CONDENSATE EXTRACTION PUMP

GENERAL: The WKT centrifugal pump is a hydrodynamic machine. It is characterized by the fact that pressure is generated by a continuous flow of fluid through the pump. Mechanical work is imparted to the fluid by a rotating impeller (109) : The impeller, diffuser and stage casing (104) together form one stage of the pump. The suction created by the fluid discharged from the impeller causes an equal volume of fresh fluid to flow into the suction casing (102 b) of the pump. The vertical barrel-type centrifugal pump consists of the pump casing, the motor stool and the barrel. Depending on the suction head available, one column pipe is provided in addition, if required. The pump rotor assembly and the intermediate shafts are guided in metal bearings of bronze, liquid-lubricated, and in case of higher temperatures, in bearings of special carbon. Under temperature conditions exceeding 100 with a thermal barrier. IMPELLERS,DIFFUSERS,STAGECASING: The impellers are designed with a neck at the entry and discharge ends. Sealing is effected at both ends by means of renewable wear rings (122), which are press-fitted into the stage casing (104) and into the diffuser respectively. The first stage (i.e. suction) impeller (202a) is specially designed to prevent cavitation, and the results in a lower NPSH requirement of the pump. The wear ring at the suction end of the first stage impeller is pressed into the suction casing. The backplates of the impellers are drilled to obtain a balanced pressure on both sides of the impeller, and the residual axial thrust of the rotating assembly is consequently very small. This residual thrust is bsorbed by an anti-friction bearing in the drive frame. The casings are sealed by O-rings on the standard pump models, but on high temperature and pressure pumps (cast steel casings), the sealing is effected by metal-to-metal contact of the precision ground mating faces of the casing flanges. SHAFTSEALING: A pacing - type stuffing box is used as a shaft seal. During the operation of the pump it reduces the leakage flow at the gap between the shaft and the casing. In case of a suction pressure < than 1 atm. Abs., the ingress of air during standstill of the pump will be prevented by admitting sealing liquid. Under higher temperature conditions, the stuffing box will be cooled The suction and discharge piping have to be laid in such a fashion that no external stresses are transmitted to the pump. Any sudden or abrupt change of direction or crosssection has to be avoided. Flat gaskets should not protrude inside the pipe. Where welded pipe lines are used, all sharp edges, welding beads and scale are to be removed before commissioning. The suction piping and vessels have to be thoroughly clean out and flushed through before commissioning. The suction piping and vessels have to be thoroughly cleaned out and flushed through before commissioning of te plant. Experience shows that welding beads, scale and other impurities often become detached from the pipe walls only after a
0

C (212

F) the distribution header is fitted

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considerable period of operation, especially when the liquied pumped is hot, it is necessary, therefore, to incorporate a strainer in the suction line to retain this foreign matter.

This strainer is to have a free flow area equal at least to 3 to 4 times the pipe crosssection area, in order to prevent too great a pressure drop when it becomes partially clogged with foreign matter. Cone-shaped strainers as illustrated in fig.2 have proved themselves well in service, they should be made of corrosion-resistant material. The suction pressure is to be carefully watched during operation. If there is a drop in pressure, the strainer is to be removed and cleaned. After several weeks of operation, when the presence of foreign matter is no longer anticipated, the strainer can be removed.

The vent line connects the suction compartment of the distribution header with the apex of the suction vessel. The connection for this line, on the distribution header, is arranged in such a fashion that any vapour or gas tending to form in the header, and which might cause the pump to splutter, will escape through the vent line to the suction vessel. COOLINGWATER: According to the temperature prevailing, i.e. when he liquid being pumped has a high temperature, the drive frame is cooled. The flow of cooling water is approx. 0.5-1 m3/h. It is useful to have throttling means in the supply line. The discharge is to be provided to the open, to facilitate observation of the rate of flow. In some designs of these pumps, the bearing bracket or the packing-type stuffing-box
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in the drive frame are cooled. The system is similar to that for the frame itself. Max. cooling water inlet emperature: approx. 20 0C (68 0F). A temperature difference of 10 0C (50 0F) between the inlet and the outlet temperature of the cooling water is allowable. SEALINGWATER: To prevent air from entering the system when the pump is not working, the stuffingbox is supplied with sealing liquid. It is recommended that his be drawn from the discharge side of the main condensate pumps. The sealing water piping is to be fitted with a check-valve to prevent the pump from discharging into this piping during its operation. LEAKAGELIQUID: There is a tapped connection provided on the motor stool to drain off any leakage. Any leaks should be allowed to drain off freely. FOUNDATION: A foundation support frame consisting of steel sections is the most appropriate foundation for the pumping set. The foundation support frame which has a machined contact face will be leveled up to a true horizontal position, then grouted in. if this is done, the pump itself will not require leveling up. The concrete should be allowed to set and dry out completely before the pump is placed on its foundation. We can supply exact measurements for the foundation support frame on request. ERECTION OF THE PUMP : The WKT pump is usually delivered assembled as a unit. It can be placed immediately on to the foundation and bolted down. Then, the true position of the pupmping set is to be verified again. If the barrel is mounted separately from the pump, care is to be taken to ensure a proper sealing between the barrel and the drive frame (O-ring, 542). If the set is supplied completely assembled, the rotating assembly of the pump need only be re-aligned after previous dismantling . CAUTION1: When delivered, the pumps have no oil in the bearing bracket. After the test run at our works, the bearings are drained of oil washed, as there is no means of knowing when the pump will be commissioned, and the oil might oxidize if left in the bearings too long para 1.82 gives indications about lubricants. PACKING OF THE STUFFING - BOX : The pup are delivered without packing in the stuffing-box. The straight lengths of the packing rings cut off smoothly by means of a jig (see fig3) are to be of such a length that, when fitted round the shaft sleeve, the sectional areas are in slight tough. Before insertion in the packing area, the packing must be thoroughly soaked in oil. Together with the stuffing-box gland, the first packing ring is inserted in the packing area and pushed to the bottom. The butt
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joints are to be taken to observe the proper sequence of packing rings and seal cage ring/ lantern ring. The nuts of the stuffing-box bolts are slightly tightened by hand. A newlyh packed stuffing-box is to leak appreciably at first. If this leakage does not cese of its own accord after some time. The nuts are to be tightened slowely ad evenly during operation, until the stuffing-box only drips slightly; this indicates that the packing is functioning correctly slightly again. Every newly packed stuffing-box needs a certain running-in period and it is to be kept under frequent observation during this period. After settling down, it needs only to be checked occasionally. If the existing packing has been compressed by approx. the width of one packing ring, the packing is to be renewed. Check also the condition of the shaft sleeve on this occasion. It is to be replace if its surface shows signs of grooving or roughness.

STARTINGUPAND: Always check the following points before starting up the pump for the first time and later on. After a prolonged shutdown: a) The bearing and stuffing-box housings must be filled with oil and the soft packing fitted in the stuffing-box respectively. b) Close the pump discharge valve: open the suction valve. c) Make sure that the pump is completely primed with the liquied pumped. d) Vent the pump (see para 1.42) e) If applicable, turn on the cooling water and check the free flow of the cooling water. f) Switch on the driver and check direction of rotation (anti-clockwise, when viewed from above, looking down onto the pump). g) Slowly, open the discharge valve. Do not exceed the current intensity (Amps) on the motor rating plate. SHUTTINGDOWNTHEPUMP: The following operations should be carried out when shutting down the pump: a) Close discharge valve. b) Switch off driver and check that the pump runs down to a standstill smoothly and evenly. c) Turn off cooling water, if applicable. d) Leave suction valve open.
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LUBRICATIONOFTHEPUMP: The pump bearings and the column pipe bearings are lubricated by the product pumped and require no supervision. On no account let the pump run dry 1 The top shaft (bearing shaft) is guided within the bearing bracket. For the lubrication of the anti-function bearings incorporated, please. If the set is fitted with oil-lubricated selfaligning bearings or with a segmental thrust bearing. The appropriated special directions must be followed. The pump, the shaft and the riser piping required no attention if there are normal working conditions. The stuffing box must leak slightly whilst the pump is running. The drive must be maintained in accordance with the special instructions given on this subject. LUBRICATION: The top shaft (bearing shaft) is guided within the motor stolol. A good-quality wellrefined mineral oil should be used only to lubricate the grooved ball bearings. As a lube oil we recommend a brand oil having the following specification: Flash point Pour point Viscosity Ash contents Spec. gravity : 200-220
0

C (390-430
0

F)

: below - 15 : 4-6
0

C (+5 0F)
0

E at 50

C (30-45 c St. at 122

F)

: below 0.05% : 0.9 kp/dma (56 Ibs/cuft)

The oil should be changed approximately once every 2000 operating hours: in any event however, at least once a year. The oil quantities required for one initial oil fill of the bearing bracket (including the constant-level oiler and the fill piping) are given in table below : Bearing size no. Oil fill, in dm3 Fluid ounces in brackets 6311 0.3 (100) 6312 0.4 (13.5) 6315 0.5 (17) 6317 0.6 (20)

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