CONSTRUCTION OF 3rd DESALINATION PLANT AT

TUAS (SINGAPORE)

Instructions and Manuals

Citric Acid Transfer Pump and motor

Doc. Nº:PUB-WSP-GFE-152
Revision: 00 Date: 11/01/17

Done by Checked Approved

Agusti Miriam C.Ortega
 Instructions and Manuals Doc. Nº.PUB-WSP-GFE-152
Rev.00 Date: 11-01-17
Citric Acid Transfer Page 2 of 3
Pump and motor

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Instructions and Manuals Doc. Nº.PUB-WSP-GFE-152
Rev.00 Date: 11-01-17
Citric Acid Transfer Page 3 of 3
Pump and motor
 CE

INSTALLATION,
OPERATION
AND
MAINTENANCE MANUAL
CENTRIFUGAL PUMP
Serie BN Generation 2000

ISO 2858 - NFE 44121 - EN 22858

De. 10/11 FA.1260

Casals Cardona Ind. S.A.
MAIN OFFICE : F. Casablancas, 24 - 08243 MANRESA Tel. + 34 93. 874.84.80 Fax. + 34 93 875 76 68
e-mail : tecnium @tecnium.es
Website : http://www.tecnium.es
 INDEX

1. Introduction - General comments on the equipment supplied

1.1. General notes

1.2. Principle of operation
1.3. Guarantee
1.4. Motor

2. Packaging. Handling and instructions for loading

2.1. General notes

2.2. Packaging
2.3. Storage
2.4. Long Term Storage Instructions
2.5. Maintenance During Prolonged Storage Periods
2.6 Handling and hoisting

3. Installation instructions

3.1. General notes

3.2. Preliminary checking
3.3. Erection instructions
3.4. Adjustment and calibration
3.5. Disassembly instructions
3.6. Assembly

4. Operating instructions

4.1. Operations prior to start-up

4.2. Start-up of the pump
4.3. Normal Operation Requirements
4.4. Equipment shut-down

5. Maintenance instructions

5.1. General notes

5.2. Preventive maintenance program
5.3. Maintenance trouble-shooting chart

6. Basic repair instructions

6.1. General notes

6.2. Spare part replacement and basic repair techniques

7. Safety

7.1. Safety instructions

8. Equipments for use in potentially explosive atmosphere

8.1. Users’ obligations

8.2. Non aired cavities
8.3. Mechanical contacts
8.4. Impeller
8.5. Overheat
8.6. Overpressure
8.7. Ground connection
8.8. Electrostatic charge

9. Enclosures

9.1 Part List of the pumps.

9.2 Part List of the mechanical seal
9.3 Assembly tolerances and fixation shaft.
1. INTRODUCTION - GENERAL COMMENTS ON THE EQUIPMENT SUPPLIED

1.1. GENERAL REMARKS

The TECNIUM pump "BN" series is designed and built for pumping up chemicals in liquid state
with a specific weight, viscosity, temperature and other physical properties that allow handling by
a centrifugal pump in a stationary installation. The properties of the liquid (pressure, temperature,
chemical aggressivity, specific weight, viscosity, vapour pressure) and of the environment must
be compatible with the characteristics of the pump, which are defined according to the
customer's order. Impeller (item M3) and body (item M9) are in contact with the fluid and are
made of thermoplastic material. The rest of components are made of highly chemical resistant
materials.

The pump performance (flow rate, total head, r.p.m.) is set according to the customer's order and
features are shown on the rating plate.

The TECNIUM pump "BN" series, built according to ISO 2858 Standard, is a centrifugal,
horizontal, single stage pump; pump shaft with own support, coupling to asynchronous electric
motor through coupling plate and spacer, with axial suction nozzle and radial discharge, support
feet of the pump body and the frame for attachment to the baseplate (item 5) as per ISO 3661
Standard.

The pump "BN" series is not a self-priming pump.

The pump "BN" series cannot run dry.

The liquid to be pumped may contain up to a 5 % max. of non abrasive solid particles which must
be smaller than 0,1 mm max.; no filamentous nor adhesive elements are allowed. Occasionally,
solids of maximum 0,5 mm may be allowed.

The rotation is clockwise viewed from the motor side.

Make sure that the physical-chemical properties of the liquid have been correctly evaluated.

The value of the kinematic viscosity must not exceed 40 cps in order to avoid substantial
modifications of the performance. Values up to max. 120 cps are admissible, adjusting impeller
and motor accordingly and to be defined as per the customer's order.

Maximum temperature of the liquid in continuous operation depends on the type of material (see
code shown on the rating plate):

40º C material type PVC code VV

60º C " type PE " RR
70º C " type PP " KK
85º C " type PP/PVDF " KL
100ºC " type PVDF " LL
130ºC " type E-CTFE " YY

Above values may vary according to the operating pressure.

Any Spare parts and/or Accessories which are not supplied, have not been tested or authorised
by Casals Cardona, we do not accept any guarantee or responsibility.

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 The environmental temperature range depends on the type of material (code shown on the rating
plate):

0-+40º C material type PVC code VV

-30-+40ºC " type PE " RR
0-+40ºC " type PP " KK
0-+40ºC " type PP/PVDF " KL
-20-+40ºC " type PVDF " LL
-40-+40ºC " type E-CTFE " YY

The maximum pressure the pump can tolerate is one and a half times the value of the total head
when discharge is closed.

The NPSH available at the installation must be higher (at least 1 m. WG.) than the NPSH
required by the pump.

The pressure value at the seal cover, in case of a double mechanical seal, must be normally 1,5
to 2 bar, due to pressure particular compensation inside the pump "BN" series. The cooling liquid
of the seal, in case of double mechanical seal, must be clean and not cause any chemical
reaction in contact with the pump liquid.

The pump does not include any device for avoiding flowback of the impelled liquid when the
motor stops.

The protection (item 229) of the coupling must always be properly placed when the pump is
working.

1.2 PRINCIPLE OF OPERATION

• HYDRAULIC OPERATION. Same as all centrifugal type pumps, it consists of an impeller

with blades which is rotating inside a stationary body. The discharge is radial (upwards
direction, with internal deflector). This rotation causes depression at the impeller center and
forces the liquid to flow from the central suction to the discharge point, flowing through the
impeller canal where it gets the necessary energy.

• MECHANICAL OPERATION. The static stress caused by the pipes is being supported by
the metal shields (support flange (item 54) and counterflange (item 42)) of the pump body.
The pump shaft hauls directly the rotating impeller and is led by the bearings that relieve
the mechanical load of the impeller over the support. The coupling to the electric motor
(IEC form B3 fixed on common base) is made of the flexible coupling and spacer (item
275),and also a detachable protector (item 229) impeding eventual access. The spacer
allows disassembly of the rotor unit without tripping pipes or taking off the motor.

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1.3 GUARANTEE

Our pumps are duly tested before they leave our factory and are guaranteed during one year
from constructional defects or technical characteristics, provided that the conditions of use and
installation are defined by our Technical Department, which can give advice for any installation
project.

Mechanical seal elements are excluded from this guarantee.

1.4 MOTOR

Wiring

The wiring of the terminals defines the direction of motor rotation, which can be checked looking
at the cooling fan of the motor (it must be clockwise viewed from the motor side).

A three-phase motor allows two connections which are different from each other because of the
position of two of the three lead wires, independently of the kind of winding connection.

The winding of the three-phase motor (e.g. voltage (a) 230-400 V; (b) 400-690 V) must be
connected "in delta" if it is fed by the lower voltage (230 for (a); 400 for (b)),

and it must be a "star"-connection if it is fed by the higher voltage (400 for (a); 690 for (b)).

The star/delta start is used for power rates higher to 7,5 kW (10 HP) in order to favour the
mechanical pump protection.
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Degree of protection

The letters IP are followed by two digits:

The first one shows the protection against penetration of solids, i.e.:
4 means solids bigger than 1 mm.
5 means dust (eventual internal deposition does not interfere with operation)
6 means dust (no penetration at all)

The second digit shows the protection against liquid penetration, i.e.:
4 means water sprinkling in all directions
5 means flow of water in all directions
6 means sea waves and surge

According to the protection shown on the motor rating plate and the installation, it is
recommendable to provide additional protection in order to guarantee good ventilation and quick
draining of rain water.

2. PACKAGING, HANDLING AND INSTRUCTIONS FOR LOADING

2.1 GENERAL NOTES

• Suction and discharge nozzles are duly protected.

• Do not load the pump by the plastic side.
• During the transport, the pump should rest on its foot or baseplate.

2.2 PACKAGING

• The pumps are secured inside the boxes to avoid any movement during transport.
• The pumps are protected with seaworthy packing depending on the place of estimation
and shipping conditions. There will be antimoisture protection inside the boxes.
• The pump must rest on the foot or baseplate on a flat surface and supported by
three cross beams.
• The oil level indicator is duly protected.
• The boxes are marked "UP" and "DOWN" . The word "FRAGILE" are clearly shown to
avoid any damage during transport.

2.3 STORAGE

• The material must be stored in its proper box in a dry and cool place.
• The material must be unpacked at the plant where it is going to be installed.

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 2.4 LONG TERM STORAGE INSTRUCTIONS

• Because of the seaworthy package of the pumps, the pump is prepared for long term
storage, however it is recommended to not put heavy equipment on the box.

2.5 MAINTENACE DURING PROLONGED STORAGE PERIODS

• If the pump has been stored during a prolonged period, it is advised before starting- up
to check manually whether the impeller can turn free and appearantry without friction.

2.6 HANDLING AND LIFTING

• To handling and lifting the pumps use the lifting eyes provided and according to
the enclosed drawings.

3. INSTALLATION INSTRUCTIONS

3.1. GENERAL NOTES

The pumps TECNIUM of the "BN" series are specially manufactured for horizontal installation. If
possible, please always install these pumps ON LOAD at a level which is lower than the liquid to
be pumped.

If the pump is installed above the liquid level, place the pump as near as possible to the intake
point and take special care about the tightness of the suction pipe. If such kind of installation is
necessary, please consult our Technical Department.

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3.2. PRELIMINARY CHECKING

The equipment has to be installed on concrete or metallic base of adequate dimensions and
level. The surface must be clean when the pump is being installed.

Pump is supplied with a common baseplate nowithstanding it is necessary to foresee a solid

base (concrete or metallic) to secure the pump baseplate with screws.

IMPORTANT: concrete or metallic base must be perfectty levelled.

The suction and discharge pipes must have their own supports and not be supported by the
pump, thus avoiding transmission of stress and vibration.
To avoid excessive pressure loss, it is recommendable to use the following pipe minimum
diameters:

Pumps type BN supplied with motor are correctly aligned on the baseplate. However before the
starting up of the pump is advisable to check about the alignment, as during transportation or
different handlings, some misalignment may happen that can revert in a malfunction of the
equipment.

flow (m3/h) 1 1,8 4 6,3 11 24 40 75 130 200 300 600 1000

DN (mm) suction 25 32 40 50 65 80 100 125 150 175 200 250 300
minimum discharge 20 25 32 40 50 65 80 100 125 150 175 200 250

This chart refers to liquids of water like density and viscosity. For liquids of higher density or
viscosity and very long pipes, the above diameter rates must be increased.

3.3 ERECTION INSTRUCTIONS

Please follow the recommendations below when you install the equipment:

• Provide safety controller preventing from dry-running.

• It will be necessary to install flan gaskets between the suction and discharge flanges and
the pipping.
• Provide expansion compensators and/or shock-isolation at suction and discharge pipes
(especially in case of long pipes or hot liquids).
• Install a non return valve (especially in case of installations with large vertical or
horizontal pipe expansion; obligatory for installations with pumps in parallel).
• Install a discharge control valve and gauge.
• Do not install elbows and other pipe fittings, too near of the intake or discharge
points. The minimum distance is 2’5 times the pipe’s diameter.
• Perform a drainage/overflow canal surrounding the pump baseplate.
• Secure the pump by using all available anchor points at the baseplate.
• Connect a completely tight pipe to the drain plug.
• The suction circuit must be linear, plain and inclined towards the pump. Put the flow
valve.
• Do not use shock-isolation for securing the pump. It is however recommendable
for the hydraulic connections (especially for DN100 pipes or over)
• It is recommendable to install a bypass recirculation pipe if the equipment works at
very low flow rates.

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 • Leave enough space surrounding the pump for a person to walk around.
• Leave enough space at the top in case the pump must be lifted.
• Mark hazardous liquids pipes in the colours as per applicable Standards.
• Do not install the pump near of heat source.
• Do not install the pump in areas with risk to get hit by any object.
• Do not install the pump in areas with explosion risk if motor and coupling are not
prepared
• Install one pump in stand by for emergencies.
• It is recommended to provide the following in the cooling circuit for double mechanical
seals:

. pressure reducer
. inlet filter
. safety valve at the inlet
. flow control valve
. pressure gauge for checking the pressure in the seal box.
. It’s necessary a flow from 0’15 to 0’25 m3/h and one presion between 1’5 to
2 Kg/cm2

3.4 ADJUSTMENT AND CALIBRATION

• Check manually whether the impeller can turn free and appearantly without friction.
• Check if motor voltage corresponds to the mains.
• Install a thermomagnetic breaker in the service lines.
• Connect the intensity controller preventing from dry-running.
• Check if environment temperature and temperature of the liquid to be pump (according
to its physical-chemical properties) are within the range set in the introduction of this
Manual.
• Check if environmental conditions meet with the IP protection class of the motor.
• Upon testing the turning sense of the machine, it is important that this operation is
• effected activating and deactivating instantly the start/stop switch.

3.5 DISASSEMBLY INSTRUCTIONS

• Only skilled workers may perform the operations.

• Shut off the motor and disconnect wires.
• It is recommended to wear protective clothing because of the acids during cleaning and
clearing the pump.
• Clean the pump before any kind of disassembly.
• Before taking down the pump, make sure that the motor is isolated and cannot start
spontaneously.
• Open the pump following the steps below.
• When disassembling the rotor group, please follow the recommendations section.

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SEQUENCE OF DISASSEMBLY

Disassembly of rotor group-casing body unit:

1. Shut the suction and discharge valves.

2. Take off the drain plug (item 125), empty the pump and wash it with clean water.
It is quick and easy to take off the complete rotor group (impeller item M3), casing cover
(item M-8 ) and frame (item 201) from the casing body (item M9), which remains
connected to suction and discharge pipes. For this:

3. Take down the coupling (item 275).

4. Back off the screw (item 159) and pull towards the motor the frame (item 201), together
with the casing cover (item M8) and impeller (item M3).

Disassembly of casing body:

1. Disconnect suction and discharge pipes of the pump.

2. Dismantling the casing discharge flange (item 106) , and suction support ring
(item 107).

3. The pump body will be loose and placed between the plate suction end (item 42) and the
adapter (item 54).

Disassembly of the rotor group

1. Unfasten the protector of the shaft nut protector ( item 95 ) with its o-ring ( item 96) and
take out the impeller (item 243 ) , which slips on the axle and its linchpin. An o-ring ( item
97 ) insures the sealing between impeller and shaft nut protector ( item 37 ) .

2. Unfasten the screw ( item 230 )

3. Taking the shaft sleeve ( item 37 ) out the mechanical seal and the casing cover ( item
17 ) can be disassembled.

Disassembly of the frame:

1. Back off the screws (item 214).

2. Remove the covers of bearings (item 204 & 205) and sealing rings (item 223 & 210).
3. Take out the shaft (item 2) (direction pump towards motor) allowing to remove the
bearings.
4. Disassemble the bearings (item 207 & 208) using the adequate tool.

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RECOMMENDATIONS FOR DISASSEMBLY

• Screws are R.H. thread type.

• Once the rotor group is disassembled, the impeller can be separated from the shaft by
• locking this shaft and loosening the locking nut (item 47) (R.H. thread). Take out the
impeller axially.
• For disassembly of the mechanical seal, please follow specific instructions.
• Broken, cracked or deformed components must always be replaced.

3.6 PREASSEMBLY

General instructions

• Generally, all joints must be replaced before re-assembly.

• It is recommended to polish the friction sides of used mechanical seals.
• The bearing on the pump side must be placed before mounting the shaft
• Axial and radial slack as well as angular unaligning values must be lower than the
stated values for each acse, as per type and bran of the bearing.

Tightening torque for pump bolts

(in spare parts in plastic reduce decrease a 25%)

Screw size M4 M6 M8 M10 M12 M16 M20 M24

Moment in Nm 4 14 24 48 60 75 120 175

Pump group:

• Follow the disassembly procedure in reverse order.

• Check the centering of discharge and drain nozzles with plate suction end (item 42)

Frame:

• The bearings (items 207 & 208) are mounted on the shaft. They are assembled by
press or heat in order to stretch the internal ring.
• Place shaft and bearings in the frame.
• Put the bearing covers (items 204 & 205) after replacing sealing rings (items 223 &
210).
• Sealing of frame and bearing covers is secured by a special glue.

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4.- OPERATING INSTRUCTIONS

4.1 REQUIREMENTS FOR START- UP

• Check correct performance of all steps related under the section INSTALLATION.
• Before starting the pump for the first time, clean carefully the inlet of pump and
suction pipe removing any dirt that might remain from assembly and transport.
• Check if the direction of rotation is correct (see direction indicator on the pump)
by supplying short current drives to the motor.

4.2. STARTING-UP OF THE PUMP

• If it has double mechanical seal, and always provided their is recirculation liquid, the flow
valve must be open . Make sure the specific pressure is given.
• Check that the NPSH value available is higher than the NPSH value required by the
pump (particularly in case of hot liquids, high vapour pressure or long suction circuit).
• Shut discharge valve; flood completely suction pipe and pump.
• Start the pump being the suction valve completely open and the discharge valve half-
closed.
• Slowly adjust the flow with the discharge valve (never with suction valve) providing that
the motor breakaway current does not exceed the value of the rated current shown on the
rating plate.
• Do not operate at the operation curve peaks: maximum height (discharge valve too much
closed) or maximum flow rate (no pressure loss at all in the circuits).
• Lead the operation to the specific point for which the pump has been designed.
• Make sure there are no irregular vibrations or noise caused by improper attachment or
cavitation.
• Avoid too short and/or frequent starts and adjust the automatic operation properly.

Motor output: kW 0,75-5,5 7,5-30 37-110 132-200 200-350

Max. starts/h: 2-4 pole 20-40 10-20 6-12 2-4 1-2

• Make sure that conditions of temperature, pressure, liquid properties etc.

specified in the order are all met.

IMPORTANT: THE PUMP MUST NEVER RUN DRY.

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4.3. NORMAL OPERATION REQUIREMENTS

• Pump operating with discharge valve closed is to be avoided.

• Do not actuate any valve nor branch during the pump operation.
• In case of improper or improvised handling, there is a risk of damage to the
pump because of hammering (the valves must only be operated by skilled
staff).
• Empty and clean carefully the pump inside if different liquids have to be pumped.
• Isolate or empty the pump if the crystallisation temperature of the liquid is equal
or upper lower than room temperature.
• Stop the pump if the liquid temperature exceeds the maximum temperature
shown under GENERAL NOTES. If this difference is about 20 %, the internal
components must be examined.
• In case of leakage, shut the valves.
• Clean with water only in case the compatibility of chemicals allows to do so.
Otherwise use a suitable solvent that will not cause hazardous exothermic
reaction.
• Consult with your supplier of the liquid for the best fire extinguishing method.

4.4 EQUIPMENT SHUT- DOWN

• Shut the discharge valve

• Shut off the motor
• Shut the suction valve
• Clear the pump in case of large outage periods (especially for liquids with strong
crystallisation tendency).

5. MAINTENANCE INSTRUCTIONS

5.1 GENERAL NOTES

• The equipment must only be handled by skilled staff.

• The risks concerning the maintenance staff's security mainly derive from improper use or
accidental damage.

Such risks may be electric failure caused by the motor, injuries on the hands if the
worker handles the open pump or damage caused by the liquid pumped.

It is extremely important to follow the instructions of this Manual in order to avoid the
causes of such incidents that might lead to breakage of the pump, escape of
hazardous liquids and cause danger to people and the environment. Follow strictly
the disassembly and maintenance instructions.

• The equipment must only be handled by skilled staff.

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 • The following major interventions may be performed by non qualified workers (after being
trained for proper use of the installation):

. starting /stopping the pump

. opening / shutting the valves
. emptying and cleaning the pump body
. cleaning of the filter elements

• Interventions to be performed by skilled staff (necessary training: general knowledge of

mechanics, electricity, installation and the pump itself):

. checking the environmental conditions

. checking the conditions of the pumped liquid
. inspection of the rotating parts of the pump (rotor group)
. detecting troubles
. inspection of the start/stop mechanism

5.2 PREVENTIVE MAINTENANCE PROGRAM

• Filter elements , nozzles and other circuit elements every 1-2 months.

• Rotating pumps parts ( rotor group ) every 5-6 months.

• Levels and elements of control every 5-6 months .

Lubrication

• Every 300 hours of operation, check the oilier level (100 cc).

• Change the oil every 2000 hours of operation (600 to 1.200 cc ). according to
the pump dimension.

• Choose the lubricating oil for its viscosity, ensuring proper lubrication at normal
operating temperature.

• The pump you receive is completely assembled, but without oil (frame empty). After
testing the pump, it is emptied for shipment. Please fill the pump with the following oil
types:

• Fill-up with oil through oil-filler pos 252 located on the top of the frame, since the oil
appears at the bottom of the oiler pos 221 (tooggling the transparent pot)

• Fill-up after the transparent pot and return it to its normal position. In case of being
necessary, do this step again in order to have a stabilized level in the transparent pot

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Control of level : Fill-up each time the oil level go down of bottom of transparent pot.

Maximum level on
Bearing box

TRADE NAME OF THE OIL

MANUFACTURER Temperature maximum from 40º
Esso Teresso 32 Teresso 68
Cepsa HM 32 HM 68
Shell Tellus 32 Tellus 68
Tribolube Tadalfluid HM 32 Tadalfluid HM 68
Repsol Telex 32 Telex 68

Viscosity 32 Viscosity 68

• Standard : ISO 6743 • Standard : ISO 6743

• Viscosity at 40º C. : 32 cSt • Viscosity at 40º C. : 68 cSt
• Burning point : > 180º C. • Burning point : > 213º C.
• Temperature maximum :100º C • Temperature maximum : 110º C
• Maximum rpm: 4000 • Maximum rpm: 4000

5.3 MAINTENANCE TROUBLE-SHOOTING CHART

• If liquid appears underneath the pump body, it might be an indication that the machine is
damaged.

• Excessive energy consumption might be an indication that the impeller is damaged.

• Vibrations might be an indication of unbalanced impeller (caused by breakage or any

substance adhering to blades).

• Low flow rate-pressure performance might be an indication that the impeller is locked or the
motor fails.

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• We would like to point out that the main reason of damage to the pump and
consequently repair is dry-running in manually operated installations, usually caused by:

. not opening the suction valve when starting the pump

. no liquid flow because intake tank is empty.

Anomaly Possible reasons Case Solutions

Badly primed pump 1 Liquid must flood the impeller of
the pump
Excessive totalhead or 2 Move the pump at a lower level
pressure drop in the Reduce flow closing discharge
suction side valve
Increase diameter and reduce
length of suction pipe
Pump does Not enough service 3 Increase pressure closing
not deliver pressure or suction pipe discharge valve
empty
Air leaking or air 4 Check suction pipe: o rings,
presence in to discharge flanges, welding, slopes,...
pipe
Specific gravity and/or 5 Decrease suction head
vapour pressure higher Restore specified conditions
than the ones specified
Make a test with water
Motor turning sense 6 Change motor connections
wrong
Suction pipe or impeller 7 Check and clean
are partially obstructed If it is necessary dismantle the
impeller
Excessive totalhead or 8 Look at case nº 2
pressure drop in the
suction side, with
captivation risk
Pump gives Insufficient diameter 9 Widen pipe diameter or reduce
little flow pipes or excessive pipe length and heads or change
pressure drop or service pump type
pressure
Specific gravity and/or 10 Look at case nº 5
vapour pressure higher
than the ones specified
Motor turning sense 11 Change motor connections or
wrong or voltage reinforce electric wire
insufficient

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 Overcharged Low pump service 12 Close discharge valve till restore
motor pressure specified pressure

Cavitation 13 Look at cases nº 2, 5 and 7

Excessive Coupling wear 14 Replace elastic ring
noise
Bearings wear 15 Replace bearings
Excessive Bad aligned coupling 16 Adjust and align
heating of
bearings
Incorrect lubrication 17 Change oil
Seal leakage Seal compounds worn 18 Change seal compounds
according to instructions
Defective shaft 19 Check shaft assembly and
assembly alignment

6.- BASIC REPAIR INSTRUCTIONS FOR REPAIR

6.1 GENERAL REMARKS

The following generalities are always very important:

• Any operation on the pump must be performed or supervised by skilled staff.

• Use adequate anti-acid protection clothing for any operation on the pump.
• Before disassembling the pump, make sure that suction and discharge valves are closed.

Important interventions that can be performed by ordinary staff but supervised by skilled personnel:

• emptying the pump body

• disconnecting pipes
• Loosening of the pump lockscrews.
• Cleaning with water or solvent as necessary.
• Transport (the electric connections previously shut off by skilled staff).

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Interventions to be performed by skilled staff (technical requirements: knowledge of mechanical
work, capacity for evaluating the wearing of pieces caused by abrasion or corrosion, experience in
working with bolts and nuts in different materials, plastic/metal, skilled in the use of precision
measuring instruments):

• Opening and closing the pump body

• Disassembling and replacing the rotor group
6.2 SPARE PARTS REPLACEMENT AND BASIC REPAIR TECHNIQUES

• It is recommended to have a minimum spare parts stock and storage it is a dry and cool
place.
• The replacement of damaged parts must be done in a clean environment.
• Any damaged piece must be replaced by an original spare part, never by a repaired piece.
• When spare parts have to be ordered it is important to mention manufacture number.

Tolerance of the charts: Dimensions +- 7 %

Weights and measurements +- 14 %

7. SAFETY

7.1 SAFETY INSTRUCTIONS

The following instructions must be strictly observed.

This Manual contains the basic instructions which have to be taken into account for machine
installation, operation and maintenance. It must be stressed that this Manual has to be carefully read
by the responsible personnel and operators before proceeding to install and start the machine. This
Manual must be always available for consulting in the place where the machine or plant is located at
each moment.
Not only the instructions given in the Chapter Safety have to be followed, but also the specific
instructions and informations contained in the rest of Sections have to be strictly complied with.

• Manual of operation instructions.

All instructions relating to safety contained in this Manual have to be strictly followed. This is
particularly applicable to those rules that, in case of non compliance, may lead to cause injury to
persons.

It is imperative that indications attached to the machine, for example

. Arrow indicating direction of rotation

. Machine identification plate.

be strictly observed and clearly legible.

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• Personnel qualification and training.

All personnel responsible of the operation, conservation, inspection and assembly must have
adequate qualification. The level of responsibility and qualification of personnel must be clearly
defined by the Plant Manager. If the personnel do not have the required knowledge, they must
receive adequate training. This can be done by the manufacturer or supplier on request of the Plant
Manager. Furthermore the Plant Manager has to make sure that the personnel concerned have fully
understood the contents of the operating instructions.

• Risks derived from non compliance of the safety instructions.

Non compliance of the safety instructions may involve hazard to persons, to environment and to the
machine itself. Furthermore any rights derived from guarantee shall be void if safety instructions are
not complied with.
Below are a few examples of eventual consequences caused by non compliance of safety rules:

• Important failures in the machine or plant operation.

• Failures in specific procedures of conservation and maintenance.
• Risk of causing injury (of electric, mechanical or chemical nature) to any person.
• Risk of causing damage to environment because of escape of dangerous gases.

• Compliance of regulations relating to safety at work.

It is mandatory that all the instructions contained in this Manual relating to safety, the regulations in
force and applicable to the country or community regarding occupational accident prevention as well
as all the company internal operation and safety instructions are strictly followed.

• Operation related safety instructions.

• Do not remove any protection, above all those of moving parts, while the machine is
running.

• If any machine component, cold or hot, may involve whatsoever risk, take measures
to prevent accidental contact.

• Any escape of dangerous gases must be immediately repaired. The applicable

legislation must be complied with.

• Take measure to prevent eventual risks derived from power supply. The electrical
installation must comply with the regulation of Low Voltage Plants. Also refer to the
VDE regulation of the German Electricians Association. Follow the instructions
of the electricity supply companies.

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• Safety instructions related to maintenance, inspection and installation work.

The Plant Manager has to make sure that all jobs related to conservation, inspection
and installation be carried out by authorized and qualified staff. The personnel must have
enough knowledge and information about the operation instructions.
In general, all jobs of this kind must be carried out with the machine stopped and the
motor disconnected. The procedure of machine shutdown has to be carried out
according to the operation instructions.
Pumps or equipments running with harmful gases must be previously aired and
cleaned.
Once all the jobs have been completed, all protection and safety devices must be
restored.
Before restarting the machine, all recommendations mentioned in the Chapter
“Requirements for start-up” and “Start-up of the pump” must be followed.

• Modifications and fabrication of spare parts by the user himself.

Any modification or remodeling of the machine requires previous approval in writing by

the manufacturer. For safety reasons of the machine, of personnel and environment,
always use original spares parts and accessories authorized by the manufacturer.

The use of non authorized parts will release the manufacturer from any responsibility and
will cause the loss of any guarantee right.

• Non authorized operation systems.

The reliability of the supplied machine shall be guaranteed only if proper use of it is
made and instructions on operation are followed. In no case the limit values specified in
the technical data sheet must be exceeded.

8. EQUIPMENTS FOR USE IN POTENTIALLY EXPLOSIVE ATMOSPHERE

The equipments marked with the CE symbol and complementary indications comply with
requirements according to the European Directive 94/9/EC of 23rd of March, 1994 (ATEX). The
following indications have to be observed when the equipments are to be applied to the use they
are intended for.

8.1. USERS’ OBLIGATIONS

The user is obligated to classify the area in which the equipment shall be installed in any of the
Groups and Categories set out by the above Directive and the user must notify the manufacturer
or supplier accordingly upon placing the purchase order.

The Chart below shows the Groups and Categories into which the machines are classified for
use in different areas with potentially explosive atmosphere according to the European Directive
94/9/EC.

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 Groups and Categories of Equipments

Groups of equipments. (Annex I of the EC-Directive 94/9/EC)

Group I Group II
(mines, gas and dust) (Other explosive atmospheres, gas and dust)
Category M. Category 1 Category 2 Category 3

G D G D G D
1 2 (gas) (dust) (gas) (dust) (gas) (dust)
(Area 0) (Area 20) (Area 1) (Area 21) (Area 2) (Area 22)

Apparatus Apparatus Apparatus equipped Apparatus equipped Apparatus equipped

equipped equipped with high protection with high protection with ordinary protection
with high with high level when they are level when they are level when they are
protection protection used in areas very used in areas likely to used in areas unlikely
level against level against likely to be exposed be exposed to to be exposed to
explosive eventually to explosive explosive atmosphere. explosive atmosphere.
atmosphere explosive atmosphere.
atmosphere

Note : For any doubt please consult Annex I of the EC-Directive 94/9/EC or contact Casals
Cardona Industrial, S. A.

On receiving the Pump, the user must check and make sure that Group and Category of the
Pump correspond to the classified area for which it is intended to be used. In no case the pump
shall be started if Group and Category don’t correspond to the use it is intended for.

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 Classification of maximum surface temperatures for equipments of Group IIG

Temperature Maximum surface temperature

Class (ºC)

T1
450

T2
300

T3
200

T4
135

T5
100

T6
85

8.2. NON AIRED CAVITIES

Although the pump has been designed to avoid any cavity in which explosive gases or dust may
accumulate, the user must perform weekly checks to make sure that no explosive dust settles on
the concave parts of protections and no gas remains inside the pump gear housing.

8.3. MECHANICAL CONTACTS

Any mechanical contact or contact with the volute chamber or other plastic parts of the pump
must be avoided, either caused by objects or mechanisms other than the pump or by
deformation of protections due to blow or defective assembly. In case the pump has been
disassembled for repair or maintenance, all elements have to be correctly reassembled.

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8.4. IMPELLER

Prevent the pump from running dry by installing a safety control device.

Monitor the level of suction by installing a control device.

8.5. OVERHEAT

Check the temperature of all the pump gaskets daily, in particular bearings, mechanical closure
and volute chamber, usually after the pump has been running for half an hour.

Stop the pump at once if any overheat is noted. A permanent temperature probe is
recommended.

8.6. OVERPRESSURE

Check the discharge circuit. Situation of valves. Deformations. Obstructions.

8.7. GROUND CONNECTION

Verify the resistance of the ground connection. It should not exceed 37 ohm. Check periodically,
at least once a month.

8.8. ELECTROSTATIC CHARGE

The plastic material of the pump subject to any kind of rub has a resistivity lower than 108
ohm.cm, and therefore the discharge occurs automatically through the earthed mechanical part.

Check the ground connection according to point 8.7 above. In very dry ambient condition it is
recommended to moisten the ground connection.

9. ENCLOSURES

• Part list of the pump

• Part list of the mechanical seal
• Assembly tolerances and fixation shaft.

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