The provided document is an instruction manual for CECO Dean Pump® Series RA Fan Cooled Hot Oil Pumps, covering installation, operation, and maintenance.
Function Description
The CECO Dean Pump® Series RA pumps are fan-cooled, horizontal, single-stage, end-suction, enclosed impeller, centrifugal hot oil pumps. They are specifically designed for use with heat transfer oils and are not suitable for other liquids. These pumps are engineered to provide reliable performance in systems requiring the circulation of hot oil, with features to manage high temperatures and pressures inherent in such applications.
Important Technical Specifications
The manual details specifications for three pump types: RA2096, RA3146, and RA3186.
General:
- Direction of Rotation (Viewed from Coupling End): RA2096 is CW (clockwise), while RA3146 and RA3186 are CCW (counter-clockwise).
- Casing Thickness, Minimum: 5/16" for all models.
- Corrosion Allowance: 1/8" for all models.
- Impeller Balance: Standard is Single Plane for all models; Optional Extra is Dynamic.
- Flanges: ANSI Class 150 (RA2096) or 300 (RA3146, RA3186). Facing is Flat Face (RA2096) or Raised Face (RA3146, RA3186) with a 125 Ra finish.
- Suction Pressure, Maximum: 100 PSIG for all models.
- Maximum Ambient Temperature (within 12" of pump): 104°F (RA2096), 118°F (RA3146, RA3186).
- Hydrostatic Test Pressure: 430 PSIG (RA2096), 550 PSIG (RA3146, RA3186).
Horsepower Rating, Maximum:
- RA2096: 35 HP @ 3500 RPM, 15 HP @ 1750 RPM, 10 HP @ 1150 RPM.
- RA3146: 100 HP @ 3500 RPM, 40 HP @ 1750 RPM, 25 HP @ 1150 RPM.
- RA3186: 250 HP @ 3500 RPM, 125 HP @ 1750 RPM, 75 HP @ 1150 RPM.
Bearings:
- Thrust Bearing, Ball Type, Grease Lubricated: RA2096 uses a Double Row bearing; RA3146 and RA3186 use Angular Contact Pair bearings.
- Radial Bearing, Sleeve Type, Pumpage Lubricated: All models.
- Seal Chamber Dimensions: Length (Depth) varies from 1 5/8" (RA2096) to 3 7/8" (RA3186). Inside Diameter (Bore Dia.) varies from 2 1/16" (RA2096) to 4 5/16" (RA3186).
- Shaft Diameter: Varies from 1 1/8" (RA2096) to 2 1/4" (RA3186).
Pump Shaft Dimensions:
- Span Between Bearings: Varies from 8 11/16" (RA2096) to 14 5/8" (RA3186).
- Span Between Radial Bearing Centerline and Impeller Centerline: Varies from 1 5/8" (RA2096) to 3 1/4" (RA3186).
- Diameter at Coupling: Varies from 7/8" (RA2096) to 1 5/8" (RA3186).
- Diameter Between Bearings: Varies from 15/16" (RA2096) to 1 7/8" (RA3186).
- Diameter at Impeller: Varies from 3/4" (RA2096) to 1 1/2" (RA3186).
Material Class:
- All models use Class 22 (Ductile Iron).
Working Pressure and Temperature:
- Maximum Working Pressure: 250 PSIG @ 100°F (RA2096), 350 PSIG (RA3146, RA3186).
- Pumping Temperature Minimum: -20°F @ 250 PSIG (RA2096), -20°F (RA3146, RA3186).
- Pumping Temperature Maximum: 650°F @ 125 PSIG (RA2096), 650°F (RA3146, RA3186).
Standard Materials of Construction (Key Components):
- Impeller (3): Cast Iron.
- Casing (5): Ductile Iron.
- Pump Shaft (29): 11-13 S/S (RA2096, RA3146), 11-13/316 S/S (RA3186).
- Mechanical Seal Stationary (95A): Silicon Carbide & Viton.
- Mechanical Seal Rotary (95B): S/S, Carbon & Viton.
- Casing Gasket (77): Grafoil.
- Grease Seal - Front (76): Viton.
- Grease Seal - Rear (76A): Buna (RA3146, RA3186).
- Radial Bearing Cartridge (180): Carbon & Steel.
Usage Features
- Installation: Requires thorough inspection upon receipt, proper storage if not immediately installed, and careful handling. Baseplate mounting and alignment are critical, with specific instructions for leveling, grouting, and alignment checks (angular and offset) using a dial indicator. Piping connections must be made without forcing, and pressure relief valves are essential for cavities subject to excessive pressure.
- Piping: Suction piping should minimize friction loss and be as short and straight as possible. Strainers or filters are recommended in the suction line to prevent damage from debris. Small piping connections for barrier oil fill, drain, seal vent/fill, and pumpage leak detection are provided.
- Lubrication: The radial bearing is pumpage-lubricated. Thrust bearings are grease-packed "for life" for RA2096, or hand-packed with lithium 12-hydroxystearate soap-thickened grease (NLG1, Grade 2) for RA3146 and RA3186.
- Mechanical Seal: "RA" pumps use a mechanical face seal selected for heat transfer oils. A barrier fluid cavity is provided between the mechanical seal stationary and the front grease seal to prevent oxygen contact with oxidizing oils. Nitrogen gas blanketing or compatible liquid barrier fluids (e.g., Calflo AF, Dowtherm RP) are recommended for oxidizing oils. For non-oxidizing oils, a barrier fluid is not needed, and connections can be plugged.
- Starting the Pump: Emphasizes checking for sealed leak locations, proper venting of air, and ensuring all connections are tight. Filling procedures vary based on whether the liquid source is below or above atmospheric pressure. Critical steps include checking motor rotation direction before full startup and slowly opening the discharge valve once the pump is up to speed.
- Safety Warnings: Numerous warnings highlight potential hazards, including injury, death, and equipment damage, if installation, operation, or maintenance procedures are not followed. Specific warnings address handling hot items, toxic materials, improper lifting, misalignment, operating at shut-off or low flow, and opening the pump with residual pressure.
Maintenance Features
- Pre-Installation Inspection: Product inspection and test procedures ensure quality and conformity to performance standards. Units are sprayed internally with rust inhibitor and sealed to prevent dirt ingress.
- Storage: Instructions for prolonged storage include sealing openings, filling with corrosion inhibiting liquid, filling the barrier cavity with inhibiting liquid, greasing the bearing end cover, applying protective coating to machined surfaces, and monthly manual shaft rotation.
- Disassembly and Reassembly: Detailed, step-by-step procedures are provided for dismantling and reassembling the pump. These include instructions for removing the coupling guard, draining fluids, bleeding pressure, removing the rotating unit from the casing, and disassembling internal components like the impeller, fan, bearings, and mechanical seal.
- Part Replacement: Emphasizes replacing all gaskets, seals, bearings, and lubricants, as well as any worn, corroded, eroded, or deteriorated parts, using only Dean authorized service parts.
- Shaft Inspection: Instructions to inspect the pump shaft for wear patterns under the lip seal and bearing area, recommending replacement if scored or if two grease seal lip contact wear patterns are present.
- Bearing Installation: Specific instructions for pressing new bearing cartridges and thrust bearings onto the shaft, ensuring correct orientation and avoiding damage.
- Grease Packing: Detailed instructions for packing thrust bearings with the specified grease for RA3146 and RA3186 models.
- Mechanical Seal Installation: Guidance on installing new grease seals, seal gland gaskets, and mechanical seal stationary seats, including lubrication and proper orientation.
- Fan and Coupling Assembly: Steps for reassembling the fan, fan collar, fan clamp ring, and coupling hub, including marking the shaft for correct fan collar positioning and tightening bolts to specified torques.
- Post-Maintenance Checks: After reassembly, the pump shaft must be rotated by hand to check for interference. Re-alignment of the pump and driver is required, and a start-up checklist ensures all critical points are verified before restarting.
- Spare Parts: Dean recommends maintaining a minimum stock of spare parts, especially for critical services. A list of common parts and their interchangeability across RA series pumps is provided, along with instructions for ordering.
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