ABS Modular SystemTM

A survey of the ABS Modular SystemTM including Bearing Assemblies and Seal Cartridges

The ABS Modular SystemTM saves money! Fewer spare parts: 6 bearing assembly sizes for 80 pump types Shorter downtime: complete modules can be replaced quickly High reliability: bearing life of at least 6 years for continuous operation Full flexibility: many shaft seal alternatives are available

1.1113 GB 10.02

A Well Engineered Modular System

Six Bearing Assemblies for 80 Pump Sizes

Since 1968 ABS pumps are designed within a modular system. Quick exchange, fewer spare parts and simplified service are the advantages with the ABS Modular SystemTM. The basis for the modular system is six sizes of bearing assemblies that together with six sets of seal cartridges, that includes shaft sleeve, seal housing and shaft seal, can be combined with lantern pieces and casing covers to fit 80 different pump sizes. A wide variety of hydraulics meets the demands within the pulp and paper industry, the chemical industry and water and sewage markets.

The replaced modules can then be reconditioned in the Maintenance Workshop in a planned way and put back into stock.

Fewer Spare Parts

The pump parts which are determined by the size of the bearing assembly account for about 80% of the total number of spare parts. Therefore, for pumps having the same bearing assembly sizes most spare parts are interchangeable. This means that the end-user spare parts stock can be minimized without any reduction of proper maintenance.

ABS Well Engineered Modular System Offers: Higher Availability of Spare Parts

Quicker Service
Servicing and repairs are made considerably easier by the modular design. Bearing assemblies and seal cartridges can be rapidly exchanged with pre-assembled units from stock. 2

Simplified Service Lower Maintenance Costs

The Bearing Assembly is the Base

Thrower Radial bearing

Five Pump Series

The 80 pumps in the modular system are from the series NB, BA and FB for pressure ratings up to 16 bar and the series NK and BK for 25 bar. All pumps in the modular system comply with the requirements of quality standard ISO 5199.

Angular contact ball bearings Bearing housing

Six Bearing Assembly Sizes

ABS pumps are built on six different bearing assembly sizes. All pumps on one bearing assembly size have the same bearing assembly and seal cartridge size. In addition, lanterns and casing covers are normally common to more than three pump types. A complete diagram of the modular system is to be found on pages 4, 5 and 6.

Sturdy Bearings for Long Life

The bearing assemblies have been designed to cope with the special combination of forces existing in centrifugal pumps. Thrust loads are carried by angular contact ball bearings and radial bearing is of roller or deep groove ball type. The bearing life (L10 rating) is at least 50,000 hours for continuous operation within the pumps normal operating range.

Ideal Seal Operating Conditions

The bearing assembly also affects the shaft seal. As the deflection of the shaft at the seal is less than 0,05 mm even with the highest shaft loads the operating conditions for the seal are ideal - appropriate conditions for long life.

Effective Thrower
The bearing adjacent to the shaft seal is effectively protected, by a special reinforced rotating rubber thrower, against any liquid. The thrower is as effective as a labyrinth seal, which is an expensive alternative.

Energy Savings
Contributing to the energy saving characteristics of the pumps, the three largest bearing assemblies are designed to handle, in most cases, the total axial thrust from the impeller, without power consuming backvanes. This reduces the energy consumption and provides for large savings at continuous operation. A fan will help maintain low bearing temperatures even with a high surrounding temperature. Grease of normal temperature quality can therefore be used under all conditions.

ABS Well Engineered Bearing Assemblies High reliability with a bearing life of at least six years for continuous operation. Shorter down times because the complete bearing assembly can be quickly replaced by a module from your stock.

Grease or Oil Lubrication

The bearings are normally grease lubricated, requiring only simple maintenance and long intervalls between relubrication. All bearing assemblies can also be delivered with oil lubrication.

This is the ABS Modular System

ABS complete modular system includes a total of 80 pump types. In this diagram only the pumps with pressure ratings up to 16 bar are shown. Bearing assembly sizes 1 and 2 are presented on this page, bearing assembly size 3 is shown on page 5 and bearing assembly sizes 4, 5 and 6 on page 6.

NB 50/32-16

NB 65/50-16 NB 80/65-16 FB 32/25-20 NB 32/25-20 NB 40/32-20 NB 50/32-20 NB 65/40-20 NB 80/50-20

NB 100/80-16 NB 100/65-20 NB 125/100-20 FB 50/50-20 NB 50/32-26

NB 65/40-26 NB 80/50-26 NB 100/65-26 NB 125/80-26 FB 50/50-26

FB 80/80-26 BA 150/80-26

BA 150/150-26 NB 65/40-32 NB 80/50-32

BA 150/80-32

Main Parts
NB 125/100-26 Bearing Assembly

3
NB 150/125-26 NB 200/150-26

Seal Cartridge NB 100/65-32

NB 125/80-32 Casing Cover and Lantern NB 125/100-32

NB 150/125-32

Closed and semi-open impellers NB

NB 200/150-32

FB 100/100-32

FB 150/150-32

Semi-open impeller BA

FB 200/200-32

BA 150/150-32

BA 200/200-32 Channel and Vortex impellers FB

BA 250/250-32

FB 125/100-38

FB 150/150-38 Pump Casing series NB FB 200/200-38

FB 300/300-38

Pump Casing series BA (small)

NB 125/100-40 NB 150/125-40

NB 200/150-40 Pump Casing series BA (large)

BA 200/100-40

BA 200/150-40

Pump Casing series FB

BA 200/150-43

BA 250/200-43

BA 300/250-43 BA 350/300-43

NB 200/150-48

BA 250/200-48

BA 400/350-48

NB 300/250-60

BA 300/250-60

BA 350/300-60

BA 500/400-60

BA 500/500-60

BA 250/150-67

BA 500/500-68

BA 600/600-85

6
BA 600/600-67

Rapid Replacement of Bearings and Shaft Seals

All pumps in the ABS Modular SystemTM are of back pull-out design. Neither the pump casing nor the motor need to be removed for pump maintenance. After removing the impeller the seal cartridge can be pulled out using a removal tool. When inserting a new cartridge, it is pressed home by the impeller screw and hub or by using a special yoke.

The Seal Cartridge Adaptable and Easy to Fit

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Shaft sleeve Shaft seal

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Seal housing

Seal cartridge

Only Six Sizes

A seal cartridge fits all pumps on the current bearing assembly size. Thus, there are only six different sizes for 80 pumps. The shaft seal, the shaft sleeve and the seal housing form one unit, the seal cartridge. Against the casing cover the cartridge is sealed off by two O-rings. The O-ring materials are selected with reference to the temperature and chemical properties of the pumped liquid.

No Special Training
A mechanical seal demands both knowledge and skill for proper installation. However, such high levels of skill are not necessary to fit a pre-assembled cartridge. Mounting the pre-assembled cartridge is easy and ensures a correctly mounted seal.

Excellent Protection
Fragile parts of a mechanical seal are totally protected when fitting the cartridge into a pump and also during transportation and in inventory.

Full Flexibility of Seal Selection

Thanks to the ABS seal cartridge, a wide range of seals can be fitted in the most suitable sealing environment available. This also means full freedom of choosing a seal supplier.

A Large Selection of Seal Arrangements

To suit every customer demand, there are many seal arrangements available. The most common seal arrangement is a single mechanical seal in ABS PSI cartridge, see Fig. 1 and 2. For double mechanical seals, a special cartridge is used shown in Fig. 3 and 4. A single or double cartridge mechanical seal can be externally mounted and supplied by the seal supplier as in Fig. 6 and 7. Gland packing, Fig. 5 and dynamic seal, Fig. 8 are two other available seal arrangements.

Reduced Down-time
To replace the shaft seal, the rotor assembly is removed from the pump casing and the impeller dismantled from the shaft. It is then possible to pull out the cartridge, without removing the casing cover, and exchange it with a preassembled replacement. The replaced cartridge can then be reconditioned in the workshop and put back into stock. By this method the down time can be reduced up to 50%. 8

System PSI - Pump Seal Integration ABS PSI Cartridge

Pump Seal Integration
In close co-operation with our customers we have gained a wealth of experience and thorough knowledge of operating conditions of shaft seal in pumps. For a mechanical seal to function properly, you must create the right environmental conditions. The first two requirements - shaft concentricity and minimum shaft deflection - call for the sturdy bearing assembly of ABS design. The third requirement is a seal chamber that is always filled with clean liquid under pressure. The solution is the System PSITM - Pump Seal Integration - cartridge for single mechanical seals. By integrationg the seal arrangement into the pump design, ABS can supply pumps, which give ideal operating conditions for the seal.

High Reliability
The PSI cartridge is designed to provide the best conditions possible for the shaft seal. The tapered design with vortex breakers transports gas and particles away from the sealing surface and out of the cartridge.

No Water Consumption
In most applications, external sealing or quench liquid can be eliminated and thus large savings can be made. In the thoughest applications where low pressure sealing liquid, quench, is needed this can easily be connected directly to the cartridge, without the need for extra parts.

Personnel Safety Modular System

The PSI cartridge is part of the modular system available in six different sizes only. This allows for intechangeability between different seal suppliers. All single DIN seals fit in the PSI cartridge. The collector integrated in the secondary seal will also handle leakage from the shaft seal, an important safety aspect. As the patented secondary seal is of the labyrinth type there are no wear parts.

Energy Saving
When using the PSI cartridge, a single mechanical seal can be used where a double seal was asked for if not hazardous. By using a single mechanical seal the largest energy savings are achieved.

ABS PSI Cartridge

The seal is an integrated part of the pump Modular system concept Energy saving Easy service High reliability No water consumption Personnel safety

Easy Service
The PSI cartridge can be quickly replaced and is easy to handle since it contains so few parts.

PSI Cartridge

1
Fig. 1 In the PSI cartridge all DIN mounted single mechanical seals can be fitted, independent of supplier.

2
Fig. 2 For difficult applications, sealing liquid of low pressure, quench, can be fitted without extra parts.

Double Mechanical Seal Cartridge

Gland Packing Cartridge

3
Fig. 3 Double mechanical seals mounted back-toback as above, or in tandem, can be fitted in our cartridge for double mechanical seals. Also here there is full flexibility with seal and seal supplier.

4
Fig. 4 A double balanced, double mechanical seal can be installed with either high or low pressure sealing fluid depending on the situation.

5
Fig. 5 For a large variety of liquids gland packing can be used, with or without sealing liquid.

Externally Mounted Cartridge

MasterSeal

6
Fig. 6 All pumps can have a cartridge seal delivered by the seal supplier. The cartridge is externally mounted on the casing cover with four bolts.

7
Fig. 7 For the chemical industry this externally mounted cartridge - seal combination, is often used.

8
Fig. 8 The dynamic seal , MasterSeal is part of the ABS Modular SystemTM. The seal is based upon a single repeller design capable of sealing off the pressure by creating hydraulic balance in the sealing chamber. As long as there is hydraulic balance the dynamic seal is leakagefree. When the pump is stationary a static diaphragm keeps the media inside the seal cavity.

ABS reserves the right to alter specifications due to technical developments.

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Agents and distributors ABS has sales and service representation in more than 100 countries the world over.

www.abspumps.com

ABS is a company in the Cardo Group