A22.SOW_REFERENCE_3_PUMP_TECHNICAL_DATA.pdf

SULZER

VUP 1001 Direct Drive, M9 Motor

PUMP DESIGN

Submersible Axial Flow Pump: The pump and integrated, close-coupled motor shall be a water tight, fully submersible unit, capable of handling raw water, screened sewage, storm water, and other similar fluids containing small solids. The pump with its appurtenances and cable shall be capable of continuous submergence in the pumped liquid to a depth of 65 feet.

Quick Connect Coupling System: The axial flow pump shall be installed vertically in a steel discharge tube or concrete discharge column, and shall engage with a tapered coupling system capable of supporting the entire weight of the pump. No portion of the pump shall bear directly on the floor of the sump. The coupling system shall consist of a steel coupling ring, with a 15 degree seating angle, welded to the bottom of the discharge tube and a mating tapered coupling seat integrated into the pump diffuser. The pump's coupling seat shall incorporate an a-ring to provide a positive seal between the pump and the coupling ring . The pump shall be self centering when lowered into the coupling system, and shall not require personnel to enter the wet well to remove or install the pump. The coupling system shall prevent rotation of the pump in the coupling ring via the 15 degree taper seat, and the weight of the pump assembly. Anti rotation pins, keys, or bars which must be engaged during installation to prevent pump rotation shall not be required . The coupling system's 15 degree seating angle shall prevent accumulation of stones and dirt which can interfere with proper pump seating. Coupling systems which have a seating angle that allows stones and dirt to accumulate on the seating surface are not considered acceptable.

PUMP CONSTRUCTION

Major pump components shall be of gray cast iron, ASTM A-48, Class 40, with smooth surfaces devoid of porosity or other irregularities. All exposed nuts and bolts shall be AISI type 316 stainless steel construction . All metal surfaces coming into contact with the pumped media (other than the stainless steel components) shall be protected by a factory applied spray coating of primer and two part epoxy finish coat.

Sealing design for the pump/motor assembly shall incorporate metal to metal contact between machined surfaces. Critical mating surfaces where a watertight seal is required shall be machined and fitted with Nitrile rubber 0 -rings. Sealing will be the result of controlled compression of rubber 0 -rings in two planes and 0-ring contact of four sides without requiring a specific torque limit.

Rectangular cross sectioned gaskets requiring specific torque limits to achieve compression shall not be considered adequate or equal. No secondary sealing compounds shall be required or used.

Impeller: The impeller shall be a multi piece design with a hub and impeller blades of cast alloy steel DIN 1.4581 (ASTM A351 CF1 OMC). The impeller blade pitch shall be adjustable, and shall be factory set to the correct pitch to provide the hydraulic performance required by the specific application. The blades shall be secured to the impeller hub via integrated stub shafts and locking nuts in the internal, water tight cavity of the impeller hub. The blades shall be locked in place with a taper seat, and factory installed locking pins , which provide positive locking in the proper pitch position. The blade pitch may be adjusted for future hydraulic conditions by removing the locking pins, loosening the locking nuts, and resetting the pitch using a special fixture designed for this purpose.

The impeller assembly shall be dynamically balanced to prevent vibration during pump operation, and shall have a slip fit onto the motor shaft and drive key. The impeller shall be fastened to the shaft by a locking impeller nut, which is mechanically prevented from loosening by a socket head cap screw, threaded through the body of the nut and into the impeller hub. The impeller shall be capable of passing a 6.5 inch spherical solid .

Pump Diffuser: The pump diffuser shall be a single piece gray cast iron, ASTM A48, Class 40 unit surrounding the impeller which directs the water flow from the discharge side of the impeller, axially along the motor, and into the discharge tube. The diffuser passages shall be smooth , and large enough to pass any solids that may exit the impeller. The diffuser shall provide a machined recess to accommodate the Wear Ring System, and a securing mechanism for the Suction Bell Mouth. The diffuser perimeter shall include a tapered seat with sealing a-ring to mate with the coupling ring which is welded (optional bolted) to the bottom edge of the discharge tube column.

Wear Ring System: A replaceable wear ring of martensitic stainless steel DIN 1.4008 (ASTM A743 CA 15), shall be securely fitted into the diffuser housing to control the clearance between the perimeter of the impeller and the diffuser housing. The wear ring shall be bolted in place so that it is easily replaced in the event of wear.

Suction Bell Mouth: A suction bell mouth shall be a single piece gray cast iron , ASTM A48, Class 40 unit, and shall be an integral part of the pump. The suction bell mouth, bolted to the bottom of the diffuser, shall incorporate a flared opening to minimize suction losses and stabilize the flow to the inlet of the impeller. Splitting vanes shall be integrated into the inside diameter of the suction bell mouth to reduce pre-rotation of the fluid column, and further stabilize the inlet flow. Splitting vanes shall be designed with rounded edges and corners, and shall be shaped to prevent fibrous solids from wrapping around and accumulating on the vanes. Suction bell mouths which are accessory items, and are not an integral part of the pump shall not be considered acceptable.

Rotating Assembly: The rotating assembly (impeller, shaft and rotor) shall be dynamically balanced such that undue vibration or other unsatisfactory characteristics will not result when the pump is in operation.

Shaft: The pump shaft and motor shaft shall be an integral, one piece unit. The shaft shall be of 420 stainless steel material and adequately designed to meet the maximum torque required at any normal start-up condition or operating point in the system.

Maximum deflection shall not exceed .002" at the lower seal. Each pump shaft shall have a polished finish and have accurately machined shoulders to accommodate bearings, seals and impeller. Carbon steel or chrome plated shafts, or multi piece friction welded shafts shall not be considered adequate or equal.

Mechanical Seals: Each pump shall be equipped with a tandem mechanical shaft seal system consisting of two totally independent seal assemblies. The seals shall operate in a lubricant reservoir that hydro-dynamically lubricates the lapped seal faces

SULZER

at a constant rate. The lower, primary seal unit, located between the pump and the lubricant chamber, shall contain one stationary industrial duty silicon-carbide seal ring and one rotating industrial duty silicon-carbide seal ring . The upper, secondary seal unit, located between the lubricant chamber and motor housing, shall contain one stationary carbon seal ring and one rotating seal ring made from corrosion resistant Cr-steel. Each seal interface shall be held in contact by its own spring system. The seals shall not require routine maintenance, or adjustment, and shall not be dependent on the direction of rotation for proper sealing. Each pump shall be provided with a lubricant chamber for the shaft sealing system which shall provide superior heat transfer and maximum seal cooling . The lubricant chamber shall be designed to prevent overfilling , and to provide lubricant expansion capacity. The drain and inspection plug shall have a positive anti-leak seal, and shall be accessible from the outside of the pump after removal of the diffuser. The seal system shall not rely upon the pumped media for lubrication and shall not be damaged when the pump is run dry.

The following seal types shall not be considered acceptable or equal: Seals of proprietary design or seals manufactured by other than major independent seal manufacturing companies. Seals requiring set screws, pins, or other mechanical locking devices to hold the seal in place, conventional double mechanical seals containing either a common single or double spring acting between the upper and lower seal faces , any system requiring a pressure differential to seat the seal and ensure sealing.

Bearings: Each pump shaft shall rotate on permanently lubricated, greased bearings. The upper bearing shall be a cylindrical roller bearing with a removable bearing cap which allows access to the bearing from the motor connection chamber. The lower bearings shall be a matched set of four heavy-duty angular contact ball bearings. Bearings shall be of sufficient size and properly spaced to transfer all radial and axial loads to the pump housing and minimize shaft deflection. L-10 bearing life shall be a minimum of 100,000 hours at flows ranging from 90% to 110% of flow at BEP (best efficiency point) .

MOTOR

The motor housing shall be gray cast iron, ASTM A48 Class 40. The motor shall be of the squirrel-cage induction shell type design (NEMA B type) , housed in an air filled , watertight chamber. The stator windings, insulation materials and stator leads shall be rated for class H (180°C} temperature, and insulated with moisture resistant Class H polyester resin varnish using the VPI (vacuum pressure impregnation) process. The VPI process effectively evacuates all moisture, and insures that the resin fully penetrates the cavities of the winding . Motors insulated using a dip and bake process or trickle impregnation process shall not be considered equal or acceptable because the resin in these processes fails to effectively penetrate all cavities of large motors. The motor shall be designed to operate at full load with a class B (80 °C) temperature rise.

The stator shall be heat-shrink fitted into the stator housing. The use of bolts , pins or other fastening devices requiring penetration of the stator housing is unacceptable. The motor shall be designed for continuous duty operation, handling pumped media of up to 40°C (104°F) and be capable of handling up to 15 evenly spaced starts per hour. The motor service factor (as defined in NEMA MG1) shall be a minimum of 1.10. The motor shall have a voltage tolerance of +/- 10% from nameplate rated voltage. The motor shall be suitable for operation on all modern PWM type variable frequency drives.

The rotor bars and short circuit rings shall be made of aluminum or copper. The motor shall be designed for continuous duty service.

The explosion proof variant of the motor shall be approved by Factory Mutual as explosion proof for use in NEC Class 1, Division 1, Group C&D hazardous locations (T3C).

Thermal Protection: Each phase of the motor shall contain a bi-metallic temperature monitor in the upper portion of the stator windings. These thermal switches shall be connected in series and set to open at 140°C +/- 5°C. They shall be connected to the control panel, and used in conjunction with and supplemental to external motor overload protection. The motor shall also be supplied with bi-metallic sensors to monitor the temperature of the upper and lower bearings. These sensors shall be connected to the control panel and shall provide advanced warning of high bearing temperature.

Seal Failure Early Warning System: An electrical probe shall be provided in the seal oil chamber, motor chamber and electrical connection chamber for detecting the presence of water. These probes shall be provided for both standard and explosion proof versions. Solid-state devices mounted in the pump control panel or in a separate enclosure shall send a low voltage, low amperage signal to the probes. If water enters the monitored chambers, the probe shall signal the solid state relay in the control panel. The relay shall then energize a warning light or shutdown circuit in the control panel , protecting the motor from damage. Systems using float switches, dual probes, or any other monitoring devices are not considered to be early warning systems, and shall not be considered equal.

Power Cables: The power cables shall be sized according to NEC and CSA standards and shall be of sufficient length to reach the junction box without requiring splices. The outer jacket of the cable shall be oil resistant chloroprene rubber, and shall be capable of continuous submerged operation underwater to a depth of 65 feet.

Cable Entry/Junction Chamber: The cable entry design shall not require specific torque requirements to insure a watertight seal.

The cable entry shall consist of a cylindrical elastomer grommet, flanked by stainless steel washers. A cable cap incorporating a strain relief shall mount to the cable entry boss compressing the grommet ID to the cable while the grommet OD seals against the bore of the cable entry. The junction chamber shall be isolated and sealed from the motor by means of sealing glands. Electrical connections between the power cables and motor leads shall be made via a post type terminal board.

12 Pole, M9 Motor VUP 1001 VUP Tab -----

MOTOR SPECIFICATIONS

Motor Design NEMA desiqn B, squirrel cage induction, air filled Motor Type Enclosed submersible Insulation Class Class H, rated at 356°F (180°C) Bimetallic Temp Setting 356°F ± 9°F (140°C ± 5°C)

Motor Protection Thermal Bimetallic in each Phase, at upper and lower bearings LeakaQe DI Moisture in seal chamber, in motor housinq and junction chamber

Maximum Submergence 65 feet (20 meters) Max. Fluid Temperature 104°F (40°C) Voltage Tolerance ± 10%

RPM 595

Agency Aoorovals Explosion Proof Variant: FM & CSA Class 1, Div. 1 Group C & D (T3C)

PUMP & MOTOR DATA

Nominal DischarQe Size 48" Impeller Blade Pitch, degrees 12.0 Solid Size-lnches(mm) 6.88 (175) Nominal Impeller DIA inches {mm) 39.4 (1000) WK~ LB-FT~ (with water) - kg-m~ 380 (16) Impeller weiQht LBS. (kQ) 507 (230) Minimum Flow GPM {Ifs) Based on motor power, consult performance curves Motor M2200/12-92 HP (Kw) 295 (220) Phase 3

MATERIALS of CONSTRUCTION

Motor Housing Cast Iron ASTM A48 Class 40 Oil Chamber Cast Iron ASTM A48 Class 40 Seal Plate Cast Iron ASTM A48 Class 40 Impeller Hub Stainless Steel [ASTM A351 Gr CF-10MCj 1.4581 Impeller Blades Stainless Steel fASTM A351 Gr CF-1 OM Cl 1.4581 Diffuser and Suction Bell Cast Iron ASTM A48 Class 40 Diffuser Wear RinQ Alloy Cast Steel fASTM A217-75 Gr CA-151 1.4008 martensitic stainless steel I Coupling Ring Alloy Steel 1.0446 (no direct ASTM equivalent) Pump and Motor Shaft 420 SS External Hardware 316 SS 0-Rings and Cable Glands BUNA "N" (NITRILE) I Uooer Bearinq Cylindrical Roller Bearinq Permanently Lubricated, insulated for VFD compatibility Lower Bearings Angular Contact Ball Bearings Permanently Lubricated Tandem Lower Silicon Carbide on Silicon Carbide Mechanical Seal Upper Chrome Steel on Carbon

WEIGHT OF PUMP AND MOTOR, LBS (Kg); AND VOLUTE DIMENSIONS roof 9834 4460 Nominal Suction Size

CABLE SPECIFICATIONS (For sizing conduit; consult factory for sizing strain relief grips)

Type H07RN-F, Ozoflex Power Cable Number I 2 I I I

OD inches(mm) I 2.37max (60) I I I Type H07RN-F, Ozoflex

Control Cable Number I 1 I I I OD inches(mm) I 0.77max (19.5) I I I

Cable Length 64 feet (20 Meters)

Specifications subject to change without notice

- Test Certificate OT13 Rev.00

VUP 0501 ME 250/8-43.60 60 Hz pump No. 34762 rated voltage (U) 460 v duty point(s) order No. 720886 impeller 14 rated input (P1) 27,4 kW H [ft} Q [USGpM] RM - No. 418650 vane 3 rated power (P2) 25,0 kW 6 10000 discharge ON 700 rated current (I) 45 ,0 A meas-ON 619mm rated speed (n) 877 1/min meas-voltage 460 v type of hydraulic VUP 0501

Htot Q Hst Q P1 I p.f. Eff tot Eff mot Eff p P2 [ft] [USGpMJ [m] [m3/h] [kW] [A] [%] [%] [%] (hp]

13,56 7671 4,00 1742 29,5 48,5 0,76 66,5 89,6 74,2 35,5 11,99 8340 3,50 1894 27,0 44,8 0,76 69,8 90,1 77,5 32,7

10.44 8992 3,00 2042 24,6 41,3 0,75 72,0 90,5 79,5 29,8 8,87 9498 2,50 2157 22,1 37,9 0,73 71 ,9 90,7 79,3 26,9 7,29 9934 2,00 2256 20,0 35,2 0,71 68,1 90,8 75,0 24,4 6,06 10299 1,61 2339 18,0 32,7 0,69 65,4 90,9 72,0 21,9 5,72 10440 1,50 2371 17,6 32,1 0,69 63,9 90,9 70.4 21 ,5 4,14 10810 1,00 2455 15,2 29,3 0,65 55,6 90 ,6 61 ,4 18.4 2,57 11224 0,50 2549 13,1 27,0 0,61 41 ,6 89,8 46,3 15,7

Acceptance test according to Hydraulic Institute (in clear water)

Htot Eff p (f1h ,,.. [%}

10 - 100

6 - 60 - ~ -

~~ 40 - .... " 2 20

0 I 0 P2 [hp]

7500 8000 8500 9000 9500 10000 10500 11000

Q [USGpMJ date : 25.06.07 tested by : Ockenfeld