INSTALLATION AND OPERATING INSTRUCTIONS

CONTENTS

SL NO. DESCRIPTION

1 INTRODUCTION

2. OPERATION AND INSTRUCTION MANUAL

2.1 GENERAL
2.2 ASSEMBLY OF THE SYSTEM

3 PUTTING INTO OPERATION

4 MAINTENANCE

4.1 ROUTINE MAINTENANCE

4.2 OVERHAULING
1. INTRODUCTION
2. OPERATIONAL AND INSTRUCTION MANUAL:

2.1 GENERAL:

The seal flushing system is engineered and manufactured for providing a positive
pressure in the seal chamber of a machine in an industrial environment. In addition, the
circulating liquid picks up heat from the seal chamber and provides a certain degree of
cooling to the seal chamber and the machine.
2.2 ASSEMBLY OF THE SYSTEM:

Clean Barrier liquid is to be manually filled into the Reservoir unit (Tank). Port with
plug is provided in the top cover to facilitate filling of liquid. A Drain Valve (at bottom)
serves to empty out the liquid during maintenance. A Breather Filter is provided for
exhaling the hot air from inside the reservoir and for inhaling fresh air. A level gauge is
provided on the front wall of the reservoir to give a visual indication of the liquid level in
the reservoir. To monitor the liquid level in the reservoir remotely, a level
switch/transmitter is provided on the top cover. To ascertain the temperature prevailing
in the reservoir a temperature gauge is provided on the front wall of the reservoir. A
cooler is provided in the reservoir and serves to cool the liquid in the reservoir.

The reservoir has been provided with suction ports with isolation valves that serve to
feed the liquid to a strainer. The strainer is provided with a screen, which prevents
ingress of dirt and debris and offers protection to the pump. The clean liquid from the
strainer is fed in to the suction port of the gear/plunger pump The pump is coupled to
the drive motor thro a flexible coupling. The pump and motor duly coupled are mounted
on the base plate and anchored to the base plate. Two Pumping units are provided,
while one is working the other unit serves a 100% stand by and is to be kept in floating
condition.

Being a positive displacement pump, the piping loop incorporates a relief valve, which
serves to prevent the system from over pressure. Adjusting the spring tension can alter
the pressure setting at which the relief valve will operate. The liquid that is relieved
from the relief valve is diverted back to the reservoir.

The pump delivery-piping loop is provided with a check valve, which serves to prevent
back flow to the pump and an isolation valve, which serves to isolate the pump for any
maintenance work.

The pressure prevailing in the system can be ascertained from the pressure gauge by
operating the instrument isolation valve.

The liquid is then led into the simplex cartridge filter thro set of isolation valves. The
filter is anchored to the system base thro a vertical support. The filter cleans the liquid
with a cleanliness of 10 Microns and is provided with vent/drain ports. The filter loop is
provided with a by pass check valve that comes into play when the filter element starts
to clog.

The clean liquid from the filters is merged into a single line and led into the seal inlet
line, which incorporates a check valve an accumulator - pulsation damper and a
pressure gauge/transmitter that gives the pressure at which the liquid is entering the
seal.
The accumulator evens out the pulsations in the liquid being pumped by the
gear/plunger pump and also serves to deliver liquid to the seal in the unlikely event of a
pressure/power loss. The accumulator is anchored to the system base plate and
provided with an isolation valve and a drain valve.

An isolation valve is provided across the seal inlet line and the seal return line and
serves to bypass the liquid flow to the seal chamber.

The return line from the seal chamber has a sight flow indicator, which gives a visual
indication of the liquid flow back to the reservoir.

The return line also incorporates a pressure switch/transmitter, a solenoid valve and a
Globe valve

The pressure switch/transmitter is provided to sense loss of pressure in the seal loop
beyond the preset limit and the contacts can used, either to start the stand by pump or
close the solenoid valve to lock the pressure in the seal chamber and prevent further
pressure loss.

The solenoid valve (Normally Closed condition) is provided to lock the pressure in the
seal chamber when a low-pressure condition exists and should always be in energized
condition (open condition) and allow liquid circulation thro the seal chamber.

The Back pressure control valve will maintain the required pressure in the seal chamber
and ensure circulation when the pump is in operation.

The instruments are mounted in an instrument panel. Impulse lines from the piping
loop are connected to instruments thro the instrument isolation valves.

The electrical leads of the motors and the instruments are terminated in a terminal box.
The terminal box is also anchored to the system base plate. The terminal box is
dedicated to the operation of the system solenoid valve as the valve requires a 110V AC
voltage for energizing the coil.
On delivery at site, the system will be in assembled condition. The following sequence
may be followed to complete the integration of the system with the serving machine.

The system base plate which houses the system components is to be erected on the
civil foundation and anchored to the foundation by means of the foundation bolts and
properly grouted.

The machine (seal) inlet / outlet piping to be completed by the user department and
properly supported and connected to the seal flushing system inlet / outlet port
preferably with isolation valves.

The reservoir cooling coil water inlet / outlet piping to be completed by the user
department and properly supported and connected to the plant cooling water circuit
preferably with isolation valves.

The reservoir drain line piping and the accumulator drain line piping are to be
completed by the user department and properly supported if dedicated drain lines are
planned.

While installing the system piping and components, pay attention to the fact that the
lines are free from any obstructions and contamination.

The electrical feed leads (415 VAC) / instrument feed leads (110 VDC) are to be made
to the motors/instruments and terminated at the system terminal box by the user
department.

It should be ensured that all components that have been supplied are installed in an
orderly and satisfactory manner.
3. PUTTING INTO OPERATION:

Before putting the system into use, please ensure that following points are addressed or
measures taken.

a. Check the system and the connecting lines for orderly installation as per the drawing.

b. Check the electrical power supply to the Motors.

c. Check the electrical/instrument wiring is as per the drawings. De - couple the motors
and check the direction of rotation of the motors. Re - couple the pump and motor.

d. Check for any obstruction in the steel tubing. Ensure leak tightness of the joints.

e. Ensure that the system is mechanically and electrically complete and none of the
system controls / interlocks are bypassed.

The following are the suggested interlocks to the system and may be incorporated by
the user department.

a. The pumping unit should be started if and only if the liquid level in the tank is
healthy as reflected by the level switch signal and also thro visual level gauge.

b. The signal leads of the pressure switch/transmitter to be linked either to the

motor or to the solenoid valve based on the user requirement.

c. The system solenoid valve gets energized (valve opens) before the serving
machine is to be taken in line and the flushing system is ready for start.

d. The system pump to be in operation even before the serving machine is in taken
in line.
3.1 PUTTING INTO OPERATION:

Once the above points are attended / interlocks are in place the system can be put into
operation by following the suggested sequence of operation given below:

Control Voltage – 110 VDC to be provided for the instruments.

Ensure motors are in off state.

The reservoir cooling coil line to be charged and water should be in circulation.
The drain valve of the reservoir should be in CLOSED condition.
The drain plug of suction strainers should be in closed condition.
Charge the reservoir with water and ensure level switch signal is healthy.
The pump suction valves should be in OPEN condition.
The pump delivery line valves should be in OPEN condition
The filter inlet / outlet valves should be in OPEN condition valve
The drain and vent plugs of filter should be in crack OPEN condition
The accumulator drain valve should be in CLOSED condition.
The accumulator gas charging port should be in CLOSED condition.
The accumulator inlet valve should be in OPEN condition.
The instrument isolation valves should be in crack OPEN condition.
The user machine (seal) inlet / return line isolation valves to be in CLOSED condition
The system bypass valve is in OPEN condition
The system solenoid valve is in OPEN condition (Coil is energized).

Power supply – 415 VAC to the Terminal box should be switched on.
The pump 1 motor to be switched ON and kept in running condition.
Check for the liquid circulation in the sight flow indicator
The pump 1 motor to be switched OFF after about 05 minutes
Check for any joint leakages and tighten the filter plugs and arrest joint leakage.
The pump 2 motor to be switched ON and kept in running condition.
Check for the liquid circulation in the sight flow indicator
The pump 2 motor to be switched OFF after about 05 minutes.
Check for any joint leakages and tighten and arrest joint leakage.

The system can now be put to TEST

The pump 1 motor is to be switched ON.
The liquid flow can be seen in the sight flow indicator.
Throttle system globe valve and adjust system pressure.
Check for any joint leakages and tighten the same to arrest leakage
Once the flow and pressure has been checked, the pump 1 motor to be switched OFF.
Repeat the above test with pump 2 and motor to be switched OFF.

Drain and empty out the water from the system.

PUTTING INTO OPERATION(continued)

The system can now be put into OPERATION

Charge the reservoir with barrier fluied and ensure level switch signal is healthy.

The pump 1 motor is to be switched ON.

The liquid flow can be seen in the sight flow indicator.

The user machine (seal) inlet / return line valves to be OPENED by the user department

The system bypass valve is to be CLOSED. This is will ensure that the liquid will be
diverted to the seal in the user machine.

Keep pump in running condition and take system into service. Ensure that the pump 2
is in floating condition

The Temperature of the liquid in the reservoir can be directly read on the temperature
gauge.
4. MAINTENANCE:

It is imperative that the operation and instruction of individual components as detailed

in the leaflets are meticulously to ensure reliability of the system, which in turn reduces
down time and maintenance.

4.1 ROUTINE MAINTENANCE:

As a good maintenance practice, the following guidelines need to be followed:

a. Ensure that the oil level in the gearbox is maintained at the required level as can be
assessed by viewing the gauge provided for the purpose. This will ensure that
gearbox does not suffer for want of lubricant and the gears does not run dry.
b. For the first few weeks time when the system is used, check the filter element every
week and clean it if necessary. It is a good practice to clean the element at regular
intervals. Always keep the filter clean and ready for use.
c. Check the pipe joints for any leakage and tighten them on a fortnightly basis.
d. Keep a regular log of the pressure and temperature in the system.
e. Ensure cleanliness of the system at all times, as dirt is a major contaminant.
f. The gaskets of the system should be renewed periodically to ensure proper sealing.
g. Refer to the manufacturer’s manual for individual component maintenance practice.
4.2 OVERHAULING OF SYSTEM:

For any reason, the system needs to be overhauled, follow procedure as below:

Isolate Electrical supply for the Motor and Control voltage for the Instruments
Close the user machine inlet/return line valves
Isolate the reservoir cooling coil water circuit
Open the system bypass valve.
Close pump suction valves
Close instrument isolation valves.
Open the strainer plug to drain out trapped liquid.
Close the filter inlet/outlet valves
Open the drain plugs of filter and drain out the trapped liquid.
Open the drain valve of accumulator and drain out the trapped liquid.
Suction Strainer:
The suction line along with strainer can be taken out by loosening the joints.
Remove the Suction Strainer element by opening the plug
Clean the element and replace if necessary.
Insert the element in place and tighten the plug, renew the gaskets.
Pumping unit:
Disengage the electrical leads from the motor
De couple pump and motor
The pump can be made free of the piping by loosening the suction/ delivery joints
The pump and Motor can be unbolted from the base, follow manufacturers manual for
its maintenance. Top up the gearbox oil periodically
Filter unit:
The filter can be made free of the piping by loosening the filter in/ out joints
The top cover of the filter can be unbolted to approach the element.
Remove element from element holder, clean the element and replace if necessary.
Insert the element in place, replace cover and tighten the bolts, renew gaskets.
It is good maintenance practice to replace the filter element annually.
Accumulator:
The accumulator can be made free of the piping by loosening the joints. Follow
manufacturers manual for its maintenance.
Instruments & Valves
These components rarely require maintenance if properly operated. Follow
manufacturers manual for instrument calibration and maintenance.

Clean the piping once every year to ensure no build up.

CAUTION:
1. AVOID DRY RUNNING OF PUMP.
2. AVOID RUNNING OF THE SYSTEM WITH THE CONTROLS BYPASSED
NOTE:
USE OF ORIGINAL SPARES IS AN INSURANCE AGAINST PREMATURE FAILURE.