ammonia o&m training - salinas valley ammonia safety...
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Containment, Reliability & Safety by Design
O & M Trainingfor
TeikokuModel R
Ammonia Pump
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Pump Internals
•Centrifugal Pump•Single Stage•Enclosed Impeller•Stator & Rotor “Canned”•True Secondary
Containment•Product Lubricated &
Cooled Motor•Carbon Sleeve Bearings•304 SS w/ Hard Chrome
SleevesThrust Collars
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Exploded View
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Type RReverse Circulation
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Type RReverse Circulation
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Containment, Reliability & Safety by Design
Restriction OrificeRear Bearing Housing
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Containment, Reliability & Safety by Design
Teikoku Type R & RWReverse Circulation Piping Arrangement
Note 1:Piping must becontinuously risingNote 2:Piping must returnto vapor zoneNote 3:No check valvesallowed in pipingNote 4:Each pump musthave separate pipe
06-16-2012
Containment, Reliability & Safety by Design
Sleeve Bearing Details
Bearing WithSpiral Grooves Only
Bearing WithSpiral & Straight Grooves
Refer to pump specific cross sectional drawingfor correct Sleeve Bearing type and location
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Type RCross Sectional Drawing
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Containment, Reliability & Safety by Design
TeikokuVertical Type R Cross
Sectional Drawing
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Canned Motor Pumps
Precision Liquid Film BearingsLubrication Provided by RefrigerantLiquid Cooled Canned MotorTrue Secondary ContainmentDirection of Rotation IndicationTRG Bearing Wear Monitor
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Rotary Guardian (TRG)
Pump Mounted Meter
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Rotary Guardian (TRG)
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Containment, Reliability & Safety by Design
Teikoku TRG Volt Meter Scale
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Rotary Guardian (TRG)
GREENNormal Operation
YELLOW or REDStop Pump and Check for Possible Causes
Single PhaseUnbalanced Input PowerLoose Connections
PEGGED REDPump Rotating in Reverse DirectionPinched TRG WiresTCO Wires Connected to TRG Terminals
Initial Readings
03-14-2011
Containment, Reliability & Safety by Design
Teikoku Rotary Guardian (TRG)
GREENNormal Operation
YELLOWSchedule Pump for MaintenanceRecommended to Swap to Spare Pump
REDStop Pump and Remove for MaintenanceNever Operate Pump with TRG in RED Zone
03-09-2011
Normal Operating Readings
Containment, Reliability & Safety by Design
Pump Performance Curve
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Containment, Reliability & Safety by Design
System Head Curve
TUSA Copyright 2011 03-10-2011
Containment, Reliability & Safety by Design
Typical Performance Test Curve
and Inspection
Report
03-09-2011
Containment, Reliability & Safety by Design
Cautions & Warnings
Do not start or operate pump without liquidDo not cavitate pumpDo not operate pump when TRG shows REDVerify that the correct Restriction Orifice isinstalled in the reverse circulation lineDo not operate pump with forward flow fully shut off for more than thirty (30) secondsWait at least five (5) minutes between startsLimit number of starts to six (6) per hour
03-09-2011
Containment, Reliability & Safety by Design
Initial Priming Procedure
1. Inspect Installation2. Open Suction Valve 100%3. Open Discharge Valve 100%4. Open Reverse Circulation Valve 100%5. Open Minimum Flow Valve 100%6. Let Pump Fill with Liquid for ten (10) Minutes
or Until a Layer of Frost Covers the Motor
03-09-2011
Containment, Reliability & Safety by Design
Rotation Check Using TRG
1. Pump Must be Primed & Vented2. Set Suction Valve at 100% Open3. Set Discharge Valve at 20% Open4. Set Reverse Circulation Valve at 100% Open5. Set Minimum Flow Valve at Recommended Set Point6. Start Pump for 3 to 5 Seconds and Observe TRG7. If TRG is in the Green the Rotation is Correct8. If TRG is Pegged Red the Pump is Rotating in the
Reverse DirectionSwap Two Motor Leads and Repeat Rotation Check
03-09-2011
Containment, Reliability & Safety by Design
Teikoku Rotary Checker (TRC)
03-09-2011
Containment, Reliability & Safety by Design
Rotation Check Using TRC
1. Pump Must be Primed and Vented2. Set Suction Valve at 100% Open3. Set Discharge Valve at 20% Open4. Set Reverse Circulation Valve at 100% Open5. Set Minimum Flow Valve at Recommended Set
Point6. Hold TRC on Motor per Instructions7. Start Pump for 3 to 5 Seconds and Observe TRC 8. If the Direction of Rotation is Not Correct, Swap
Two Motor Leads and Recheck
03-09-2011
Containment, Reliability & Safety by Design
Rotation Check Using Pressure & Amps
1. Pump Must be Primed2. Set Suction Valve at 100%3. Set Discharge Valve at 20% Open4. Set Reverse Circulation Valve at 100% Open5. Set Minimum Flow Valve at Recommended Set Point6. Start Pump – Record Pressure & Amps7. Swap Two of the Motor Lead Wires8. Start Pump – Record Pressure & Amps9. Compare the Readings Between Steps 4 & 6
The higher readings is the correct rotation10. Wire the Motor Accordingly
03-09-2011
Containment, Reliability & Safety by Design
Normal Start Up Procedure
1. Pump Must be Primed and Rotation Checked2. Set Suction Valve at 100%3. Set Discharge Valve at 20%4. Set Reverse Circulation Valve at 100%5. Set Minimum Flow Valve at Recommended Set Point6. Start Pump7. Gradually Open Discharge Valve Until
Specified Capacity is Achieved
03-09-2011
Containment, Reliability & Safety by Design
Checks During Operation
Verify Discharge Pressure is CorrectTeikoku TRG Meter Indicates GreenVerify Motor Amps and/or Load is CorrectVerify Pump Operating Properly Without Excessive or Abnormal Noise or Vibrations
03-09-2011
Containment, Reliability & Safety by Design
MaintenanceDisassembly
and
Reassembly
Teikoku-USA
03-14-2011
Containment, Reliability & Safety by Design
Checks Prior to Disassembly
Has the motor been meggered?Has the pump been decontaminated?Are you familiar with the pumped fluid?Has the Stator Can been breached?Is your work area clean?Do you have the required tools?
03-14-2011
Containment, Reliability & Safety by Design
Unbolt Pump Case / Volute
03-14-2011
Containment, Reliability & Safety by Design
Remove Pump Case / Volute
03-14-2011
Containment, Reliability & Safety by Design
Remove Pump Case Gasket
03-14-2011
Containment, Reliability & Safety by Design
Bend Down Impeller Lock Tab
03-14-2011
Containment, Reliability & Safety by Design
Remove Impeller Lock Bolt
03-14-2011
Containment, Reliability & Safety by Design
Slide Impeller Off Shaft
03-14-2011
Containment, Reliability & Safety by Design
Remove Key
03-14-2011
Containment, Reliability & Safety by Design
Remove Adjusting Washers(If Required)
Measure and Record Quantity and Thickness
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Containment, Reliability & Safety by Design
Unbolt Front Bearing Housing (Adapter)
03-14-2011
Containment, Reliability & Safety by Design
Loosen Front Bearing Housing
Jack Bolt Holes Facilitate Removal
03-14-2011
Containment, Reliability & Safety by Design
Remove Front Bearing Housing (Adapter)
Warning: Rotor & Shaft Sleeve may slide out03-14-2011
Containment, Reliability & Safety by Design
Unbolt Rear Bearing Housing
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Containment, Reliability & Safety by Design
Slide Out Rear Bearing Housing
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Containment, Reliability & Safety by Design
Remove Gasket
03-14-2011
Containment, Reliability & Safety by Design
Carefully Remove Rotor Assembly
CAUTION:Support Rotor AssemblyDo Not Allow Rotor Assemblyto Drop and Hit Stator Liner
03-14-2011
Containment, Reliability & Safety by Design
Visual Inspection
Check Filter & Circulation Pipe (If Required)Check Stator Liner for contact marks/wearCheck Rotor Liner for contact marks/wearCheck for wear, scratches & scoring on:• Shaft Sleeves• Thrust Collars• Bearings – Inside Bore• Bearings – Thrust Face
03-14-2011
Containment, Reliability & Safety by Design
Inspect & Record Bearing Wear
01-06-2011
Containment, Reliability & Safety by Design
Bend Down Lock Tab
03-14-2011
Containment, Reliability & Safety by Design
Remove Rear Lock BoltLeft Hand Threads
CAUTION:Left Hand Threads
03-14-2011
Containment, Reliability & Safety by Design
Remove Shaft Sleeves & Thrust Collars
WARNING:WARNING:Key/Pin may be loose Key/Pin may be loose and fall out unnoticedand fall out unnoticed
03-14-2011
Containment, Reliability & Safety by Design
Remove Set Screw From Front & Rear Bearing Housings
03-14-2011
Containment, Reliability & Safety by Design
Slide Out Bearing FromFront & Rear Bearing Housings
Note: Some heat on thebearing housing may beused to assist with theremoval of the bearing
03-14-2011
Containment, Reliability & Safety by Design
Remove Adjusting Washers fromRear Bearing Housing Only (If Required)
Measure and Record Thickness and Quantity
03-14-2011
Containment, Reliability & Safety by Design
Measure & Record Balance GrooveInside & Outside Diameters
03-14-2011
Containment, Reliability & Safety by Design
Measure & Record Impeller BackWear Ring Inside & Outside Diameters
03-14-2011
Containment, Reliability & Safety by Design
Measure & Record Impeller FrontWear Ring Outside Diameter
03-14-2011
Containment, Reliability & Safety by Design
Measure & Record Pump CaseWear Ring Inside Diameter
03-14-2011
Containment, Reliability & Safety by Design
RadialClearances
ChartHorizontal
Mount
03-14-2011
Containment, Reliability & Safety by Design
RadialClearances
ChartVerticalMount
03-14-2011
Containment, Reliability & Safety by Design
Reassembly of Pump
Insure that work space is cleanClean & dry all componentsInspect all componentsMegger check motorCheck resistance of windings
03-14-2011
Containment, Reliability & Safety by Design
Sleeve Bearing Details
Bearing WithSpiral Grooves Only
Bearing WithSpiral & Straight Grooves
Refer to pump specific cross sectional drawingRefer to pump specific cross sectional drawingfor correct Sleeve Bearing type and locationfor correct Sleeve Bearing type and location
03-14-2011
Containment, Reliability & Safety by Design
Install Adjusting Washers IntoRear Bearing Housing Only (If Required)
03-14-2011
Containment, Reliability & Safety by Design
Install Bearing IntoFront & Rear Bearing Housings
Flat washermust beinstalledas shown
V-Groovesmust belocated onoutside end
03-14-2011
Containment, Reliability & Safety by Design
Install Set Screw Into Front & Rear Bearing Housings
Make SureBearing IsSeated WhenTighteningSet Screw
Do not overtightenset screw
03-14-2011
Containment, Reliability & Safety by Design
Thrust Collar Detail
InboardSide
OutboardSide
Chamfer
03-14-2011
Containment, Reliability & Safety by Design
Install Shaft Sleeves & Thrust Collars
Line up slot in Thrust Collar& Shaft Sleeve to Pin
Outboard SideChamfer SideInboard Side
05-03-201003-14-2011
Containment, Reliability & Safety by Design
Install Shaft Sleeve Lock Bolt,Lock Washer & Flat Washer
Lock washer tabmust fit into slotand extend beyondface of flat washer
03-14-2011
Containment, Reliability & Safety by Design
Torque Lock Bolt – Refer to Chart
Left Hand Threads
Lock Washer tabmust fit into slot inShaft Sleeve
03-14-2011
Containment, Reliability & Safety by Design
TorqueValues
forBolting
03-14-2011
Containment, Reliability & Safety by Design
Bend Up Tabs on Lock Washer
03-14-2011
Containment, Reliability & Safety by Design
Check Front Rotor Shaft Sleevefor Proper Engagement into Pin/Key
03-14-2011
Containment, Reliability & Safety by Design
Verify Correct Installation of Sleeve
Correct Not Correct
03-14-2011
Containment, Reliability & Safety by Design
Carefully Slide Rotor into Stator
CAUTION:Support Rotor AssemblyDo Not Allow Rotor Assemblyto Drop and Hit Stator Liner
03-14-2011
Containment, Reliability & Safety by Design
Install Rear Gasket
03-14-2011
Containment, Reliability & Safety by Design
Install Rear Bearing Housing
Vent line/hole must belocated at top
03-14-2011
Containment, Reliability & Safety by Design
Install Rear Bearing Housing Bolting
03-14-2011
Containment, Reliability & Safety by Design
Torque Rear Bearing Housing BoltsCross Pattern - Refer to Chart
03-14-2011
Containment, Reliability & Safety by Design
Install Front Bearing Housing (Adapter)
03-14-2011
Containment, Reliability & Safety by Design
Install Front Bearing Housing Bolting
03-14-2011
Containment, Reliability & Safety by Design
Check Axial End Play (Playing Gap)Refer to Chart – Adjust as Required
Note: Rotor Must Rotate Freely Without Contact
03-14-2011
Containment, Reliability & Safety by Design
Axial End Play (Playing Gap)
01-06-2011
Containment, Reliability & Safety by Design
Verify Correct Installation of Sleeve
Correct Not Correct
03-14-2011
Containment, Reliability & Safety by Design
Install Adjusting Washers(If Required)
Warning: Make sure Shaft Sleeve is engaged in Pin/Key
03-14-2011
Containment, Reliability & Safety by Design
Install Impeller Key
03-14-2011
Containment, Reliability & Safety by Design
Install Impeller On Shaft
03-14-2011
Containment, Reliability & Safety by Design
Install Impeller Lock Bolt,Lock Washer & Flat Washer
Lock Washer tab mustfit into slot & extendbeyond face of flat washer
Lock washertab must fitinto keyway
03-14-2011
Containment, Reliability & Safety by Design
Torque Impeller Lock BoltRefer to Chart
Rotor Assembly Must Rotate Freely Without Contact
01-06-2011
Containment, Reliability & Safety by Design
0.25 ( +/- 0.010” )
01-06-2011
Measurement of Standard “g” GapTypes A or E
Containment, Reliability & Safety by Design
Pull Impeller Forward
Measurement of Standard “g” GapTypes A or E
01-06-2011
Containment, Reliability & Safety by Design
Tolerance of“g” Gap =
+/- 0.25 mm(+/- 0.010”)
Measurement“g” Gap
Standard DesignTypes A or E
01-06-2012
Containment, Reliability & Safety by Design
Bend up Tabs on Lock Washer
01-06-2011
Containment, Reliability & Safety by Design
Install Pump Case Gasket
01-06-2011
Containment, Reliability & Safety by Design
Install Pump Case / Volute
01-06-2011
Containment, Reliability & Safety by Design
Install Pump Case / Volute Bolting
01-06-2011
Containment, Reliability & Safety by Design
Torque Pump Case Volute BoltingUse Cross Pattern – Refer to Chart
01-06-2011
Containment, Reliability & Safety by Design
Check For Free Rotation
01-06-2011
Containment, Reliability & Safety by Design
Electrical Considerations
Thermal Cutout Devices IncorporatedBearing Monitors Functioning ProperlyMonitor Motor Amps and/or LoadSet Overload Relays at 1.10 to 1.15 Above Normal Operating Current
01-06-2011
Containment, Reliability & Safety by Design
Teikoku-USA Repair Centers
Field Service
Chempump959 Mearns RoadWarminster, PA 18974Terry Flynn(267) 468-1028
ChempumpState Route 2 NorthBelmont, WV 26134John Ebersbach(267) 486-1026
Teikoku USA5880 Bingle RoadHouston, TX 77092Paul Grogg(281) 246-2852
Teikoku USA5880 Bingle RoadHouston, TX 77092Keith Yutzy(713) 805-7574
03-09-2011