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Sulzer AHLSTAR 2.15 Series User Manual

Sulzer AHLSTAR 2.15 Series
122 pages
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COPYRIGHT © SULZER PUMPS FINLAND OY
ORIGINAL INSTRUCTION
SERIES 2.15
SPP id: 150201 / Replaces 141101 / en / N32197 / 5
AHLSTAR
PROCESS PUMPS
Installation, operation and maintenance instruction
Intended use
Safety instructions
Hoisting and transportation
Commissioning
Installation at the site
Operation
Preventive maintenance
Corrective maintenance
Spare parts recommendation

Table of Contents

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Sulzer AHLSTAR 2.15 Series Specifications

General IconGeneral
TypeCentrifugal Pump
ApplicationIndustrial
Impeller TypeClosed
MaterialCast iron, stainless steel
SpeedUp to 3600 rpm
Pressure Rating16 bar
Connection SizeDN 32 to DN 300

Summary

Intended Use

General

Details regarding the general intended use of the pump and its components.

Document Identification

Information on how to identify the specific Sulzer document and its version.

Type Designation

Explains the coding system used for pump type designation.

Parts Number Designation

Details the system for designating part numbers for modules and components.

Nameplate Designation

Describes the information presented on the pump's nameplate.

Capacity and Head

Explains how pump capacity and head are determined and specified.

Decommissioning

Instructions for safely decommissioning the pump at the end of its lifecycle.

Safety Instructions

General

General safety precautions and considerations for pump operation and maintenance.

Safety of Machinery

Focuses on machinery safety requirements, directives, and responsibilities.

Protection Against Mechanical Hazards

Addresses risks from mechanical parts, falling objects, sharp edges, and moving parts.

Protection Against Other Hazards

Covers electrical safety, static electricity, extreme temperatures, fire, noise, and emissions.

Maintenance Safety

Safety considerations related to machinery maintenance, including PPE and working conditions.

Indicators and Definitions

Information and warning devices, residual risks, and definitions of key terms.

Hoisting and Transfers

Safety Measures for Hoisting

Crucial safety precautions and PPE required for hoisting and transferring the pump.

Hoisting and Transfer Procedures

Step-by-step guidance and techniques for safe lifting and moving of pump units.

Commissioning

Purchase Inspection

Procedures for inspecting the pump upon delivery to ensure it meets order specifications.

Storage Guidelines

Guidelines for proper short-term and long-term storage of the pump unit.

Installation at the Site

Safety Procedures Before Installation

Essential safety checks and PPE required before commencing pump installation.

Wet End Installation

Installation details for the pump's wet end, including pipework and supporting.

Sealing Unit Installation

Instructions for installing auxiliary piping for shaft seals and degassing systems.

Coupling Unit Installation

Procedures for installing and aligning the coupling between the pump and motor.

Baseplate Installation

Guidance on installing the pump baseplate, including grouted and mechanical foot options.

Drive Motor Installation

Steps for installing the drive motor onto the baseplate and aligning it with the pump.

Operation

Safety Procedures Before Start-Up

Critical safety checks and preparations required before initial pump start-up.

Starting the Pump

Step-by-step instructions for safely starting the pump under various configurations.

Controls During First Run

Monitoring and control procedures during the initial operation of the pump.

Shut-Down Procedure

Safe steps for shutting down the pump under normal and specific conditions.

Controls After First Run

Checks and adjustments required after the initial run-up period.

Troubleshooting Operation

Guidance on identifying and resolving common operational problems with the pump.

Preventive Maintenance

General Maintenance Overview

Overview of preventive maintenance strategy, its importance, and measuring instruments.

Wet End Maintenance

Maintenance procedures for the wet end, including corrosion, wear, and clearance adjustments.

Sealing Unit Maintenance

Maintenance guidelines for gland packing and mechanical seals.

Bearing Unit Lubrication

Lubrication procedures (grease and oil) and intervals for the bearing unit.

Corrective Maintenance

General Safety for Maintenance

Safety and environmental precautions before performing corrective maintenance.

Pump Unit Disassembly and Reassembly

Procedures for disassembling and reassembling the pump unit.

Wet End Corrective Maintenance

Corrective maintenance steps for the pump's wet end, including impeller and sideplate.

Sealing Unit Corrective Maintenance

Disassembly and reassembly procedures for various types of mechanical seals and gland packing.

Bearing Unit Corrective Maintenance

Steps for disassembling and reassembling the bearing unit, including bearing replacement.

Spare Parts Recommendation

Recommended Spare Parts

Guidance on recommended spare parts and kits for maintaining the pump.

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