors where unexpected automatic starting will be dangerous to personnel WARNING Do not use automatic reset protected motor where unexpected start could cause injury to operating personnel Dual voltage motors can be connected for the desired voltage using the connection diagram inside of the conduit box Minimum clearances between un-insulated live parts and between such parts and earth must not be below 8mm at Volts≤550V,10mm at Volts≤725V, 14mm at Volts≤1000V Because no presence of foreign objects, dirt or moisture is admitted in the conduit box, close unused cable entrance holes and the box itself in a dust- and watertight manner of 14 For motors with brakes, check satisfactory functioning of brake before commissioning Standard connection diagrams for three phase motors without any accessories are shown as below and rotation can be changed by interchanging any two line leads Use appropriate cable terminals with proper crimping tools and protective and permanent conductor connection without loose wire ends is important for safety (1) Leads, Single voltage (2) Leads, Dual voltage & voltage ratio to √3, Single voltage 1) Direct-on-line Start & Run 2) Wye Start & Delta Run(Low voltage only) of 14 3) Control for Wye Start & Delta Run (Low voltage only) (3) Leads, Dual voltage & voltage ratio to 2, Wye interconnection 1) Direct-on-line Start & Run 2) Control for Wye Start & Delta Run(Low voltage only) of 14 (4) 12 Leads, Dual voltage, Delta interconnection 1) Direct-on-line Start & Run 2) Wye Start & Delta Run(Low voltage only) 3) Control for Wye Start & Delta Run (Low voltage) 4)Control for Wye Start & Delta Run (High voltage) 10 of 14 5) Part winding start (Low vlotage only) * For part winding start with magnetic contactor, M2 contactor should be closed within two seconds after M1 contactor is closed * Part winding start at low voltage is satisfactory only for 4pole and above ( 4p, 6p, 8p and above ) OPERATION If the motor has been stored for an extensive period or in a damp location, check the insulation resistance of stator winding & bearings If the resistance of stator winding is lower than 1Mega Ω, dry out motors thoroughly with maximum drying temperature of 85℃ (185℉) in one of the following ways 1) Dry the stator in an oven until the insulation resistance is constant for a one-half hour period 2) Enclosure the motor with a canvas or similar covering leaving a opening at the top for moisture to escape Insert heaters or lamps with care to avoid localized damage due to too closer heating to the winding and leave them until the insulation resistance is constant for a one-half hour period 3) With the rotor locked, apply approximately 10% of rated voltage and increase current gradually through the windings until temperature measured with thermometer reaches 85℃(185℉; Do not exceed this limit) Maintain 85℃ until the insulation resistance is constant for a one-half hour period Turn the shaft by hand to check the bearing and it may be necessary to re-grease or 11 of 14 change rusted bearings depending on the period and condition of storage Operate motor at no load (disconnected load) and check rotation (without key if uncoupled) for free running Interchange any two leads to change direction of rotation for three phase motor Connect load and operate for an initial period of at least one hour to check any unusual noise, vibration or hot spots and check those items periodically even after successful start-up Acceptable vibration severities can be decided by NEMA MG1-7 (2∼6pole:0.15, 8pole:0.12in/sec peak) and IEC34-14 (H≤132:1.8,132＜H≤225:1.8 (4pole and larger) & 2.8(2pole), H≥225:2.8(4pole and larger) & 4.5(2pole) in mm/sec rms.) for no load and uncoupled condition Check operating current against nameplate current Be careful not to exceed the value of nameplate amperes multiplied by the service factor under continuous load When 208-230/460V motors with alternate voltage of 200V at 1.0 SF are used on 200V, the sip of motors will increase approximately 30% and torques will be reduced by approximately by 20 to 30% Therefore, user should check and determine that motors will start and accelerate without injurious heating and with adequate torque MAINTENANCE INSPECT motor regularly and keep motor clean and dry In case of heavy dirt or deposits, clean air channels periodically If the period of storage or stop of running of motor is more than one month, turn the shaft by hand to check the smooth rotation of bearings every one month and check the insulation resistance of winding every three months as minimum Special features of Explosion-proof motors should be maintained in accordance with U/L, CSA or other authorized standard in hazardous area Therefore, repair of Explosion-proof motors is recommended to be made by Hyundai, U/L, CSA or other listed authorized service centers to maintain those listings, safety and special features In order to clean stator windings, use a soft brush and a slow acting solvent (if necessary) without affecting on coils, insulation and varnish in a well ventilated room for safety 12 of 14 LUBRICATION for maintenance Double shield and pre-lubricated ball bearing motors without grease fittings are adequately greased for life at the factory and not need re-lubrication Motors with re-greasing facilities are shipped with grease for initial running and should be checked and re-lubricated periodically depending on the type of service (see below table) to maintain maximum bearing life Do not lubricate excessively or too frequently to avoid damage of bearing and leakage of grease Conditions Standard Severe Very Severe Operation per day 8hrs, 1or 2shifts 24hrs, Cont duty Loading normal or high light shock, vibration heavy shock, vibration Ambient condition 40℃ ambient, clean dirt, dust dirt, dust, high ambient 0.5∼7.5 HP 7yrs 3yrs 9mos 10∼30 HP 3yrs 1yrs 4mos 40-75HP 10mos 6mos 3mos 100-150HP 6mos 4mos 2mos 200-350HP 3mos 1mos 0.5mos Clean grease nipples and grease plugs with removing any hardened grease at the openings Re-grease the motor with the equivalent grease as the initially filled grease until new grease appears at grease outlet(with grease plugs removed) using lowpressure grease gun Re-grease while the motor is warm with the shaft stationary for the safety and best purging of old grease If re-lubrication is to be performed with the motor running, stay clear of rotating parts and allow running for 20 to 30 minutes before replacing grease relief plugs In case of lubrication for TEFC motors, remove the plastic caps on the fan cover for access to the grease fittings WARNING Make sure all guards are in place and stay clear of all moving parts 13 of 14 SERVICE Hyundai motors should be serviced by qualified personnel using proper tools, equipment and genuine Hyundai renewal parts For further information, please contact nearest sales office of Hyundai heavy industries or sales agent When ordering spares or renewal parts, please specify information on the nameplate such as model No., serial No., HP(or kW), frame size and pole Office : FACTORY : Hyundai B/D, 140-2, Kye-dong 1-Chonha-dong, Dong-ku, Chongro-ku, Seoul, Korea Ulsan, Korea TEL:(82)(2)-746-7516,7578 TEL:(82)(52)-230-8527 , 230-8528 FAX:(82)(2)-746-7646/8 FAX:(82)(52)230-8520 , 230-6995 TLX: K28361 HDYARD FAX : K52172K53752HEECO 14 of 14 ...MK III PUMPS IOM - 11/8/02 10:10 AM Page Dan K Snelson Clients:023-FLOWSERVE Pumps: 023- Job Files:023-Closed Jobs:IOMs:1181-(P- Pump Division I.O.M Installation, Operation and Maintenance... refer to Appendix A for guidelines on installation, operation, and maintenance MK III PUMPS IOM - 11/8/02 10:13 AM Page 16 Dan K Snelson Clients:023-FLOWSERVE Pumps: 023- Job Files:023-Closed Jobs:IOMs:1181-(P... system operational • Bearing lubrication • Bearing housing cooling system operational • Support leg cooling for centerline mounting option operational • Heating/cooling for jacketed casing/cover operational