Transfer Pump Manual

USER’S MANUAL

Issue date : 2/4/2009

I N S T R U C T I O N S

FOR OPERATION AND MAINTENANCE

OF

CENTRIFUGAL PUMPS FOR LIQUEFIED GASES

Type: CO120/6.4-C/O Comm. No.: ECC39282-01 Customer: PRAXAIR Order No.: 186-LFPSG/DM

The purpose of these instructions is to facilitate the operation of your pump and to avoid errors. Reading these instructions carefully before installation and start-up means safe-guarding your interests and will be repaid by satisfactory service and performance of the machine and low cost of repair.

We recommend you to keep on stock all spare parts mentioned in these instructions and would be grateful if, when placing orders for spares, you would use our designation and indicate the number of your pump. You will find the machine number of the name plate of each pump.

Orders can be placed at : Sales and service departments Manufacturer Cryostar-USA Cryostar-USA 5897 Colony Drive 9211 S. Greenleaf Ave. Bethlehem, PA 18017 Santa Fe Springs , CA 90670 Telephone: (484) 281-3401 Telephone : (562) 903-1290 fax: (484) 281-3402 fax : (562) 903-4511

USER’S MANUAL


GLOBAL LOCATIONS

CRYOSTAR – FRANCE S.A. CRYOSTAR SINGAPORE CRYOSTAR UK GLOBAL HEADQUARTERS Zone Industrielle 203 Henderson Road Station Road, Industrial Estate B.P. 48 Blk B# 10-09 Unit 4+5 Hesingue Henderson Industrial Park GB - WOMBWELL, Barnsley F-68221 HEGENHEIM CEDEX SGP - SINGAPORE 159546 S73 OHA, S. Yorkshire Tel: +33(3) 89 70 27 27 Tel: +65 276 7441 Tel: +44 1226 759 921 Fax: +33(3) 80 67 59 54 Fax: +65 276 7442 Fax: +44 1226 756 729

USER RESPONSABILITY This equipment will perform in accordance with the instructions and information contained in this manual, and its referenced documents, when such equipment is installed, operated and maintained in compliance with such instructions. The equipment must be checked periodically. Defective equipment shall not be used. Parts that are brocken, missing, plainly worn, distorted or contaminated shall be replaced immediately. Should such repair or replacement become necessary, CRYOSTAR recommends that a request for service will be made. We recommend you to keep on stock all spare parts mentioned in these instructions. At the end of the manual we indicate how to put in an ordre for spares. The equipment, or any of its parts, shall not be altered without the prior written approval of CRYOSTAR. The user and /or purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, the use of spare parts that are not from CRYOSTAR, improper repair or alteration by any party other than the manufacturer.

Attention It is essential to read the directions for use prior to unpacking and installation. Moreover, the machine must be used and maintained by qualified personnel. Note This document is the property of BOC-AG Cryostar. It is not permitted to copy it, or to relate its contents to other persons, or to misuse it in any other way.

TABLE OF CONTENTS

USER’S MANUAL


1. TECHNICAL DATA 6 1.1. Pump data 6 1.2. Operating data 6 1.3. Motor data 6 1.4. Acoustic pressure 6 1.5. Test 7 1.6. Description of the Design 8

2. SAFETY 9 2.1. Warning 9 2.2. Isolation and energy dissipation 10

2.2.1. Isolation and dissipation of gas process energy 11 2.2.2. Isolation and dissipation of purging gas energy 11 2.2.3. Isolation and dissipation of electrical energy 11

2.3. Safety form for oxygen pump 12 2.4. Customer safety instructions - Summary 14

3. STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION 16 3.1. BOC AG - Cryostar Delivery Inspection 16 3.2. Degreasing and Lubricating Grease/Oil for Oxygen Duty 16 3.3. Inspection by Customers on Arrival 16 3.4. Storage of the Pump 16

4. INSTALLATION 17 4.1. Handling 17 4.2. Erection 17 4.3. Installation Scheme 17 4.4. Storage Tank 17 4.5. Piping 18

4.5.1. Suction Line 18 4.5.2. Discharge Line 19 4.5.3. Bypass Line 20 4.5.4. Vent Line 20

4.6. Valves and Fittings 20

5. LUBRICANTS 21 5.1. Characteristics 21

6. START-UP 22 6.1. Pre-Start-Up Inspection 22

6.1.1. Spin Test by Hand 22 6.1.2. Direction of Rotation 22 6.1.3. Vent 22 6.1.4. In labyrinth pump : centering labyrinth rings 22

USER’S MANUAL


6.2. Cool-down and Start-up of the Pump 23 6.3. Suction Pressure and Mechanical Seal 24 6.4. Shut-down of the Pump 25

7. TROUBLE SHOOTING 26

8. MAINTENANCE INSTRUCTIONS 29 8.1. General 29

8.1.1. Assembly / Disassembly : Table of tightening torques and forces 29 8.2. Periodical Revisions and Maintenance 31 8.3. Dismantling of the pump 32 8.4. Assembly of the Pump 32 8.5. Adjustment of the Mechanical Seal 33

9. CRYOSTAR’S MAINTENANCE AND SPARE PARTS SERVICE 34 9.1. Order Instructions 34

10. ANNEX 35 10.1. NPSH 35 10.2. Appendix to spare parts lists 37 10.3. Documentation 38

USER’S MANUAL


LIST OF DRAWINGS AND OTHER ENCLOSURES DRAWING TITLE DRAWING SPARE PART NUMBER LIST NUMBER Flow diagram 705070145 Handling drawing 708114352 Dimensional drawing 702114258-01 Performance curve Test curve Top Assembly 763150972-02 E–763150972-02 Special tools 763026005 Checklist 706110196

USER’S MANUAL


1. TECHNICAL DATA

1.1. Pump data

Serial number ECC39282-01 Type CO120-6.4 C/O Number of stages 1 Nominal impeller diameter 120 mm Speed 6400 rpm Position of suction nozzle Axial Position of discharge nozzle I Material Execution Bronze / Bronze Year / Month built 2007 / 12

1.2. Operating data

Medium LN2 Liquid temperature -196°C Max. Suction pressure 5 barg Minimum NPSH 0.6 m Flow rate 25 gpm Differential head 380 ft

1.3. Motor data

Cryostar ref. 792605195-01/004 Type 213T NEMA Protection IP 55 Insulation class F Temperature rise B Frequency 104 Hz Phase 3 Voltage 460 V Power 10 HP Speed 6400 rpm Forced ventilation 3x480V, 60 Hz

1.4. Acoustic pressure

Average value ≈ 85 dB A

USER’S MANUAL


1.5. Test

Medium Nitrogen Test speed Refer to acceptance report Note : Working data have been measured at the test stand. The test allows pressure to be checked under cryogenic working conditions. Note : if required, test protocoles, material certificates or pressure test certificates are

included in the quality data book depending on the contract conditions.

USER’S MANUAL


1.6. Description of the Design

The pump is a single stage high speed centrifugal pump driven by an electromotor. The pump is mounted with a support to the motor flange. The pump is directly coupled to the motor shaft. For the support of the impeller, the motor bearings are of the highest precision and are fully externally sealed. The undesirable cold creep from the pump cold end to the bearings is reduced to a minimum by an insulation ring, small contact surfaces and long support arms. The pump seal is a special mechanical seal. These instructions contain a description of the pump, as well as complete descriptions of installation, operation and maintenance of the pump. Options The rear chamber of the seal can be provided with a connection for N2-purging. A temperature probe can be installed on the motor bearing for maximum and minimum temperature control. A space heater can be installed on the motor bearing.

USER’S MANUAL


2. SAFETY

2.1. Warning

Safety norms applied on site must be scrupulously respected. The enforcement of a safety area will limit access to authorized personnel

only. Any operation on equipment in use is prohibited

Any operation on equipment in use is prohibited Any normal operation must be made according to the recommendations in the instructions Any repairs must be made according to the recommendations in the instructions FATAL OR MOST SERIOUS INJURIES MAY OCCUR IF SERVICE PERSONNEL DO NOT FOLLOW THE SAFETY REGULATIONS High voltage is applied in the operation of this equipment. The use of liquid gases or gases under high pressure has high risk factors if service personnel do not follow safety regulations. Fatal or most serious injuries, fire, explosions or suffocation may occur depending on the liquid gas used in the system. Please, refer to the motor instructions

Explosion hazard in the presence of oxygen

Cleaning and degreasing for use with oxygen All components and equipment must be cleaned and degreased and must be

safe for use with oxygen.

USER’S MANUAL


After cleaning and degreasing, the components and equipment should be sealed and protected against contamination. The sealing and protection should not be removed until immediately before installation. Consult Cryostar.

Explosion hazard in the presence of oxygen !

Carefully remove all degreasing fluid, which may also be extremely hazardous in the presence of oxygen! For obvious technical reasons linked to ice formation, it is not possible to completely isolate all pump components.

Burning hazard !

During cool-down and working periods, it is strictly forbidden to touch the machine

Our products must be handled with a handling system. Please, refer to

the Installation scheme

2.2. Isolation and energy dissipation

(Maintenance)

Our products must be installed in a unit which ensures all functions of cutting, separation, locking, pressure purging and checking

All energy external to our product originating from the customer (electricity, purging gas, compressed air, N2-purging, etc...) must be isolated and dissipated by means of isolating switches (hand operated valves with padlocks, locking electric switches..). Gas line valves must be chosen

USER’S MANUAL


carefully so as to permit a VOLUNTARY locking or unlocking of the user with valve isolation.

2.2.1. Isolation and dissipation of gas process energy Components and instruments which permit the isolation and the dissipation of the gas process energy depend on the users internal procedures of isolation and energy dissipation and the parameters of their networks. Thus, it is not possible for CRYOSTAR to plan the installation of this type of equipment on the supplied machine.

2.2.2. Isolation and dissipation of purging gas energy The user must ensure that all purging pipes have been isolated before any operation on the product.

2.2.3. Isolation and dissipation of electrical energy Before each operation on parts or equipment normally under voltage, the personnel must isolate them when the equipment is at a standstill. - Cut off and separate the equipment from the supply source by switching off. - Lock the switch in a separation position with a padlock or any equivalent locking device. The locking switch must be in an open position. - Before operation, check that there is no more accumulated residual voltage (Note : All orange coloured electrical circuit of the electrical equipment supplied by CRYOSTAR remain permanently under voltage).

All electrical operation should be carried out by trained and authorized personnel. The electrical connections must be connected by trained and empowered personnel who must respect the local regulations and protection rules in force.

USER’S MANUAL


2.3. Safety form for oxygen pump

Physical properties: . Formula : O2 . Atomic number Z=8 . Molecular weight : 31.9988 g.mole-1 . Molecular dimensions : 4,2-2,8Å . First ionization potential : 12.059 eV . Gas density S.T.P. : 1,4289 kg.m-3

Oxygen is a gas colorless, odorless and testeless.

Working recommendations : . No smoking near the pump. . Oil and grease stained clothing must not be worn. . Greasy rags should not be left lying about and the floor must be free of oil stains. . Work with flame should be avoided in the enclosure of the pump.

Recommendations in case of accident (fires, burnd) : In case of clothing fires, it is essential to act with maximum speed. Water is still the best extinguisher in several cases. Hence quick action with a shower, bath or extinguisher is necessary. It appears that hasty wrapping in a blanket is of doubtful effectiveness.

First aid for burn victims (low temperatures of liquid oxygen) :

Burns of this type are generally local. Burnt parts of the body should be warmed gradually and then treated as conventional burns. While awaiting the doctor, carry out the following first aid measures : . If large blisters have been formed on the skin or if the eyes are suffering from burns, immerse the burnt area in water or apply cold compresses, and convey the victim to a doctor. . If the injury is less serious (spattering on the skin, small blisters), immerse the burned area in cold water until the pain stops, coat the area with vaseline and keep it wet for 24 hours by means of a cold 30 g/l boric acid solution. . Do not pierce the blistes. . Do not touch or undress the victim . Do not speak to the victim face to face . If possible, wrap burnt parts of the body in sterilized compresses . Always summon a doctor immeditately.

USER’S MANUAL


. Cover the victim with a sterilized blanket.

Leak detection and analysis : Before employing a pump intended for use with pressurized oxygen, test the assembly with a leak detector such as a helium detector. The atmosphere surrounding an installation containing oxygen must be monitored for oxygen concentration. Any rise in the latter considerably increase the risk of accident. Portable oxygen analyzers may be employed.

USER’S MANUAL


2.4. Customer safety instructions - Summary

WARNING AVERTISSEMENT ACHTUNG

All operations must be carried out by appropriately trained personnel Gases and liquid under high pressure

Toutes les interventions doivent être effectuées par un personnel habilité Gaz et liquides sous haute pression

Alle Arbeiten müssen von entsprechend geschultem Personal ausgeführt werden Flüssigkeiten und Gase unter hohem Druck

LIFTING LEVAGE HEBEN

Vertical lifting : prevent uncontrolled rotation

Levage vertical : Empêcher toute rotation non contrôlée

Senkrechtes Heben : unkontrolliertes Drehen vermeiden

PRE-INSTALLATION CHECKS CONTRÔLES AVANT INSTALLATION

UEBERPRUEFUNGEN VOR DER INSTALLATION

Every pump should be checked immediately upon delivery Check nameplate details Check stored equipment every 6 months No loose fasteners

Toute pompe doit être contrôlée dès réception Vérifier les informations sur la plaque signalétique Vérifier le matériel entreposé tous les 6 mois Pas de fixations desserrées

Jede Pumpe sollte unverzüglich nach Ankunft untersucht werden Typenschilddetails prüfen Gelagertes Material alle 6 Monate kontrollieren Keine losen Befestigungen

MECHANICAL INSTALLATION INSTALLATION MECANIQUE MECHANISCHE INSTALLATION Gaskets and seals correctly mounted

Refer to instructions

Montage correct des joints et garnitures Se reporter au manuel d’instructions

Korrekte Montage von Dichtungen und Gleitringdichtungen Siehe Betriebsanleitung

ELECTRICAL INSTALLATION INSTALLATION ELECTRIQUE ELEKTRISCHE INSTALLATION

All operations must be carried out by appropriately trained personnel Earthed Check rotation, uncoupled Connections are tight ? Covers must be fitted Fused and isolated correctly Every control box with a heating band must be ‘’on ‘ Respect tightness of the control box while cabling Shut front protection covers after use

Toutes les interventions doivent être effectuées par un personnel habilité Mis à la terre Vérifier la rotation à vide Les connexions sont-elles serrée ? Les capots de protection des boîtes à borne doivent être en place Protégé par coupe circuit et isolé correctement Toute armoire électrique équipée d’une résistance chauffante doit rester sous tension Respecter l’étanchéité de l’armoire électrique lors du câblage Veiller à fermer les capots de

Alle Arbeiten müssen von entsprechend geschultem Personal ausgeführt werden geerdet Maschine in Leerlauf prüfen Sind die Anschlüsse fest angezogen ? Abdeckungen der Klemmenkasten müssen angebracht sein Korrekt abgesichert und isoliert Jeder Elektro-Schrank mit Heizband muss unter Spannung sein Beim Anschlussen des Elektro-Schrank Dichtheit beachten Nach dem Gebrauch vordere

USER’S MANUAL


protection en façade après utilisation Abdeckungen zumachen CONNECTIONS CONNEXIONS ANSCHLUESSE

Check connection diagram Check driven equipment is free Correct terminal arrangement

Vérifier le schéma de câblage Vérifier que la machine entraînée soit libre Vérifier le repérage des bornes

Anschlüsse nach Anschlussplan überprüfen Prüfen, ob angetriebene Maschine frei beweglich ist Auf einwandfreien elektrischen Anschluss achten

PROBLEMS PROBLEMES PROBLEME

Pump does not prime Rated capacity and pressure not achieved Mechanical seal leaking Vibrations

La pompe n’aspire pas Débits et pressions trop faibles Fuites garniture Vibrations

Pumpe saugt nicht Durchsatz und Förderhöhe nicht erreicht Gleitringdichtung undicht Pumpe vibriert

Pump overloads drive Moteur surchargé Pumpe überlastet den Antrieb

Bearings overheated Roulements s’échauffent Lager laufen sich heiss

Refer to supplier Consulter le fournisseur Hersteller fragen

MAINTENANCE ENTRETIEN WARTUNG Isolate

Refer to supplier for details of greasing etc...

isoler Pour les détails de lubrification etc.. consulter le fournisseur

trennen Schmierung usw. siehe Herstellungsangaben

SPARES PIECES DE RECHANGE ERSATZTEILE

Refer to supplier Quote equipment number, stock number, designation

Consulter le fournisseur Indiquer le numéro de la machine, le numéro de plan de la pièce, la désignation

An Hersteller wenden Maschinennummer, Zeichnungsnummer, Benennung angeben

HAZARDOUS AREAS ZONES DANGEREUSES GEFAHRENBEREICHE

All operations must be carried out by appropriately trained personnel Refer to: construction standard EN 294

Toutes les interventions doivent être effectuées par un personnel habilité Se reporter à: norme de construction EN 294

Alle Arbeiten müssen von entsprechend geschultem Personal ausgeführt werden Bitte nachschlagen in : Baunorme EN 294

STORAGE STOCKAGE LAGERUNG

Storage in a dry environment the right way round

Stockage en lieu sec à l’endroit

Lagerung in trockenem Raum Richtig stellen

USER’S MANUAL


3. STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION

3.1. Cryostar Delivery Inspection

Every pump undergoes a trial operation with liquid nitrogen before leaving our works, hence only perfectly functioning machines are delivered from our factory.

3.2. Degreasing and Lubricating Grease/Oil for Oxygen Duty

Pumps labelled 'degreased for running with oxygen' may be run with oxygen without further treatment. They are delivered with a grease/oil suitable for oxygen service. Pumps delivered, by customer request, with mineral grease, are labelled 'not for oxygen'.

3.3. Inspection by Customers on Arrival

Every pump should be checked immediately upon delivery, and any damages incurred during transportation should be reported immediately to the transporters or to Cryostar. Refer to Sales Conditions, Incoterms, Issue 1990.

3.4. Storage of the Pump

If the pump is not for immediate use, it must be stored in a dry environment, protected from oil, dust and water.

Important: The polyethylene wrapping around the pump, and the protective covers on the pipe connections should only be removed immediately before installation.

CAUTION: Check stored equipment and spare parts at regular intervals e.g. every six months at minimum. Any moisture, dust, rust etc. must be removed before use. Note, parts for oxygen service which are stored or installed for more then six months prior to use must be dismantled and checked carefully prior to start-up. The time period given above is our recommendation only and must be adapted to the users own safety regulations. Fatal or most serious injuries may occur if service personnel do not follow the safety regulations.

USER’S MANUAL


4. INSTALLATION

4.1. Handling

Every machine that weights more than 55 kg must only be handled with a Handling System. Please refer to Handling drawing. PUMP TYPE HANDLING DRAWING No. Weight ≤ 500 Kg Pump with gearbox

708111520

Weight ≤ 500 Kg Pump without gearbox

708114352

VCS 705113963 LOX 705104881 CBSH 705111521

4.2. Erection

Place skid on a flat surface that has been prepared according to the dimensional layout drawing and capable of supporting the indicated load. Secure the skid to the surface with the required amount and size of bolts as indicated in the foundation drawing. The skid to be preferably grouted to limit vibration. The stability of the whole installation must be ensured.

4.3. Installation Scheme

The enclosed installation schematic drawing and operating instructions on the following pages apply in normal operating circonstances only. Therefore, they are relatively general and only the most important points for all different service applications are mentioned. The installation schematic drawing shows only indispensable equipment and piping for the operation of a pump for liquefied gases and should be completed accordingly for different applications.

4.4. Storage Tank

Most suitable is a pressurised storage tank which maintains the required NPSH of the pump (see par. 10.1). The machine must be installed as close as possible from the tank. The tank discharge connection should be in the bottom of the tank and short. A syphon or plunging pipe are unsuitable as gas which is formed in the line is collected and cannot leave the pipe.

USER’S MANUAL


The diameter of the tank discharge connection should be adjusted to the flow. It should not be too small (minimum diameter same as the pump suction connection) to keep the pressure drop small.

4.5. Piping

Piping must be carefully designed so as not to transmit any stresses or forces to the pump during operation or during stand still. Temperature contractions and elongations must also be taken into consideration. For this reason, flexible pipe parts should be installed.

4.5.1. Suction Line The suction line connects the tank discharge and the pump suction connection and should be as direct and as short as possible. The pipe must have a constant downwards inclination to the pump to allow forthcoming gas to return into the tank. The pipe diameter should be selected and designed for flow with an average velocity of approx. 1 m/sec. Smaller velocities reduce the friction losses, but disadvantageously increase the heat inleak accordingly. This reduces the available NPSH (see par. 10.1) and increases the gas vaporization loss during the cool down period. Good insulation is therefore essential. But it should not hinder the movements of flexible pipe parts (flexible hose). In view of gas vaporization losses the shut-off valves and the filter should not be too large, as larger sizes mean increased heat inleak and longer cool down time. Pumps for oxygen service must be protected against foreign particles by a filter in the suction line. Particles, which enter the pump are a potential fire or explosion hazard. The filter should have approx. 560 micron mesh and the useful surface should be two times the suction pipe area at minimum. Manifolds without a constant liquid flow should be shut-off as close as possible to the branch in order to minimize the liquid gas vaporization. All piping sections which can be shut-off must be equipped with safety valves to avoid excessive pressure increase due to the vaporization of liquid gas.

USER’S MANUAL


4.5.1.1. Design of the suction line Installation of the suction line • The pipe must be as short and direct as possible • Well insulated and applying no force to the pump • Same diameter as the pump suction connection (also fittings and valves) • Fitting and valves limited to a minimum • Constant inclination downward to the pump Required Fittings and Valves • a) Shut-off valve • b) Safety valve • c) Flexible pipe section • d) Filter for oxygen service (only if the pump is used with oxygen) • e) Non-return valve on the pump discharge Recommendations • e) Shut-off valve in every branch • f) Pressure gauge • g) Gradual pipe diameter changes branch connections • h) Dérivaton oblique • Filter even for non oxygen service • k) Insulation

4.5.1.2. Suction line : Installation Errors

Possible Installation Errors

Trouble

Abrupt pipe or valve diameter changesPressure drop

Pressure drop

Narrow bends, T-branches Pressure drop Long pipe without insulation Pressure drop and heat inleak Branch shut-off walve not close enough, branch pipe not insulated

Gas formation, the gas will be sucked into the pump or the suction line will be clogged

High point in the line Gas accumulation, gas bubbles will be sucked into the pump or the suction line will be clogged

Flexible elbow Additional force Lack or filter or safety valve Pump or seal failure possible

Note: Pressure drop, heat inleak = lowers the NPSH

4.5.2. Discharge Line The discharge pipe should have the same diameter as the discharge connection of the pump, or somewhat larger for longer piping and when excessive pressure loss would restrict the flow too much.

USER’S MANUAL


The discharge line characteristic must be put into consideration with the pump characteristic curve! A shut-off valve, a non-return valve and pressure gauge should be installed in the discharge line.

4.5.3. Bypass Line For faster cool down and for easier start-up a bypass line should be provided. The bypass pipe should have the same diameter as the pump discharge line or should be designed for the pump minimum flow.

4.5.4. Vent Line A vent pipe with shut-off valve is advantageous for the venting of piping and pump and for faster cool down.

4.6. Valves and Fittings

All valves, fittings, filters, manometers, etc.. must be adapted to a company’s own internal safety regulations and must also correspond to health-safety legislation.

For any damages caused by unsuitable assembly of the piping system, CRYOSTAR cannot be held responsible.

USER’S MANUAL


5. LUBRICANTS

The following lubricants should be used: Motor-bearing Grease For oxygen service ESSO Beacon 325 For service with argon, nitrogen or hydrocarbon

ESSO Beacon 325

Caution: Because of explosion risk, do not use normal, commercially mineraloil-based lubricants for oxygen service.

5.1. Characteristics

ESSO BEACON 325 CHARACTERISTICS UNIT AVERAGE VALUE Appearance creamy smooth grease Soap base Lithium Temperature range -55 to 120°C Base oil synthetic ester Kin. viscosity at 40°C at 100°C

cSt cSt

11.8 3.25

Drop point °C 180 Penetration-unworked 260 Penetration-worked x60 280 Bearing performance against corrosion Test NF T 60-135

0

Resistance to water washing out at 40°C Loss

% wt

1

Tests on bearings at high temperature Test FTMS 791 b-331-2 at 120°C

h

>1000

Vaporization losses Test ASTM D 972 (22 h à 121°C), loss

% wt

0.5

USER’S MANUAL


6. START-UP

6.1. Pre-Start-Up Inspection

Check whether all pipes, fittings, fixing bolts and electric connections are ready for start-up. Prepare the complete system, in which the pump is installed for start-up. For gearbox driven pumps, check the oil level.

6.1.1. Spin Test by Hand Spin the pump by hand using the slinger ring on the pump shaft or an offset spanner on the motor fan screw to control the rotation.

6.1.2. Direction of Rotation Start the motor for a short run (the pump must not be operated without liquid!) and check whether the pump shaft rotation is the same as the arrow direction on the pump volute.

6.1.3. Vent

CAUTION BEFORE OPERATING THE PUMP, ALL SUCTION LINES, DISCHARGE

LINES AND THE PUMP SHOULD BE VENTED SO AS TO PREVENT HUMIDITY OR ICE FROM BUILDING-UP IN THE PUMP DURING THE

COOL DOWN PERIOD

THE LENGTH OF TIME FOR THIS WILL VARY DEPENDING UPON LOCAL CONDITIONS : ONE DAY MINIMUM after a long break

6.1.4. In labyrinth pump : centering labyrinth rings Caution : For labyrinth pumps, loosen the labyrinth seal cover screws. Turn pump on end i.e. rotate the shaft manually to ensure that it rotates correctly and to ensure the self-centering of the labyrinth rings. Then, the cover screws of the labyrinth seal may be definitively tightened-up.

USER’S MANUAL


6.2. Cool-down and Start-up of the Pump

(see drawing 'Flow diagram')

W A R N I N G The pump must not run without liquid!

Safety clothes, gloves, spectacles, etc... according to « On-Site » regulations

Do not touch the equipment while in use

Warning : Pumps with mechanical seal

Before cooling down, purge the mechanical seal with dry nitrogen for at least 10 minutes to prevent moisture ingress into mechanical seal area causing freezing together of seal faces. The mechanical seal purging tubing must be in stainless steel or in copper. The gas must be clean. Refer to ‘Suction pressure and mechanical seal’. Warning : For labyrinth pumps, see Starting and pressure regulation of seal gas Warning : Pumps with lantern N2-purging In operation and especially during cooling down period, the warm box must be purged with gaseous nitrogen to prevent motor bearing and pump end from freezing. The nitrogen purging pressure must be 0.15 barg. It must be started before cooling down the pump. Nitrogen gas must be dry. Dew point: -80°C Warning : Pumps with protection chamber N2-purging The nitrogen purging pressure must be 0.15 barg. Purging in operation and during cooldown of the pump is necessary. Open seal gas inlet which must be dry nitrogen. Warning : Pumps with motor front bearing heater Heater must be electrically powered. Open suction valve and bypass valve 6 slowly. Liquid flows from storage tank into the pump and cools it down. During the cool-down period the pressure regulating valve 4 is closed and the bypass valve 6 open.

USER’S MANUAL


When cooling down, start the pump every 2-3 minutes for a short run of 2 to 3 seconds. This prevents contact freezing of the sealing surfaces. During cool-down the storage tank pressure rises. This improves the pump start-up conditions due to improved NPSH - see section NPSH. When a ventline with block-valve against air inlet is installed in the discharge or bypass line, cool-down can be accelerated by venting the gas into the atmosphere. Do not open the shut off valve for too long a period, otherwise the storage tank pressure will drop too much. Normally the pump will be cooled down after 10-15 minutes. The white frost from the pump body then begins to extend to the four support arms. If the pump is overcooled (support arms completely frosted) it should be started only after the shaft has been checked for freedom of rotation. After the pump is well cooled down fully open the suction valve. If one is installed, close the ventline and block valve and regulate the bypass valve according to the diameter of the pipe. Start the pump. Adjust to the required discharge pressure with bypass valve 6. Then simultaneously open pressure regulating valve 4 and close bypass valve 6. This starts liquid gas delivery to the consumer. Do not control the flow with the suction shut off valve! This valve must remain fully open during operation. Partial closure will decrease the available NPSH and could disturb the trouble free operation.

6.3. Suction Pressure and Mechanical Seal

For good priming and trouble-free operation every liquid gas pump needs a certain net positive suction head (NPSH), i.e. some over pressure above the liquid gas vapor pressure in the pump suction nozzle (see also section 10.1 - NPSH). Sometimes the geodetical head of the tank (the liquid column above the pump suction nozzle) is not sufficient to equalize the friction losses and the heat inleak in the suction line. In such a case build-up the gas pressure in the storage tank. The necessary pressure increase in the storage tank is a function of the required pump NPSH and of the installation, and therefore it can be determined by test only. Operate the pump with the lowest possible storage tank pressure.

USER’S MANUAL


The pump mechanical seal is designed for a suction pressure of 5 bars. Keep the pump suction pressure as low as possible. This improves the life time of the mechanical seal.

6.4. Shut-down of the Pump

(see drawing 'Flow diagram') For shutdown this sequence should be followed: 1. Shut-off the motor, open the bypass valve 6 and close the pressure regulating valve 4 2. Close the suction valve 3. After the pump has been defrosted, close bypass valve 6

USER’S MANUAL


7. TROUBLE SHOOTING

Trouble Probable Cause Trouble Shooting Pump does not prime, Insufficient cool-down Continue the cool-

down or the priming is of the pump or insuffi- or increase suction lost cient suction pressure pressure (NPSH) (insufficient NPSH) Vapor pocket in the Vent the gas from

the suction line liquid gas line Contamination in the Purge inner parts of pump cold end with clean gas and dry; or dismantle and clean Worn-out parts Repair/overhaul cold end Wrong direction of Exchange two phase rotation leads on motor

Mechanical seal Pump suction pressure Reduce the pump leaking too high suction pressure to prescribed value Mechanical seal pre- Increase the preload load too low to prescribed value Mechanical seal ring Exchange the seal worn-out

USER’S MANUAL


Trouble Probable Cause Trouble Shooting Rated capacity Pump does not prime Improve suction and/or pressure not well conditions, clean the achieved suction filter Vapor in suction line NPSH not sufficient Impeller or volute Clean the clogged passages clogged parts Wear rings worn, Exchange worn or impeller damaged damaged parts Discharge system back Check the pump and pressure higher than system characteristic rated curves and improve

the system piping Pump/Motor speed in- correct

Pump overloads drive Drive rating insuffi- Exchange the drive cient Pump noisy, internal Repair the pump rubbing noise Flow higher than rated Reduce the flow Low voltage Increase voltage to rated value

USER’S MANUAL


Trouble Probable Cause Trouble Shooting Pump vibration Pump cavitating Improve suction conditions Pump operation below Increase flow to the minimum recommended minimum value flow Impeller clogged, un- Clean, balance rota- balance ting parts Pump fixation and/or Improve fixation foundation not rigid

enough and/or foundation

Mechanical parts worn- Exchange worn-out out (bearings, impel- parts ler, gears etc.)

Bearings over- Bearings too tight or Use prescribed heated or wearing preload too high bearings and right rapidly preload Improper lubrication Improve lubrication, check lubricant flow passages Dirt or water in Clean or exchange bearings bearings Too high vibration Reduce vibration as prescribed above

USER’S MANUAL


8. MAINTENANCE INSTRUCTIONS

8.1. General

The following maintenance instructions are sufficient in normal use. Estimates and proposals for spare parts and revisions will be supplied upon request. Nevertheless it is not recommended nor practical to attempt to completely overhaul it due to the close tolerances and precision finishes of the interior components. When extensive overhaul works or complete revisions are necessary, we recommend that the help of our service engineer is requested.

WARNING Before use, ensure that the pump is not under voltage and that it is not cold. If necessary, the installation must be isolated and the energy must be dissipated according to safety procedures.

WARNING Before use, ensure that no impurity enters into the pump or the pipes.

8.1.1. Assembly / Disassembly : Table of tightening torques and forces After manual tightening, the end tightening must be made with a torque wrench, at 75% of the limit of elasticity or at the drawing value.

USER’S MANUAL


Torques and forces for Bolts of type H, in stainless steel, class A1, A2, A4 Bolts class of resistance: 70

Torque (Nm) Max

Standard

Force (Nm) Max.

Standard

M6 5.9 5 6.85 6 M8 14.5 12 12.6 11 M10 30 25 20 17 M12 50 42 29.1 24 M14 79 66 40 33 M16 121 101 55 46 M18 174 145 69 58 M20 244 203 88.6 74 M22 182 152 61.5 51 M24 234 195 70.9 59 M27 328 273 90 75 M30 445 371 109.4 91

Bolts class of resistance : 80

Torque (Nm) Max

Standard

Force (Nm) Max.

Standard

M6 8 7 9.13 8 M8 19.3 16 16.7 14 M10 39.4 33 26.6 22 M12 67 56 38.8 32 M14 106 88 53.3 44 M16 161 134 73.3 61 M18 232 193 92 77 M20 325 271 118.1 98

Torques (Nm) for hexagon socket flat or small head cap screws in stainless steel, class A2, A4

Screw type

Din 6912 Chc 70 Max

Standard

Din 7991 Fhc 70 Max.

Standard

Din 7991 FHc 70 Max

Standard

M6 5 4 5 4 5 4 M8 12 10 7 6 8 7 M10 24 20 21 18 20 17 M12 40 33 30 25 33 28 M14 66 55 0 50 42 M16 110 92 66 55 55 46 M18 M20 170 142 120 100 75 63 M22 M24 235 196 200 167

USER’S MANUAL


8.2. Periodical Revisions and Maintenance

To ensure trouble free operation over long periods the following maintenance works must be carried out: - Every 1000 hours of operation or annually Dismantle the pump completely, change damaged parts, clean all parts. - Lubricants See the section 'Lubrication'. The time limits given above should be adapted to the type of pump operation, the atmospheric exposure, the internal operating practice and operating experience. The given time limits are a recommendation only.

USER’S MANUAL


8.3. Dismantling of the pump

(see drawing 'Cold End') Dismantle the pump carefully and in the following sequence: - Disconnect the electrical connections and electrical accessories - Remove the suction-, by-pass-, discharge-and vent lines, fitting 29, etc. - For further dismantling , prepare clean work place (cover the work table with new paper) - Remove screws 1 with its spring washers 2 - Remove the pump casing 4 - Remove the flexitallic gasket 3 - Remove nuts with its washers (parts 8,9,14) - Pull-off carefully the inducer 6 of the pump shaft - Pull-off carefully the impeller 10 of the pump shaft - Remove keys 7, shim 18, seal ring 11 and shim 13 - Unscrew the mechanical seal clockwise (left thread) from intermediate piece 5 For dismantling or tightening the mechanical seal use only the special tool drawing no. 768026005. CAUTION Using other tools to screw or unscrew the mechanical seal could damage the seal ring or the whole mechanical seal and must therefore be avoided. - Remove screws 15,16 - Remove the intermediate piece 5 with its back-up rings - Push off the thermal insulation 20 and back-up rings 22 - Dismantle the screws 25,28,17 between the motor flange and the support and dismantle the support 27 - Dismantle the slinger ring 23 of the shaft - Remove pin 26 and push off the pump shaft 21

8.4. Assembly of the Pump

Assemble the pump in the reverse of the stated dismantling sequence. The following care should be taken: The mechanical seal ring and the seal ring must be lapped to best surface quality. Assemble the mechanical seal very carefully, so that its tightness is guaranteed during stand still as well as in operation. The seal bellow must be dry.

USER’S MANUAL


Do not damage the O-ring. Before assembling the pump, carefully clean all pump parts and any changed parts. For a pump in oxygen service, all parts must be degreased. The flexitallic gasket between pump housing parts must be carefully inserted and the screws tightened crosswise. Check the freedom of rotation of the pump shaft. For special position of the pump discharge nozzle turn the pump housing against the support. Never turn the support against the motor flange.

8.5. Adjustment of the Mechanical Seal

Screw the mechanical seal into the pump casing in an anticlockwise direction using the special tool. CAUTION Left thread. Do not forget the O-ring seal. Push the mobile ring smoothly on the shaft towards the sealing ring. Measure with a precision depth gauge the distance between the shaft end and the mobile ring. Press the mobile ring up against the mechanical seal up to the shoulder shaft. Measure the distance between the shaft end and the mobile ring as before. The difference between both measured distances is the preload of the mechanical seal. The correct preload is listed on the checklist. Adjust to the correct preload with shims between the shaft shoulder and the sealing ring. Caution: When the sealing ring is partially worn, adjust the preload so that the sealing ring is beyond the shoulder of the mechanical seal housing.

USER’S MANUAL


9. CRYOSTAR’S MAINTENANCE AND SPARE PARTS SERVICE

9.1. Order Instructions

Lists of spare parts are enclosed with these instructions. On each sectional drawing, the spare parts are marked with item numbers corresponding with those on the spare parts list; on the spare parts list, stock part number and designation are added to each item. It is advisable to always keep in stock the spare parts recommended in these lists; you may save unwelcome waiting time. When ordered the spare parts, please indicate the following: 1.Equipment number 2.Stock number of the required part 3.Designation of the required part When extensive overhaul works or complete revisions are necessary, we recommend return of the machine to our works or that the help of our service engineer is requested.

USER’S MANUAL


10. ANNEX

10.1. NPSH

NPSH = ”Net positive Suction Head” = difference between the static pressure (Ps) and the actual vapour pressure (Pt) of the vapourfree liquid in the suction nozzle of the pump. To allow a cryogenic pump to start and operate correctly, a specific NPSH must be available. The NPSH in the suction nozzle of the pump has to prevent local vaporization of the liquid and can also be described as relative undercooling ( DT). The actual vapour pressure (Pt) is determined only by the temperature (Ts) in the suction nozzle of the pump, expressed in meters of liquid head.

The required NPSH (=NPSHr) must be available during starting as well as during operation of the pump. The available NPSH (NPSHa) in the suction nozzle of the pump can be attained or improved by: - Increasing the static liquid head - Relative undercooling of the liquid - Pressure built-up in the tank over the actual vapour pressure - Better insulation of the piping - Reduction of pressure loss in the piping

USER’S MANUAL


The necessary NPSH must be guaranteed during start-up as well as under service conditions of the pump. The necessary NPSH in the suction nozzle may be reached or improved by: - Increasing the static liquid head (higher position of the tank) - Undercooling of the liquid - Pressure increase in the tank - Better piping insulation in the given installation - Reduction of piping pressure

USER’S MANUAL


10.2. Appendix to spare parts lists

P U A B Ref. No. Explanation

Position on drawing

Quantity of parts per unit

Parts subject to normal wear to be kept on stock, to be replaced at each disassembly

Commissioning spares

Recommended spare parts for 2 years operation

XXXXXXXX Stock number

IMPORTANT : The prices are subject to change without previous notice. The prices are net, in French currency, for supply ex works, including packing, excluding any customs duties or taxes. The handling charge for orders under Ffr. 250,00 is Ffr. 100,00 per order.

Every part should be replaced by a CRYOSTAR genuine part. CRYOSTAR accepts no responsability if these rules are not respected.

USER’S MANUAL


10.3. Documentation

CRYOSTAR Ref. DESIGNATION CRYOSTAR DOC. Safety valves must be set every year

LEAFLETS

792605195-01/004 Motor Leroy Sumer 56

Use

r:B

ill o

f Mat

eria

l/ N

omen

clat

ure

Pos

quan

tity

Fact

orU

nit

P/N

Des

crip

tion

ID

Mat

eria

lD

imen

tions

printed on: 04FEB09 12

Page: 1

ROBLEDS

Valid BOM

Created:14DEC07 by:ORTEGAC

List

P/N

: 7

6315

0972

-02

CO 120-6.4 C/O-FC, PUMP ASSEMBLY

Updated:14DEC07

001

1.000

1.000740150336

PC

Plate Insulating

-----------------------------------------------------------------------------------------------------------------------------------------

002

1.000

1.000769111843

PC

Welded support

-----------------------------------------------------------------------------------------------------------------------------------------

003

1.000

1.000740081885

C

PC

Pump casing (from casting)

-----------------------------------------------------------------------------------------------------------------------------------------

004

1.000

1.000798160823

PC

Spiral wound gasket

-----------------------------------------------------------------------------------------------------------------------------------------

005

1.000

1.000740150332

PC

Casing Cover CO120

-----------------------------------------------------------------------------------------------------------------------------------------

006

1.000

1.000740108277

PC

Isolating ring

-----------------------------------------------------------------------------------------------------------------------------------------

007

1.000

1.000730000169

PC

O-ring

-----------------------------------------------------------------------------------------------------------------------------------------

008

1.000

1.000798250060

PC

Mechanical seal

-----------------------------------------------------------------------------------------------------------------------------------------

009

1.000

1.000740026827

B

PC

Sealing ring

-----------------------------------------------------------------------------------------------------------------------------------------

010

1.000

1.000740104736

PC

Shim

-----------------------------------------------------------------------------------------------------------------------------------------

011

1.000

1.000740026828

E

PC

Shim

-----------------------------------------------------------------------------------------------------------------------------------------

012

2.000

1.000795080919

PC

KEY

-----------------------------------------------------------------------------------------------------------------------------------------

013

1.000

1.000740027146

B

PC

Impeller from casting

-----------------------------------------------------------------------------------------------------------------------------------------

014

1.000

1.000740026826

C

PC

Inducer

-----------------------------------------------------------------------------------------------------------------------------------------

015

1.000

1.000740150333

PC

Shaft CO120

-----------------------------------------------------------------------------------------------------------------------------------------

016

1.000

1.000740111839

PC

Slinger ring shaft

-----------------------------------------------------------------------------------------------------------------------------------------

017

1.000

1.000730001637

PC

Hexagon socket set screw cone point

-----------------------------------------------------------------------------------------------------------------------------------------

Use

r:B

ill o

f Mat

eria

l/ N

omen

clat

ure

Pos

quan

tity

Fact

orU

nit

P/N

Des

crip

tion

ID

Mat

eria

lD

imen

tions

printed on: 04FEB09 12

Page: 2

ROBLEDS

Valid BOM

Created:14DEC07 by:ORTEGAC

List

P/N

: 7

6315

0972

-02

CO 120-6.4 C/O-FC, PUMP ASSEMBLY

Updated:14DEC07

018

1.000

1.000795080954

PC

Spring type straight pin

-----------------------------------------------------------------------------------------------------------------------------------------

019

1.000

1.000709058819

A

PC

Hexagon socket head cap screw

-----------------------------------------------------------------------------------------------------------------------------------------

020

1.000

1.000795061119

PC

Conical spring washer

-----------------------------------------------------------------------------------------------------------------------------------------

021

1.000

1.00072AP01002

ML

Wire

-----------------------------------------------------------------------------------------------------------------------------------------

022

8.000

1.000730150315

PC

SCREW, HEX HEAD, M8 x 30MM SS

-----------------------------------------------------------------------------------------------------------------------------------------

023

8.000

1.000730002188

PC

Spring washer

-----------------------------------------------------------------------------------------------------------------------------------------

028

4.000

1.000730150314

PC

SCREW, HEX HD, 1/2"-13 x 1.25" SS

-----------------------------------------------------------------------------------------------------------------------------------------

029

4.000

1.000730150154

PC

WASHER, LOCK 1/2" , 18-8 SST

-----------------------------------------------------------------------------------------------------------------------------------------

030

4.000

1.000769150042

PC

Flex Hose 1/4 ODx10lg

-----------------------------------------------------------------------------------------------------------------------------------------

031

6.000

1.000730150309

PC

SCREW, SOCKET HEAD CAP, M10 x 65MM

-----------------------------------------------------------------------------------------------------------------------------------------

032

6.000

1.000730000005

PC

Spring washer

-----------------------------------------------------------------------------------------------------------------------------------------

033

1.000

1.000792605195-01/004

PC

Asynchron-Motor for variable speed

-----------------------------------------------------------------------------------------------------------------------------------------

034

1.000

1.000791564839

PC

Coupling male - BW, conical seal

-----------------------------------------------------------------------------------------------------------------------------------------

035

1.000

1.000730150353

PC

NAMEPLATE, CENTRIFUGAL PUMP

-----------------------------------------------------------------------------------------------------------------------------------------

036

2.000

1.000740026831

PC

BACK-UP-RING

-----------------------------------------------------------------------------------------------------------------------------------------

038

2.000

1.000730150689

PC

PLUG, HEX SOCKET HEAD, 1/8" NPT

=========================================================================================================================================

Transfer Pump Manual

Documents

Transcript of Transfer Pump Manual