Transfer Pump Manual

Page 1
USERS MANUAL
Issue date : 2/4/2009
INSTRUCTIONS
FOR OPERATION AND MAINTENANCE

OF
CENTRIFUGAL PUMPS FOR LIQUEFIED GASES
Type:
CO120/6.4-C/O
Comm. No.:
ECC39282-01
Customer:
PRAXAIR
Order No.:
186-LFPSG/DM
The purpose of these instructions is to facilitate the operation of your pump and to avoid
errors. Reading these instructions carefully before installation and start-up means safeguarding your interests and will be repaid by satisfactory service and performance of the
machine and low cost of repair.
We recommend you to keep on stock all spare parts mentioned in these instructions and
would be grateful if, when placing orders for spares, you would use our designation and
indicate the number of your pump. You will find the machine number of the name plate of
each pump.
Orders can be placed at :

Sales and service departments
Cryostar-USA
5897 Colony Drive
Bethlehem, PA 18017
Manufacturer
Cryostar-USA
9211 S. Greenleaf Ave.
Santa Fe Springs , CA 90670
Telephone:
fax:
Telephone :
fax :
(484) 281-3401
(484) 281-3402
(562) 903-1290
(562) 903-4511
Page 2
USERS MANUAL
GLOBAL LOCATIONS
CRYOSTAR FRANCE S.A.
GLOBAL HEADQUARTERS
Zone Industrielle
B.P. 48
Hesingue
F-68221 HEGENHEIM CEDEX
Tel: +33(3) 89 70 27 27
Fax: +33(3) 80 67 59 54
CRYOSTAR SINGAPORE
CRYOSTAR UK
203 Henderson Road

Blk B# 10-09
Henderson Industrial Park
SGP - SINGAPORE 159546
Tel: +65 276 7441
Fax: +65 276 7442
Station Road, Industrial Estate

Unit 4+5
GB - WOMBWELL, Barnsley
S73 OHA, S. Yorkshire
Tel: +44 1226 759 921
Fax: +44 1226 756 729
USER RESPONSABILITY
This equipment will perform in accordance with the instructions and information contained in this manual, and
its referenced documents, when such equipment is installed, operated and maintained in compliance with
such instructions. The equipment must be checked periodically. Defective equipment shall not be used. Parts
that are brocken, missing, plainly worn, distorted or contaminated shall be replaced immediately. Should such
repair or replacement become necessary, CRYOSTAR recommends that a request for service will be made.
We recommend you to keep on stock all spare parts mentioned in these instructions. At the end of the manual
we indicate how to put in an ordre for spares.
The equipment, or any of its parts, shall not be altered without the prior written approval of CRYOSTAR. The
user and /or purchaser of this equipment shall have the sole responsibility for any malfunction which results
from improper use, faulty maintenance, damage, the use of spare parts that are not from CRYOSTAR,
improper repair or alteration by any party other than the manufacturer.
Attention
It is essential to read the directions for use prior to unpacking and installation.
Moreover, the machine must be used and maintained by qualified personnel.
Note
This document is the property of BOC-AG Cryostar. It is not permitted to copy it, or to relate its contents to
other persons, or to misuse it in any other way.
TABLE OF CONTENTS
Page 3
USERS MANUAL
1. TECHNICAL DATA
1.1. Pump data
1.2. Operating data
1.3. Motor data
1.4. Acoustic pressure
1.5. Test
1.6. Description of the Design
2. SAFETY
2.1. Warning
2.2. Isolation and energy dissipation
2.2.1. Isolation and dissipation of gas process energy
2.2.2. Isolation and dissipation of purging gas energy
2.2.3. Isolation and dissipation of electrical energy
2.3. Safety form for oxygen pump
2.4. Customer safety instructions - Summary
3. STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION

3.1. BOC AG - Cryostar Delivery Inspection
3.2. Degreasing and Lubricating Grease/Oil for Oxygen Duty
3.3. Inspection by Customers on Arrival
3.4. Storage of the Pump
4. INSTALLATION
4.1. Handling
4.2. Erection
4.3. Installation Scheme
4.4. Storage Tank
4.5. Piping
4.5.1. Suction Line
4.5.2. Discharge Line
4.5.3. Bypass Line
4.5.4. Vent Line
4.6. Valves and Fittings
5. LUBRICANTS
5.1. Characteristics
6. START-UP
6.1. Pre-Start-Up Inspection
6.1.1. Spin Test by Hand
6.1.2. Direction of Rotation
6.1.3. Vent
6.1.4. In labyrinth pump : centering labyrinth rings
6
6
6
6
6
7
8
9
9
10
11
11
11
12
14
16
16
16
16
16
17
17
17
17
17
18
18
19
20
20
20
21
21
22
22
22
22
22
22
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6.2. Cool-down and Start-up of the Pump

6.3. Suction Pressure and Mechanical Seal
6.4. Shut-down of the Pump
23
24
25
7. TROUBLE SHOOTING
26
8. MAINTENANCE INSTRUCTIONS
29
8.1. General
8.1.1. Assembly / Disassembly : Table of tightening torques and forces
8.2. Periodical Revisions and Maintenance
8.3. Dismantling of the pump
8.4. Assembly of the Pump
8.5. Adjustment of the Mechanical Seal
9. CRYOSTARS MAINTENANCE AND SPARE PARTS SERVICE

9.1. Order Instructions
10. ANNEX
10.1. NPSH
10.2. Appendix to spare parts lists
10.3. Documentation
29
29
31
32
32
33
34
34
35
35
37
38
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USERS MANUAL
LIST OF DRAWINGS AND OTHER ENCLOSURES
DRAWING TITLE
DRAWING
NUMBER
Flow diagram
Handling drawing
Dimensional drawing
Performance curve
Top Assembly
Special tools
Checklist
705070145
708114352
702114258-01
Test curve
763150972-02
763026005
706110196
SPARE PART
LIST NUMBER
E763150972-02
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USERS MANUAL
1.
TECHNICAL DATA
1.1.
Pump data
Serial number
Type
Number of stages
Nominal impeller diameter
Speed
Position of suction nozzle
Position of discharge nozzle
Material Execution
Year / Month built
1.2.
Operating data
Medium
Liquid temperature
Max. Suction pressure
Minimum NPSH
Flow rate
Differential head
1.3.
LN2
-196C
5 barg
0.6 m
25 gpm
380 ft
Motor data
Cryostar ref.
Type
Protection
Insulation class
Temperature rise
Frequency
Phase
Voltage
Power
Speed
Forced ventilation
1.4.
ECC39282-01
CO120-6.4 C/O
1
120 mm
6400 rpm
Axial
I
Bronze / Bronze
2007 / 12
792605195-01/004
213T NEMA
IP 55
F
B
104 Hz
3
460 V
10 HP
6400 rpm
3x480V, 60 Hz
Acoustic pressure
Average value
85 dB A
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USERS MANUAL
1.5.
Test
Medium
Test speed
Nitrogen
Refer to acceptance report
Note :
Working data have been measured at the test stand.
The test allows pressure to be checked under cryogenic working conditions.
Note : if required, test protocoles, material certificates or pressure test certificates are
included in the quality data book depending on the contract conditions.
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USERS MANUAL
1.6.
Description of the Design

The pump is a single stage high speed centrifugal pump driven by an
electromotor.
The pump is mounted with a support to the motor flange.
The pump is directly coupled to the motor shaft. For the support of the
impeller, the motor bearings are of the highest precision and are fully
externally sealed.
The undesirable cold creep from the pump cold end to the bearings is reduced
to a minimum by an insulation ring, small contact surfaces and long support
arms.
The pump seal is a special mechanical seal.
These instructions contain a description of the pump, as well as complete
descriptions of installation, operation and maintenance of the pump.
Options
The rear chamber of the seal can be provided with a connection for N2purging.
A temperature probe can be installed on the motor bearing for maximum and
minimum temperature control. A space heater can be installed on the motor
bearing.
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USERS MANUAL
2.
SAFETY
2.1.
Warning
Safety norms applied on site must be scrupulously respected. The

enforcement of a safety area will limit access to authorized personnel
only. Any operation on equipment in use is prohibited
Any operation on equipment in use is prohibited
Any normal operation must be made according to the recommendations

in the instructions
Any repairs must be made according to the recommendations in the
instructions
FATAL OR MOST SERIOUS INJURIES MAY OCCUR IF SERVICE

PERSONNEL DO NOT FOLLOW THE SAFETY REGULATIONS
High voltage is applied in the operation of this equipment.
The use of liquid gases or gases under high pressure has high risk factors
if service personnel do not follow safety regulations.
Fatal or most serious injuries, fire, explosions or suffocation may occur
depending on the liquid gas used in the system. Please, refer to the motor
instructions
Explosion hazard in the presence of oxygen

Cleaning and degreasing for use with oxygen
All components and equipment must be cleaned and degreased and must be
safe for use with oxygen.
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USERS MANUAL
After cleaning and degreasing, the components and equipment should be

sealed and protected against contamination. The sealing and protection
should not be removed until immediately before installation. Consult Cryostar.
Explosion hazard in the presence of oxygen !

Carefully remove all degreasing fluid, which may also be extremely
hazardous in the presence of oxygen!
For obvious technical reasons linked to ice formation, it is not possible to
completely isolate all pump components.
Burning hazard !
During cool-down and working periods, it is strictly forbidden to touch
the machine
Our products must be handled with a handling system. Please, refer to

the Installation scheme
2.2.
Isolation and energy dissipation
(Maintenance)
Our products must be installed in a unit which ensures all functions of
cutting, separation, locking, pressure purging and checking
All energy external to our product originating from the customer (electricity,
purging gas, compressed air, N2-purging, etc...) must be isolated and
dissipated by means of isolating switches (hand operated valves with
padlocks, locking electric switches..). Gas line valves must be chosen
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USERS MANUAL
carefully so as to permit a VOLUNTARY locking or unlocking of the user with

valve isolation.
2.2.1.
Isolation and dissipation of gas process energy
Components and instruments which permit the isolation and the dissipation of
the gas process energy depend on the users internal procedures of isolation
and energy dissipation and the parameters of their networks. Thus, it is not
possible for CRYOSTAR to plan the installation of this type of equipment on
the supplied machine.
2.2.2.
Isolation and dissipation of purging gas energy
The user must ensure that all purging pipes have been isolated before any
operation on the product.
2.2.3.
Isolation and dissipation of electrical energy
Before each operation on parts or equipment normally under voltage, the

personnel must isolate them when the equipment is at a standstill.
- Cut off and separate the equipment from the supply source by switching off.
- Lock the switch in a separation position with a padlock or any equivalent
locking device. The locking switch must be in an open position.
- Before operation, check that there is no more accumulated residual voltage
(Note : All orange coloured electrical circuit of the electrical equipment
supplied by CRYOSTAR remain permanently under voltage).
All electrical operation should be carried out by trained and authorized
personnel. The electrical connections must be connected by trained and
empowered personnel who must respect the local regulations and
protection rules in force.
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USERS MANUAL
2.3.
Safety form for oxygen pump
Physical properties:
. Formula :
. Atomic number
. Molecular weight :
. Molecular dimensions :
. First ionization potential :
. Gas density S.T.P. :
O2
Z=8
31.9988 g.mole-1
4,2-2,8
12.059 eV
1,4289 kg.m-3
Oxygen is a gas colorless, odorless and testeless.
Working recommendations :
. No smoking near the pump.
. Oil and grease stained clothing must not be worn.
. Greasy rags should not be left lying about and the floor must be free of oil stains.
. Work with flame should be avoided in the enclosure of the pump.
Recommendations in case of accident (fires, burnd) :

In case of clothing fires, it is essential to act with maximum speed.
Water is still the best extinguisher in several cases. Hence quick action with a shower, bath or
extinguisher is necessary. It appears that hasty wrapping in a blanket is of doubtful effectiveness.
First aid for burn victims (low temperatures of liquid oxygen) :

Burns of this type are generally local.
Burnt parts of the body should be warmed gradually and then treated as conventional burns.
While awaiting the doctor, carry out the following first aid measures :
. If large blisters have been formed on the skin or if the eyes are suffering from burns, immerse the
burnt area in water or apply cold compresses, and convey the victim to a doctor.
. If the injury is less serious (spattering on the skin, small blisters), immerse the burned area in cold
water until the pain stops, coat the area with vaseline and keep it wet for 24 hours by means of a
cold 30 g/l boric acid solution.
. Do not pierce the blistes.
. Do not touch or undress the victim
. Do not speak to the victim face to face
. If possible, wrap burnt parts of the body in sterilized compresses
. Always summon a doctor immeditately.
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USERS MANUAL
. Cover the victim with a sterilized blanket.
Leak detection and analysis :

Before employing a pump intended for use with pressurized oxygen, test the assembly with a leak
detector such as a helium detector.
The atmosphere surrounding an installation containing oxygen must be monitored for oxygen
concentration. Any rise in the latter considerably increase the risk of accident. Portable oxygen
analyzers may be employed.
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USERS MANUAL
2.4.
Customer safety instructions - Summary

WARNING
All operations must be carried out by
appropriately trained personnel
AVERTISSEMENT
Toutes les interventions doivent tre
effectues par un personnel habilit
ACHTUNG
Alle Arbeiten mssen von
entsprechend geschultem Personal
ausgefhrt werden
Gases and liquid under high pressure
Gaz et liquides sous haute pression
Flssigkeiten und Gase unter hohem

Druck
LIFTING
Vertical lifting : prevent uncontrolled
rotation
LEVAGE
Levage vertical : Empcher toute
rotation non contrle
HEBEN
Senkrechtes Heben : unkontrolliertes
Drehen vermeiden
PRE-INSTALLATION CHECKS
CONTRLES AVANT
INSTALLATION
Toute pompe doit tre contrle ds
rception
UEBERPRUEFUNGEN VOR DER

INSTALLATION
Jede Pumpe sollte unverzglich nach
Ankunft untersucht werden
Check nameplate details
Vrifier les informations sur la plaque

signaltique
Typenschilddetails prfen
Check stored equipment every 6

months
Vrifier le matriel entrepos tous les

6 mois
Gelagertes Material alle 6 Monate

kontrollieren
No loose fasteners
Pas de fixations desserres
Keine losen Befestigungen
MECHANICAL INSTALLATION
Gaskets and seals correctly mounted
INSTALLATION MECANIQUE
Montage correct des joints et
garnitures
MECHANISCHE INSTALLATION
Korrekte Montage von Dichtungen
und Gleitringdichtungen
Refer to instructions
Se reporter au manuel dinstructions
Siehe Betriebsanleitung
ELECTRICAL INSTALLATION
INSTALLATION ELECTRIQUE
ELEKTRISCHE INSTALLATION
ausgefhrt werden
Earthed
Mis la terre
geerdet
Check rotation, uncoupled
Vrifier la rotation vide
Maschine in Leerlauf prfen
Connections are tight ?
Les connexions sont-elles serre ?
Sind die Anschlsse fest angezogen ?
Covers must be fitted
Les capots de protection des botes

borne doivent tre en place
Abdeckungen der Klemmenkasten

mssen angebracht sein
Fused and isolated correctly
Protg par coupe circuit et isol

correctement
Korrekt abgesichert und isoliert
Every control box with a heating band

must be on
Toute armoire lectrique quipe

dune rsistance chauffante doit rester
sous tension
Jeder Elektro-Schrank mit Heizband

muss unter Spannung sein
Respect tightness of the control box

while cabling
Respecter ltanchit de larmoire

lectrique lors du cblage
Beim Anschlussen des ElektroSchrank Dichtheit beachten
Shut front protection covers after use
Veiller fermer les capots de
Nach dem Gebrauch vordere
Every pump should be checked

immediately upon delivery
Page 15
USERS MANUAL
protection en faade aprs utilisation

CONNEXIONS
Vrifier le schma de cblage
Abdeckungen zumachen
ANSCHLUESSE
Anschlsse nach Anschlussplan
berprfen
Check driven equipment is free
Vrifier que la machine entrane soit

libre
Prfen, ob angetriebene Maschine frei

beweglich ist
Correct terminal arrangement
Vrifier le reprage des bornes
PROBLEMS
Pump does not prime
PROBLEMES
La pompe naspire pas
Auf einwandfreien elektrischen

Anschluss achten
PROBLEME
Pumpe saugt nicht
Rated capacity and pressure not

achieved
Dbits et pressions trop faibles
Durchsatz und Frderhhe nicht

erreicht
Mechanical seal leaking
Fuites garniture
Gleitringdichtung undicht
Vibrations
Vibrations
Pumpe vibriert
Pump overloads drive
Moteur surcharg
Pumpe berlastet den Antrieb
Bearings overheated
Roulements schauffent
Lager laufen sich heiss
Refer to supplier
Consulter le fournisseur
Hersteller fragen
MAINTENANCE
Isolate
ENTRETIEN
isoler
WARTUNG
trennen
Refer to supplier for details of

greasing etc...
Pour les dtails de lubrification etc..

consulter le fournisseur
Schmierung usw. siehe

Herstellungsangaben
SPARES
Refer to supplier
PIECES DE RECHANGE
Consulter le fournisseur
ERSATZTEILE
An Hersteller wenden
Quote equipment number, stock

number, designation
Indiquer le numro de la machine, le

numro de plan de la pice, la
dsignation
Maschinennummer,
Zeichnungsnummer, Benennung
angeben
HAZARDOUS AREAS
ZONES DANGEREUSES
GEFAHRENBEREICHE
ausgefhrt werden
Refer to:
construction standard EN 294
Se reporter :
norme de construction EN 294
Bitte nachschlagen in :
Baunorme EN 294
STORAGE
Storage in a dry environment
the right way round
STOCKAGE
Stockage en lieu sec
lendroit
LAGERUNG
Lagerung in trockenem Raum
Richtig stellen
CONNECTIONS
Check connection diagram
Page 16
USERS MANUAL
3.
STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION

3.1.
Cryostar Delivery Inspection

Every pump undergoes a trial operation with liquid nitrogen before leaving our
works, hence only perfectly functioning machines are delivered from our
factory.
3.2.
Degreasing and Lubricating Grease/Oil for Oxygen Duty

Pumps labelled 'degreased for running with oxygen' may be run with
oxygen without further treatment. They are delivered with a grease/oil suitable
for oxygen service. Pumps delivered, by customer request, with mineral
grease, are labelled 'not for oxygen'.
3.3.
Inspection by Customers on Arrival

Every pump should be checked immediately upon delivery, and any damages
incurred during transportation should be reported immediately to the
transporters or to Cryostar. Refer to Sales Conditions, Incoterms, Issue 1990.
3.4.
Storage of the Pump
If the pump is not for immediate use, it must be stored in a dry

environment, protected from oil, dust and water.
Important: The polyethylene wrapping around the pump, and the protective covers on the
pipe connections should only be removed immediately before installation.
CAUTION: Check stored equipment and spare parts at regular intervals e.g. every six
months at minimum. Any moisture, dust, rust etc. must be removed before
use. Note, parts for oxygen service which are stored or installed for more then
six months prior to use must be dismantled and checked carefully prior to
start-up.
The time period given above is our recommendation only and must be
adapted to the users own safety regulations. Fatal or most serious injuries
may occur if service personnel do not follow the safety regulations.
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USERS MANUAL
4.
INSTALLATION
4.1.
Handling
Every machine that weights more than 55 kg must only be handled with a
Handling System. Please refer to Handling drawing.
PUMP TYPE
Weight 500 Kg
Pump with gearbox
Weight 500 Kg
Pump without gearbox
VCS
LOX
CBSH
4.2.
HANDLING DRAWING No.

708111520
708114352
705113963
705104881
705111521
Erection
Place skid on a flat surface that has been prepared according to the
dimensional layout drawing and capable of supporting the indicated load.
Secure the skid to the surface with the required amount and size of bolts as
indicated in the foundation drawing. The skid to be preferably grouted to limit
vibration. The stability of the whole installation must be ensured.
4.3.
Installation Scheme
The enclosed installation schematic drawing and operating instructions on the
following pages apply in normal operating circonstances only. Therefore, they
are relatively general and only the most important points for all different
service applications are mentioned. The installation schematic drawing shows
only indispensable equipment and piping for the operation of a pump for
liquefied gases and should be completed accordingly for different applications.
4.4.
Storage Tank
Most suitable is a pressurised storage tank which maintains the required
NPSH of the pump (see par. 10.1). The machine must be installed as close as
possible from the tank.
The tank discharge connection should be in the bottom of the tank and short.
A syphon or plunging pipe are unsuitable as gas which is formed in the line is
collected and cannot leave the pipe.
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USERS MANUAL
The diameter of the tank discharge connection should be adjusted to the flow.
It should not be too small (minimum diameter same as the pump suction
connection) to keep the pressure drop small.
4.5.
Piping
Piping must be carefully designed so as not to transmit any stresses or forces
to the pump during operation or during stand still. Temperature contractions
and elongations must also be taken into consideration. For this reason,
flexible pipe parts should be installed.
4.5.1.
Suction Line
The suction line connects the tank discharge and the pump suction connection
and should be as direct and as short as possible.
The pipe must have a constant downwards inclination to the pump to allow
forthcoming gas to return into the tank.
The pipe diameter should be selected and designed for flow with an average
velocity of approx. 1 m/sec. Smaller velocities reduce the friction losses, but
disadvantageously increase the heat inleak accordingly. This reduces the
available NPSH (see
par. 10.1) and increases the gas vaporization loss during the cool down
period.
Good insulation is therefore essential. But it should not hinder the movements
of flexible pipe parts (flexible hose).
In view of gas vaporization losses the shut-off valves and the filter should not
be too large, as larger sizes mean increased heat inleak and longer cool down
time.
Pumps for oxygen service must be protected against foreign particles by a
filter in the suction line. Particles, which enter the pump are a potential fire or
explosion hazard.
The filter should have approx. 560 micron mesh and the useful surface should
be two times the suction pipe area at minimum.
Manifolds without a constant liquid flow should be shut-off as close as
possible to the branch in order to minimize the liquid gas vaporization.
All piping sections which can be shut-off must be equipped with safety valves
to avoid excessive pressure increase due to the vaporization of liquid gas.
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USERS MANUAL
4.5.1.1. Design of the suction line
Installation of the suction line

The pipe must be as short and direct as possible
Well insulated and applying no force to the pump
Same diameter as the pump suction connection (also fittings and valves)
Fitting and valves limited to a minimum
Constant inclination downward to the pump
Required Fittings and Valves
a) Shut-off valve
b) Safety valve
c) Flexible pipe section
d) Filter for oxygen service (only if the pump is used with oxygen)
e) Non-return valve on the pump discharge
Recommendations
e) Shut-off valve in every branch

f) Pressure gauge
g) Gradual pipe diameter changes branch connections
h) Drivaton oblique
Filter even for non oxygen service
k) Insulation
4.5.1.2. Suction line : Installation Errors

Possible Installation Errors
Abrupt pipe or valve diameter
changesPressure drop
Narrow bends, T-branches
Long pipe without insulation
Branch shut-off walve not close enough,
branch pipe not insulated
High point in the line
Flexible elbow
Lack or filter or safety valve
Trouble
Pressure drop
Pressure drop
Pressure drop and heat inleak
Gas formation, the gas will be sucked
into the pump or the suction line will be
clogged
Gas accumulation, gas bubbles will be
sucked into the pump or the suction line
will be clogged
Additional force
Pump or seal failure possible
Note: Pressure drop, heat inleak = lowers the NPSH

4.5.2.
Discharge Line
The discharge pipe should have the same diameter as the discharge
connection of the pump, or somewhat larger for longer piping and when
excessive pressure loss would restrict the flow too much.
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USERS MANUAL
The discharge line characteristic must be put into consideration with the pump
characteristic curve!
A shut-off valve, a non-return valve and pressure gauge should be installed in
the discharge line.
4.5.3.
Bypass Line
For faster cool down and for easier start-up a bypass line should be provided.
The bypass pipe should have the same diameter as the pump discharge line
or should be designed for the pump minimum flow.
4.5.4.
Vent Line
A vent pipe with shut-off valve is advantageous for the venting of piping and
pump and for faster cool down.
4.6.
Valves and Fittings

All valves, fittings, filters, manometers, etc.. must be adapted to a companys
own internal safety regulations and must also correspond to health-safety
legislation.
For any damages caused by unsuitable assembly of the piping system,
CRYOSTAR cannot be held responsible.
Page 21
USERS MANUAL
5.
LUBRICANTS
The following lubricants should be used:
Motor-bearing Grease
ESSO Beacon 325
ESSO Beacon 325
For oxygen service

For service with argon, nitrogen or
hydrocarbon
Caution:
Because of explosion risk, do not use normal, commercially mineraloil-based
lubricants for oxygen service.
5.1.
Characteristics
CHARACTERISTICS
ESSO BEACON 325

UNIT
Appearance
Soap base
Temperature range
Base oil
Kin. viscosity
at 40C
at 100C
Drop point
Penetration-unworked
Penetration-worked x60
Bearing performance against corrosion
Test NF T 60-135
Resistance to water washing out at 40C
Loss
Tests on bearings at high temperature
Test FTMS 791 b-331-2 at 120C
Vaporization losses
Test ASTM D 972 (22 h 121C), loss
AVERAGE VALUE
creamy smooth grease
Lithium
-55 to 120C
synthetic ester
cSt
cSt
C
11.8
3.25
180
260
280
0
% wt
>1000
% wt
0.5
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USERS MANUAL
6.
START-UP
6.1.
Pre-Start-Up Inspection
Check whether all pipes, fittings, fixing bolts and electric connections are
ready for start-up.
Prepare the complete system, in which the pump is installed for start-up.
For gearbox driven pumps, check the oil level.
6.1.1.
Spin Test by Hand
Spin the pump by hand using the slinger ring on the pump shaft or an offset
spanner on the motor fan screw to control the rotation.
6.1.2.
Direction of Rotation
Start the motor for a short run (the pump must not be operated without liquid!)
and check whether the pump shaft rotation is the same as the arrow direction
on the pump volute.
6.1.3.
Vent
CAUTION
BEFORE OPERATING THE PUMP, ALL SUCTION LINES, DISCHARGE
LINES AND THE PUMP SHOULD BE VENTED SO AS TO PREVENT
HUMIDITY OR ICE FROM BUILDING-UP IN THE PUMP DURING THE
COOL DOWN PERIOD
THE LENGTH OF TIME FOR THIS WILL VARY DEPENDING UPON LOCAL
CONDITIONS : ONE DAY MINIMUM after a long break
6.1.4.
In labyrinth pump : centering labyrinth rings
Caution : For labyrinth pumps, loosen the labyrinth seal cover screws. Turn
pump on end i.e. rotate the shaft manually to ensure that it rotates
correctly and to ensure the self-centering of the labyrinth rings. Then, the
cover screws of the labyrinth seal may be definitively tightened-up.
Page 23
USERS MANUAL
6.2.
Cool-down and Start-up of the Pump

(see drawing 'Flow diagram')
WARNING
The pump must not run without liquid!
Safety clothes, gloves, spectacles, etc... according to On-Site regulations
Do not touch the equipment while in use
Warning : Pumps with mechanical seal

Before cooling down, purge the mechanical seal with dry nitrogen for at
least 10 minutes to prevent moisture ingress into mechanical seal area
causing freezing together of seal faces. The mechanical seal purging tubing
must be in stainless steel or in copper. The gas must be clean. Refer to
Suction pressure and mechanical seal.
Warning : For labyrinth pumps, see Starting and pressure regulation of
seal gas
Warning : Pumps with lantern N2-purging
In operation and especially during cooling down period, the warm box must be
purged with gaseous nitrogen to prevent motor bearing and pump end from
freezing.
The nitrogen purging pressure must be 0.15 barg.
It must be started before cooling down the pump.
Nitrogen gas must be dry.
Dew point: -80C
Warning : Pumps with protection chamber N2-purging
The nitrogen purging pressure must be 0.15 barg. Purging in operation and
during cooldown of the pump is necessary. Open seal gas inlet which must be
dry nitrogen.
Warning : Pumps with motor front bearing heater
Heater must be electrically powered.
Open suction valve and bypass valve 6 slowly. Liquid flows from storage tank
into the pump and cools it down. During the cool-down period the pressure
regulating valve 4 is closed and the bypass valve 6 open.
Page 24
USERS MANUAL
When cooling down, start the pump every 2-3 minutes for a short run of 2 to 3
seconds. This prevents contact freezing of the sealing surfaces.
During cool-down the storage tank pressure rises. This improves the pump
start-up conditions due to improved NPSH - see section NPSH.
When a ventline with block-valve against air inlet is installed in the discharge
or bypass line, cool-down can be accelerated by venting the gas into the
atmosphere. Do not open the shut off valve for too long a period, otherwise
the storage tank pressure will drop too much.
Normally the pump will be cooled down after 10-15 minutes.
The white frost from the pump body then begins to extend to the four support
arms. If the pump is overcooled (support arms completely frosted) it should be
started only after the shaft has been checked for freedom of rotation.
After the pump is well cooled down fully open the suction valve. If one is
installed, close the ventline and block valve and regulate the bypass valve
according to the diameter of the pipe. Start the pump.
Adjust to the required discharge pressure with bypass valve 6. Then
simultaneously open pressure regulating valve 4 and close bypass valve 6.
This starts liquid gas delivery to the consumer.
Do not control the flow with the suction shut off valve! This valve must remain
fully open during operation. Partial closure will decrease the available NPSH
and could disturb the trouble free operation.
6.3.
Suction Pressure and Mechanical Seal

For good priming and trouble-free operation every liquid gas pump needs a
certain net positive suction head (NPSH), i.e. some over pressure above the
liquid gas vapor pressure in the pump suction nozzle (see also section 10.1 NPSH).
Sometimes the geodetical head of the tank (the liquid column above the pump
suction nozzle) is not sufficient to equalize the friction losses and the heat
inleak in the suction line.
In such a case build-up the gas pressure in the storage tank. The necessary
pressure increase in the storage tank is a function of the required pump NPSH
and of the installation, and therefore it can be determined by test only.
Operate the pump with the lowest possible storage tank pressure.
Page 25
USERS MANUAL
The pump mechanical seal is designed for a suction pressure of 5 bars. Keep
the pump suction pressure as low as possible. This improves the life time of
the mechanical seal.
6.4.
Shut-down of the Pump

(see drawing 'Flow diagram')
For shutdown this sequence should be followed:
1. Shut-off the motor, open the bypass valve 6 and close the pressure
regulating valve 4
2. Close the suction valve
3. After the pump has been defrosted, close bypass valve 6
Page 26
USERS MANUAL
7.
TROUBLE SHOOTING
Trouble
Probable Cause
Trouble Shooting
Pump does not prime,
Insufficient cool-down
Continue the cooldown
or the priming is
of the pump or insuffi-
or increase suction
lost
cient suction pressure
pressure (NPSH)
(insufficient NPSH)
Vapor pocket in the
Vent the gas from

the
suction line
liquid gas line
Contamination in the
Purge inner parts of
pump
cold end with clean

gas and dry; or dismantle and clean
Worn-out parts
Repair/overhaul cold
end
Wrong direction of
Exchange two phase
rotation
leads on motor
Mechanical seal
Pump suction pressure
Reduce the pump
leaking
too high
suction pressure to
prescribed value
Mechanical seal pre-
Increase the preload
load too low
to prescribed value
Mechanical seal ring
Exchange the seal
worn-out
Page 27
USERS MANUAL
Trouble
Probable Cause
Trouble Shooting
Rated capacity
Pump does not prime
Improve suction
and/or pressure not
well
conditions, clean the
achieved
suction filter
Vapor in suction line
NPSH not sufficient
Impeller or volute
Clean the clogged
passages clogged
parts
Wear rings worn,
Exchange worn or
impeller damaged
damaged parts
Discharge system back
Check the pump and
pressure higher than
system characteristic
rated
curves and improve

the
system piping
Pump/Motor speed incorrect

Pump overloads drive
Drive rating insuffi-
Exchange the drive
cient
Pump noisy, internal
Repair the pump
rubbing noise
Flow higher than rated
Reduce the flow
Low voltage
Increase voltage to
rated value
Page 28
USERS MANUAL
Trouble
Probable Cause
Trouble Shooting
Pump vibration
Pump cavitating
Improve suction conditions
Pump operation below
Increase flow to the
minimum recommended
minimum value
flow
Impeller clogged, un-
Clean, balance rota-
balance
ting parts
Pump fixation and/or
Improve fixation
foundation not rigid

enough
and/or foundation
Mechanical parts worn-
Exchange worn-out
out (bearings, impel-
parts
ler, gears etc.)

Bearings over-
Bearings too tight or
Use prescribed
heated or wearing
preload too high
bearings and right
rapidly
preload
Improper lubrication
Improve lubrication,
check lubricant flow
passages
Dirt or water in
Clean or exchange
bearings
bearings
Too high vibration
Reduce vibration as
prescribed above
Page 29
USERS MANUAL
8.
MAINTENANCE INSTRUCTIONS
8.1.
General
The following maintenance instructions are sufficient in normal use.
Estimates and proposals for spare parts and revisions will be supplied upon
request.
Nevertheless it is not recommended nor practical to attempt to completely
overhaul it due to the close tolerances and precision finishes of the interior
components.
When extensive overhaul works or complete revisions are necessary, we
recommend that the help of our service engineer is requested.
WARNING
Before use, ensure that the pump is not under voltage and that it is not cold. If
necessary, the installation must be isolated and the energy must be dissipated
according to safety procedures.
WARNING
Before use, ensure that no impurity enters into the pump or the pipes.
8.1.1.
Assembly / Disassembly : Table of tightening torques and forces
After manual tightening, the end tightening must be made with a torque
wrench, at 75% of the limit of elasticity or at the drawing value.
Page 30
USERS MANUAL
Torques and forces for Bolts of type H, in stainless steel, class A1, A2, A4
Bolts class of resistance: 70
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Torque (Nm)
Max
5.9
14.5
30
50
79
121
174
244
182
234
328
445
Standard
5
12
25
42
66
101
145
203
152
195
273
371
Force (Nm)
Max.
6.85
12.6
20
29.1
40
55
69
88.6
61.5
70.9
90
109.4
Standard
6
11
17
24
33
46
58
74
51
59
75
91
Bolts class of resistance : 80
M6
M8
M10
M12
M14
M16
M18
M20
Torque (Nm)
Max
8
19.3
39.4
67
106
161
232
325
Standard
7
16
33
56
88
134
193
271
Force (Nm)
Max.
9.13
16.7
26.6
38.8
53.3
73.3
92
118.1
Standard
8
14
22
32
44
61
77
98
Torques (Nm) for hexagon socket flat or small head cap screws in stainless
steel, class A2, A4
Screw
type
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
Din 6912
Chc
70
Max
5
12
24
40
66
110
Standard
4
10
20
33
55
92
170
142
Din 7991
Fhc
70
Max.
5
7
21
30
66
Standard
4
6
18
25
0
55
Din 7991
FHc
70
Max
5
8
20
33
50
55
Standard
4
7
17
28
42
46
120
100
75
63
235
196
200
167
Page 31
USERS MANUAL
8.2.
Periodical Revisions and Maintenance

To ensure trouble free operation over long periods the following maintenance
works must be carried out:
- Every 1000 hours of operation or annually
Dismantle the pump completely, change damaged parts, clean all parts.
- Lubricants
See the section 'Lubrication'.
The time limits given above should be adapted to the type of pump operation,
the atmospheric exposure, the internal operating practice and operating
experience. The given time limits are a recommendation only.
Page 32
USERS MANUAL
8.3.
Dismantling of the pump

(see drawing 'Cold End')
Dismantle the pump carefully and in the following sequence:
- Disconnect the electrical connections and electrical accessories
- Remove the suction-, by-pass-, discharge-and vent lines, fitting 29, etc.
- For further dismantling , prepare clean work place (cover the work table with
new paper)
- Remove screws 1 with its spring washers 2
- Remove the pump casing 4
- Remove the flexitallic gasket 3
- Remove nuts with its washers (parts 8,9,14)
- Pull-off carefully the inducer 6 of the pump shaft
- Pull-off carefully the impeller 10 of the pump shaft
- Remove keys 7, shim 18, seal ring 11 and shim 13
- Unscrew the mechanical seal clockwise (left thread) from intermediate piece
5
For dismantling or tightening the mechanical seal use only the special tool
drawing no. 768026005.
CAUTION
Using other tools to screw or unscrew the mechanical seal could
damage the seal ring or the whole mechanical seal and must
therefore be avoided.
- Remove screws 15,16
- Remove the intermediate piece 5 with its back-up rings
- Push off the thermal insulation 20 and back-up rings 22
- Dismantle the screws 25,28,17 between the motor flange and the support
and dismantle the support 27
- Dismantle the slinger ring 23 of the shaft
- Remove pin 26 and push off the pump shaft 21
8.4.
Assembly of the Pump

Assemble the pump in the reverse of the stated dismantling sequence. The
following care should be taken:
The mechanical seal ring and the seal ring must be lapped to best surface
quality. Assemble the mechanical seal very carefully, so that its tightness is
guaranteed during stand still as well as in operation. The seal bellow must be
dry.
Page 33
USERS MANUAL
Do not damage the O-ring.

Before assembling the pump, carefully clean all pump parts and any changed
parts. For a pump in oxygen service, all parts must be degreased.
The flexitallic gasket between pump housing parts must be carefully inserted
and the screws tightened crosswise.
Check the freedom of rotation of the pump shaft.
For special position of the pump discharge nozzle turn the pump housing
against the support.
Never turn the support against the motor flange.
8.5.
Adjustment of the Mechanical Seal

Screw the mechanical seal into the pump casing in an anticlockwise direction
using the special tool.
CAUTION
Left thread. Do not forget the O-ring seal.
Push the mobile ring smoothly on the shaft towards the sealing ring. Measure
with a precision depth gauge the distance between the shaft end and the
mobile ring.
Press the mobile ring up against the mechanical seal up to the shoulder shaft.
Measure the distance between the shaft end and the mobile ring as before.
The difference between both measured distances is the preload of the
mechanical seal.
The correct preload is listed on the checklist. Adjust to the correct preload with
shims between the shaft shoulder and the sealing ring.
Caution:
When the sealing ring is partially worn, adjust the preload so that the sealing
ring is beyond the shoulder of the mechanical seal housing.
Page 34
USERS MANUAL
9.
CRYOSTARS MAINTENANCE AND SPARE PARTS SERVICE

9.1.
Order Instructions
Lists of spare parts are enclosed with these instructions. On each sectional
drawing, the spare parts are marked with item numbers corresponding with
those on the spare parts list; on the spare parts list, stock part number and
designation are added to each item.
It is advisable to always keep in stock the spare parts recommended in these
lists; you may save unwelcome waiting time.
When ordered the spare parts, please indicate the following:
1.Equipment number
2.Stock number of the required part
3.Designation of the required part
When extensive overhaul works or complete revisions are necessary, we

recommend return of the machine to our works or that the help of our service
engineer is requested.
Page 35
USERS MANUAL
10.
ANNEX
10.1. NPSH
NPSH = Net positive Suction Head = difference between the static
pressure (Ps) and the actual vapour pressure (Pt) of the vapourfree liquid
in the suction nozzle of the pump.
To allow a cryogenic pump to start and operate correctly, a specific NPSH
must be available.
The NPSH in the suction nozzle of the pump has to prevent local vaporization
of the liquid and can also be described as relative undercooling ( DT). The
actual vapour pressure (Pt) is determined only by the temperature (Ts) in the
suction nozzle of the pump, expressed in meters of liquid head.
The required NPSH (=NPSHr) must be available during starting as well as

during operation of the pump.
The available NPSH (NPSHa) in the suction nozzle of the pump can be
attained or improved by:
- Increasing the static liquid head
- Relative undercooling of the liquid
- Pressure built-up in the tank over the actual vapour pressure
- Better insulation of the piping
- Reduction of pressure loss in the piping
Page 36
USERS MANUAL
The necessary NPSH must be guaranteed during start-up as well as under

service conditions of the pump.
The necessary NPSH in the suction nozzle may be reached or improved by:
- Increasing the static liquid head (higher position of the tank)
- Undercooling of the liquid
- Pressure increase in the tank
- Better piping insulation in the given installation
- Reduction of piping pressure
Page 37
USERS MANUAL
10.2. Appendix to spare parts lists

P
Ref. No.
Explanation
Position on drawing
Quantity of parts per unit
Parts subject to normal wear to be kept on stock, to be replaced at each disassembly

Commissioning spares
Recommended spare parts for 2 years operation

XXXXXXXX
IMPORTANT :
Stock number
The prices are subject to change without previous notice. The

prices are net, in French currency, for supply ex works,
including packing, excluding any customs duties or taxes.
The handling charge for orders under Ffr. 250,00 is Ffr.
100,00 per order.
Every part should be replaced by a CRYOSTAR genuine part.

CRYOSTAR accepts no responsability if these rules are not respected.
Page 38
USERS MANUAL
10.3. Documentation
CRYOSTAR Ref.
DESIGNATION
CRYOSTAR DOC.
Safety valves must be set every year
LEAFLETS
792605195-01/004
Motor
Leroy Sumer
56
1.000
quantity
Unit
Factor
P/N
Description
CO 120-6.4 C/O-FC, PUMP ASSEMBLY
Bill of Material / Nomenclature
Material
Dimentions
Created:14DEC07
Updated:14DEC07
Valid BOM
by:ORTEGAC
Page:
1.000 740150336
PC
Plate Insulating
---------------------------------------------------------------------------------------------------------------------------------------002
1.000
1.000 769111843
PC
Welded support
---------------------------------------------------------------------------------------------------------------------------------------003
1.000
1.000 740081885
C
PC
Pump casing (from casting)
---------------------------------------------------------------------------------------------------------------------------------------004
1.000
1.000 798160823
PC
Spiral wound gasket
---------------------------------------------------------------------------------------------------------------------------------------005
1.000
1.000 740150332
PC
Casing Cover CO120
---------------------------------------------------------------------------------------------------------------------------------------006
1.000
1.000 740108277
PC
Isolating ring
---------------------------------------------------------------------------------------------------------------------------------------007
1.000
1.000 730000169
PC
O-ring
---------------------------------------------------------------------------------------------------------------------------------------008
1.000
1.000 798250060
PC
Mechanical seal
---------------------------------------------------------------------------------------------------------------------------------------009
1.000
1.000 740026827
B
Sealing ring
PC
---------------------------------------------------------------------------------------------------------------------------------------010
1.000
1.000 740104736
PC
Shim
---------------------------------------------------------------------------------------------------------------------------------------011
1.000
1.000 740026828
E
PC
Shim
---------------------------------------------------------------------------------------------------------------------------------------012
2.000
1.000 795080919
PC
KEY
---------------------------------------------------------------------------------------------------------------------------------------013
1.000
1.000 740027146
B
PC
Impeller from casting
---------------------------------------------------------------------------------------------------------------------------------------014
1.000
1.000 740026826
C
PC
Inducer
---------------------------------------------------------------------------------------------------------------------------------------015
1.000
1.000 740150333
PC
Shaft CO120
---------------------------------------------------------------------------------------------------------------------------------------016
1.000
1.000 740111839
PC
Slinger ring shaft
---------------------------------------------------------------------------------------------------------------------------------------017
1.000
1.000 730001637
PC
Hexagon socket set screw cone point
----------------------------------------------------------------------------------------------------------------------------------------
001
Pos
List P/N : 763150972-02
User: ROBLEDS
printed on: 04FEB09 1
1.000
quantity
Unit
Factor
P/N
Description
CO 120-6.4 C/O-FC, PUMP ASSEMBLY
Bill of Material / Nomenclature
Material
Dimentions
Created:14DEC07
Updated:14DEC07
Valid BOM
by:ORTEGAC
Page:
1.000 795080954
PC
Spring type straight pin
---------------------------------------------------------------------------------------------------------------------------------------019
1.000
1.000 709058819
A
PC
Hexagon socket head cap screw
---------------------------------------------------------------------------------------------------------------------------------------020
1.000
1.000 795061119
PC
Conical spring washer
---------------------------------------------------------------------------------------------------------------------------------------021
1.000
1.000 72AP01002
ML
Wire
---------------------------------------------------------------------------------------------------------------------------------------022
8.000
1.000 730150315
PC
SCREW, HEX HEAD, M8 x 30MM SS
---------------------------------------------------------------------------------------------------------------------------------------023
8.000
1.000 730002188
PC
Spring washer
---------------------------------------------------------------------------------------------------------------------------------------028
4.000
1.000 730150314
PC
SCREW, HEX HD, 1/2"-13 x 1.25" SS
---------------------------------------------------------------------------------------------------------------------------------------029
4.000
1.000 730150154
PC
WASHER, LOCK 1/2" , 18-8 SST
---------------------------------------------------------------------------------------------------------------------------------------030
4.000
1.000 769150042
Flex Hose 1/4 ODx10lg
PC
---------------------------------------------------------------------------------------------------------------------------------------031
6.000
1.000 730150309
PC
SCREW, SOCKET HEAD CAP, M10 x 65MM
---------------------------------------------------------------------------------------------------------------------------------------032
6.000
1.000 730000005
PC
Spring washer
---------------------------------------------------------------------------------------------------------------------------------------033
1.000
1.000 792605195-01/004
PC
Asynchron-Motor for variable speed
---------------------------------------------------------------------------------------------------------------------------------------034
1.000
1.000 791564839
PC
Coupling male - BW, conical seal
---------------------------------------------------------------------------------------------------------------------------------------035
1.000
1.000 730150353
PC
NAMEPLATE, CENTRIFUGAL PUMP
---------------------------------------------------------------------------------------------------------------------------------------036
2.000
1.000 740026831
PC
BACK-UP-RING
---------------------------------------------------------------------------------------------------------------------------------------038
2.000
1.000 730150689
PC
PLUG, HEX SOCKET HEAD, 1/8" NPT
========================================================================================================================================
018
Pos
List P/N : 763150972-02
User: ROBLEDS
printed on: 04FEB09 1

Transfer Pump Manual

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Page 1

FOR OPERATION AND MAINTENANCE

Orders can be placed at :

203 Henderson Road

Station Road, Industrial Estate

3. STORAGE OF THE EQUIPMENT PRIOR TO INSTALLATION

6.2. Cool-down and Start-up of the Pump

9. CRYOSTARS MAINTENANCE AND SPARE PARTS SERVICE

LIST OF DRAWINGS AND OTHER ENCLOSURES

Description of the Design

Safety norms applied on site must be scrupulously respected. The

Any normal operation must be made according to the recommendations

FATAL OR MOST SERIOUS INJURIES MAY OCCUR IF SERVICE

Explosion hazard in the presence of oxygen

After cleaning and degreasing, the components and equipment should be

Explosion hazard in the presence of oxygen !

Our products must be handled with a handling system. Please, refer to

Isolation and energy dissipation

carefully so as to permit a VOLUNTARY locking or unlocking of the user with

Isolation and dissipation of gas process energy

Isolation and dissipation of purging gas energy

Isolation and dissipation of electrical energy

Before each operation on parts or equipment normally under voltage, the

Safety form for oxygen pump

Oxygen is a gas colorless, odorless and testeless.

Recommendations in case of accident (fires, burnd) :

First aid for burn victims (low temperatures of liquid oxygen) :

. Always summon a doctor immeditately.

. Cover the victim with a sterilized blanket.

Leak detection and analysis :

Customer safety instructions - Summary

Gases and liquid under high pressure

Gaz et liquides sous haute pression

Flssigkeiten und Gase unter hohem

UEBERPRUEFUNGEN VOR DER

Check nameplate details

Vrifier les informations sur la plaque

Check stored equipment every 6

Vrifier le matriel entrepos tous les

Gelagertes Material alle 6 Monate

Pas de fixations desserres

Keine losen Befestigungen

Se reporter au manuel dinstructions

Check rotation, uncoupled

Vrifier la rotation vide

Maschine in Leerlauf prfen

Connections are tight ?

Les connexions sont-elles serre ?

Sind die Anschlsse fest angezogen ?

Covers must be fitted

Les capots de protection des botes

Abdeckungen der Klemmenkasten

Fused and isolated correctly

Protg par coupe circuit et isol

Korrekt abgesichert und isoliert

Every control box with a heating band

Toute armoire lectrique quipe

Jeder Elektro-Schrank mit Heizband

Respect tightness of the control box

Respecter ltanchit de larmoire

Beim Anschlussen des ElektroSchrank Dichtheit beachten

Shut front protection covers after use

Veiller fermer les capots de