Teikoku ALP 0104QM User manual

INSTRUCTION MANUAL

for Installation, Operation, and Maintenance

IOM-22-ALP13SE-1122 November 2022

ALPTM

ADVANCED LOW-PROBABILITY

AMMONIA TRANSFER PUMP

TYPE-R (Plan 13-SE)

0104QM Multi-Stage Reverse Circulation Pump

Thank you for purchasing the Advanced Low-Probability Ammonia Transfer Pump (ALPTM).

Please carefully read this instruction manual and all Safety Warnings prior to use.

Introduction

Safety Terms

Please pay close attention to these terms. When you see them

in this manual, read the information thoroughly and follow the

instructions given.

Attention!

Indicates careful attention is required. The instruc-

tion includes protective information for the device and

product.

Caution!

Ignoring this warning can cause personal injury and/or

damage to the device and product.

Hazard!

Ignoring this warning can cause serious injury or even

death. It can also be used to alert against unsafe practices.

NOTE: Information included in NOTES gives additional helpful

information and recommendations.

Applicable Standards and Regulations

The Type-R (Plan 13-SE) reverse circulation ALP multi-stage

pump conforms to the following standards:

1. Japanese Industrial Standard (JIS)

2. Japan Electrical Manufacturers’ Standard (JEM)

3. American Society of Mechanical Engineers (ASME) B-16.5

4. Canadian Standards Association (CSA): UL 778 CSA 22.2

No 108

5. International Institute of Ammonia Refrigeration (IIAR):

ANSI/IIAR 2-2014

Product Warranty Period

This product is warranted for two years from date of delivery.

Please refer to Teikoku USA’s Terms and Conditions of Sale for

additional warranty coverage and restrictions.

Rights

All rights on products manufactured by Teikoku, corresponding

software, and this instruction manual are registered to Teikoku

Electric Mfg Co., Ltd.

It is not permitted to reproduce or transmit any portion of this

instruction manual unless prior written consent has been ob-

tained from Teikoku USA Inc., Teikoku Electric Mfg Co., Ltd. or

its subsidiaries.

Advanced Low-Probability Ammonia Transfer Pump and ALPTM

are trademarks of Teikoku Electric Mfg. Co., Ltd.

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

Attention!

Do not run dry!

If the pump is allowed to run dry, the bearings, sleeves,

and other components could be damaged and serious

overheating of the motor windings can occur.

Attention!

Avoid rapid temperature changes!

Large changes in temperature must be avoided. Rapid

changes can cause leaks to occur in gaskets. Published

procedures for proper heating and cooling must be fol-

lowed. If published procedures are not available, check

with Teikoku before operating the equipment.

Caution!

Hot – Do not touch!

Motor and pump can be hot, even when pumping cold

liquids.

Caution!

If motor trips, do not restart before determining the

cause!

Restarting the motor before ascertaining the cause may

result in excessive heat, causing pump or motor failure.

Hazard!

Do not remove internal bolts in terminal box.

If it is necessary to remove the terminal box for any reason,

ﬁrst loosen the bolts by 2 or 3 turns to check if any internal

pressure or liquid is present. You must take measures if the

possibility exists that the gas or liquid is toxic or hazardous

to personnel or the environment.

Hazard!

Do not remove any bolts on pump, motor, or drain

plugs!

The internal pressure can be higher than the atmosphere.

Ensure that the pump and motor are properly de-pressur-

ized and decontaminated prior to performing any work.

Proper protective measures must be taken if the possibility

exists that the gas or liquid is toxic or hazardous to person-

nel or the environment.

Hazard!

Always assume that there is liquid left in the pump!

There is always the possibility that residual liquid could

remain in the pump and motor in spite of thorough de-

contamination. Pay particular attention to the clearance

between the shaft and the impeller, bearings, sleeves,

bearing housings, internal bolting and gaskets. You must

take adequate precautions to protect personnel and the

environment if the liquid could be considered hazardous.

Safety Warnings

Important:

Before operating the canned motor pump, read these Safety Warnings

and this entire Instruction Manual to avoid improper operation.

It is essential for your safety and to avoid disaster.

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

Contents

Introduction 2

Overview 5

1. General Information 6

2. Installation 9

3. Operation 12

4. Maintenance 15

Appendix 20

Appx. A. Motor Pump Data Sheet...........................................21

Appx. B. Outline R-210P-0104Q, 13-SE ..................................22

Appx. C. Sectional View (R42-217P4BL-0104QM4-J)...............23

Appx. D. Type-R (Plan 13-SE) Installation Instructions...............24

Appx. E. Troubleshooting .......................................................25

Appx. F. TRC-1 Information Sheet..........................................26

Appx. G. NH3Reference Curve (20°F)......................................27

Appx. H. NH3Reference Curve (-50°F) ....................................28

Appx. I. Type 217-120 Motor Data Sheet...............................29

Appx. J. 13-SE Temperature/Pressure Proﬁle ...........................30

Appx. K. Optional Rotor Cavity Thermowell ............................31

Appx. L. Terminal Box Assembly .............................................32

Appx. M. Allowable Piping Forces and Moments......................33

Appx. N. Optional TSG NH3Speed Control Panel ....................34

Appx. O. Wiring Diagram Optional TSG NH3

Speed Control Panel.................................................35

Appx. P. Decontamination Form.............................................36

Appx. Q. Teikoku Pump Repair Policy ......................................39

Figures

Figure 1-1. Type-R (Plan 13-SE) Reverse Circulation ALP

Multi-stage Pump ...................................................6

Figure 1-2. Flow Path ................................................................7

Figure 1-3. Typical NH3Transfer System Requirements................8

Figure 2-1. Teikoku TRG Bearing Wear Monitor .......................10

Figure 3-1. Teikoku Rotary Indicator TRC-1 ..............................13

Figure 4-1. First Bowl Bearing – Only Straight Grooves ............17

Figure 4-2. Motor Bearings – Spiral and Straight Grooves .......17

Figure 4-3. Bearing Wear Limits...............................................18

Figure 4-4. Measurement of “g” Gap......................................18

Figure 4-5. Type-R (Plan 13-SE) Model Number Indentiﬁcation

Code Example .......................................................19

Tables

Table 2-1. Conditions indicated on the TRG Meter ..............10

Table 2-2. Inverter Parameter Settings.................................11

Table 4.1 Recommended Tools...........................................15

Table 4-2. Impeller Axial Gap ..............................................18

Table 4-3. Bearing Wear Limit .............................................19

Table 4-4. End Play .............................................................19

Table 4-5. Tightening Torques .............................................19

Table 4-6. Torque Values for Motor Terminal Connections

– Terminal Box and Connection Stud Size............19

Table 4-7. Pump Ring Clearance (Standard Horizontal

Pump) ................................................................19

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

Overview

Teikoku’s revolutionary Advanced Low-Probability

Ammonia Transfer Pump (ALP) sets a new industry

standard for operating efﬁciency and safety in

ammonia transfer systems. Utilizing a smaller and

more powerful motor than those typically coupled

to ﬁxed-speed pumps, Type-R (Plan 13-SE) reverse

circulation ALP multi-stage pumps rotate faster in

a more compact package with enhanced rotor-

dynamic effects. This increases reliability with the

same secondary containment features synonymous

with all Teikoku pump solutions. Driven by any

commercially available variable frequency drive

(VFD), Type-R (Plan 13-SE) reverse circulation ALP

multi-stage pumps feature advanced hydraulics for

low ﬂow, high head, low NPSHr performance that

can be tuned to variable process requirements.

The pump is manufactured in accordance with the

latest industry requirements governing design for

safety and containment. Refer to the data package

submitted in response to the order covering the

supply of this pump for the details of rating and

speciﬁcations, as well as any Inspection Certiﬁcates

of Performance that may have been supplied in

response to order requirements.

Please keep this manual with the drawings and

inspection certiﬁcates.

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

1.General Information

Figure 1-1. Type-R (Plan 13-SE) Reverse Circulation ALP Multi-stage Pump

1.1 General Design and Operation

The Type-R (Plan 13-SE) ALP multi-stage pump is a combined

multi-stage centrifugal pump and squirrel cage induction elec-

tric motor designed and produced as a single hermetically-sealed

unit. The pump impellers are enclosed and mounted on one end

of the motor rotor shaft, which extends from the motor section

into the pump impeller casings. The motor rotor is hermetically

sealed or “canned” with a corrosion resistant, non-magnetic, al-

loy shell to isolate it from contact with the pumped liquid being

circulated through the liquid cooled motor assembly. The rotat-

ing rotor and shaft assembly and it’s supporting thin ﬁlm liquid

lubricated bearings, operate immersed in the circulating liquid,

functioning as both a motor coolant and bearing lubricant. The

motor stator winding is also canned with a corrosion resistant,

non-magnetic, alloy liner, to simultaneously isolate it from the

same circulating liquid.

The Type-R (Plan 13-SE) ALP multi-stage pump is characterized by

the use of a reverse circulation design which diverts and controls

a portion of the ﬂow of highly volatile ﬂuids and liqueﬁed gases

into the rotor cavity of the motor to effect motor cooling in this

liquid cooled motor design. Through a combination of ﬂow and

pressure control mechanisms designed into canned motor pump

assembly and the use of an oriﬁce in the separate reverse circula-

tion line connected outside of the rotor cavity, the circulating ﬂuid

is pressurized above its vapor pressure to assure required motor

cooling and the establishment of the bearing liquid ﬁlm for rotat-

ing element support. The circulating liquid is channeled into the

motor section by holes drilled in the front bearing housing. A por-

tion of the circulating liquid lubricates the front liquid ﬁlm journal

bearing and returns to the rear of the impeller. The remainder

of the circulating liquid passes over the rotor, cooling the motor,

then lubricates the rear liquid ﬁlm journal bearing and exits the

rear bearing housing and returning to the vapor space of the suc-

tion tank via a separate reverse circulation line. The Type-R (Plan

13-SE) reverse circulation ALP multi-stage pump design prevents

the heated, circulating liquid from vaporizing by the use of a pres-

sure controlling oriﬁce in the reverse circulation line.

The ﬂow path of the Type-R (Plan 13-SE) reverse circulation ALP

multi-stage pump is shown in Figure 1-1 and Figure 1-2.

The Type-R (Plan 13-SE) reverse circulation ALP multi-stage pump

offers an advanced, low probability machine by the provision of

true secondary containment as a standard design feature. In the

event of a primary containment failure, the motor external shell,

or band assembly, which is designed for the same pressure as

the pump and in conjunction with the motor’s leakproof termi-

nal plate, provides complete secondary containment. This stan-

dard feature prevents any release of the process liquid out to the

atmosphere.

IMPORTANT! NRTL certiﬁcation per UL 778 and

CAN/CSA C22.2 No. 108-14 requires operation with

oil ﬁlled stator winding

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

A standard feature of the Type-R (Plan 13-SE) reverse circulation

ALP multi-stage pump is the patented Teikoku Rotary Guardian

(TRG™) bearing wear monitor. The TRG is an electrical meter that

continuously monitors the condition of the bearings enabling

data based preventative maintenance scheduling. For more infor-

mation on the TRG see Section 3.2.1.

1.2 Stator Assembly

The stator assembly consists of a set of three-phase windings

designed for use with Pulse Width Modulated (PWM) Variable

Frequency Drive (VFD) power for 50 HZ to 120 HZ operation. Sta-

tor laminations are of low-silicon grade steel. Laminations and

windings are mounted inside the cylindrical stator band. End

bells, welded to the stator band, close off the ends of the stator

assembly. The stator liner is, in effect, a cylindrical can placed in

the stator bore and welded to the rear end bell and front end bell

to hermetically seal off the windings from contact with the liquid

being pumped.

Terminal leads from the windings are brought into an electrical

terminal box. Motor lead wires are isolated from the users’ con-

duit line by a leakproof terminal plate assembly mounted inside

the terminal box. The design of the stator assembly in conjunction

with the leakproof terminal plate assembly provides an advanced

low probabilty true positive secondary containment.

1.3 Rotor Assembly

The rotor assembly is a squirrel cage induction rotor constructed

and machined for use in the Type-R (Plan 13-SE) reverse circulation

ALP multi-stage pump. It consists of a machined corrosion-

resistant shaft, laminated core with cast aluminum bars and end

rings, corrosion-resistant end covers, and a corrosion-resistant can.

The rotor end covers are welded to the shaft and also to the

rotor can which surrounds the outside of the rotor, thus

hermetically sealing off the rotor core from contact with the liquid

being pumped.

The impellers are keyed to the shaft and held in place with a lock

bolt and lock washer. The shaft is ﬁtted with replaceable shaft

sleeves and thrust collars. These parts are pinned or keyed to pre-

vent rotation. Axial movement is restricted by the thrust collars

contacting the face of the front and rear motor bearings.

1.4 Liquid Film Journal Bearings

The liquid ﬁlm journal bearings for the Type-R (Plan 13-SE) re-

verse circulation ALP multi-stage pump are carbon graphite as

standard and are machined with special helix grooves through

the bore to assure adequate liquid circulation at the journal area.

Each liquid ﬁlm journal bearing is manufactured to close toler-

ances for a high degree of concentricity and is held in a bearing

housing by a retaining screw. Liquid ﬁlm journal bearings are eas-

ily replaced by removing the retaining screw and sliding the bear-

ing from its housing.

1.5 Thrust Collars and Shaft Sleeves

All Type-R (Plan 13-SE) reverse circulation ALP multi-stage pump

models are equipped with thrust collars, providing a replaceable

surface against which axial loads can be carried during process

upset conditions. The shaft is also ﬁtted with replaceable shaft

sleeves. Both the thrust collars and shaft sleeves are constructed

of 316SS with a Stellite wear surface for long life. These parts are

pinned or keyed to prevent rotation.

1.6 Internal Cooling Flow

Flow paths of the Type-R (Plan 13-SE) reverse circulation ALP

multi-stage pumps are shown in Figure 1-1 and Figure 1-2. The

circulating liquid is channeled into the motor section by ports in

the front bearing housing. The circulating liquid lubricates the

front liquid ﬁlm journal bearing, passes over the rotor core cool-

ing the motor, lubricates the rear liquid ﬁlm journal bearing and

then is returned to the vapor space of the suction vessel through

the reverse circulation line. The ﬂow rate is controlled by a restric-

tion oriﬁce mounted in the reverse circulation pipe.

1.7 Automatic Thrust Balance

Based on hydraulic principles, the Type-R (Plan 13-SE) reverse cir-

culation ALP multi-stage pump automatic thrust balance is ac-

complished by the pressure of the pumped liquid itself, operating

in a balance chamber at the front and rear of the impeller.

When a change in load shifts the position of the impeller away

from the balance condition, there is an equalizing change of hy-

draulic pressure in the balance chamber, which immediately re-

turns the impeller-rotor assembly to the balanced position.

1.8 ALP Pump NH3Transfer System Requirements

Figure 1-3 shows a typical anhydrous ammonia transfer system

setup to support a Type-R (Plan 13-SE) reverse circulation ALP

multi-stage pump for installation, commissioning and operation.

Figure 1-2. Flow Path

Casing Cover inlet

First Stage Impeller

Final Stage Impeller

Pipe Casing Outlet Circulation Flow

Main Flow

To the Process Line

Circulation Pipe

Rear Bearing Housing

Gap between Rear Bearing and

Rear Shaft Sleeve

Gap between Stator Can and Rotor Can

Gap between Front Bearing and

Front Shaft Sleeve

Through Reverse Flow Line Oriﬁce

Vapor Space in Suction Vessel

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

Figure 1-3. Typical NH3Transfer System Requirements

Pump casing and bowl area

must be insulated.

Solenoid valve

must be direct

acting type.

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

2.Installation

2.1 Receipt Inspection

1. Avoid rough handling during loading, transportation and un-

2. Visually inspect the shipping container for evidence of dam-

age during shipment.

3. Check unit to see that suction, discharge, and any other con-

nections are covered.

4. Inspect the suction, discharge and any other connections gas-

ket seating surface to be certain that they are clean of foreign

matter and free from nicks, gouges, and scratches.

5. Check all nameplate data against shipping papers.

6. Verify receipt of the restriction oriﬁce for the reverse circula-

tion line.

2.1.1 Storage Note

In situations where a Type-R (Plan 13-SE) reverse circulation ALP

multi-stage pump is to be stored for a period of time prior to

installation and where the climate experiences wide temperature

changes and high humidity, the terminal box, suction and discharge

ﬂange, and any other openings must be sealed to prevent

moisture from entering the internals of the pump. Teikoku's long

term storage procedures are available upon request.

2.2 Structural

The pump design and construction eliminates the necessity of

aligning the pump and motor. The pump should be supported

from the mountings provided. It should be mounted in such a way

as to have its weight properly supported. Suction and discharge

piping must be properly supported and aligned so that no strain

is placed on the pump casing.

1. Remove burrs and sharp edges from ﬂanges when making

up joints.

2. When connecting ﬂanged joints, be sure inside diameters

match within 1/16" so as not to impose a strain on the pump

casing.

3. Use pipe hangers or supports at intervals as necessary.

2.2.1 Pump Location

Locate the pump as close as possible to the liquid supply with a

positive suction head. Location of the pump and arrangement

of the system should be such that sufﬁcient Net Positive Suction

Head (NPSH) is provided over vapor pressure of the liquid at the

pump inlet. NPSH requirements at the design point are stated on

the pump order data sheet.

Note: Experience has proven that most pump troubles result from

poor suction conditions including insufﬁcient NPSH. The suction

line must have as few pressure drops as possible and available

NPSH MUST be greater than required NPSH.

Depending on job conditions, available NPSH can sometimes be

increased to meet the NPSH required by the pump for satisfac-

tory operation. NPSH can be tailored by changes in the piping,

in liquid supply level, and by several other methods. Refer to

Appx. E. Troubleshooting.

2.2.2 Mounting and Alignment

Base plate assemblies are offered on all models. Simply set the

pump on a foundation strong enough to support its weight.

There is no need to bolt down or grout a Type-R (Plan 13-SE)

reverse circulation ALP multi-stage pump.

Be sure that the suction, discharge and reverse circulation piping

is properly aligned so that no strain is placed on the pump by

out-of-line piping.

2.2.3 Piping Data

Observe the standards of the Hydraulic Institute and International

Institute of Ammonia Refrigeration when sizing and making up

suction and discharge piping. Refer to Figure 1-3 and Appx. D pip-

ing layout for Type-R (Plan 13-SE) reverse circulation ALP multi-

stage pump and follow these procedures:

1. Remove burrs and sharp edges when making up joints.

2. When using ﬂanged joints, be sure inside diameters match

properly. When gasketing ﬂanged joints, do not cut ﬂow hole

smaller than ﬂange opening.

3. Use pipe hangers or supports at necessary intervals.

4. Provide for pipe expansion when required by liquid tempera-

ture.

5. When welding joints, avoid possibility of welding shot entering

the suction or discharge line, and thereby entering the pump.

Caution!

Do not weld pipe when it is connected to pump.

6. Do not spring piping when making up any connections.

7. Make suction piping as straight as possible, avoiding unneces-

sary elbows. Where necessary, use 45-degree or long-sweep

90-degree ﬁttings.

8. Make suction piping short, direct, and never smaller in diam-

eter than suction opening of pump. The suction pipe should

be one or two sizes larger than pump suction port, depending

on piping length. The suction pipe should have 10x diameter

straight run between the pump suction inlet and the ﬁrst ﬁt-

ting.

9. Ensure that all joints in suction piping are airtight.

10. When installing valves and other ﬁttings, position them to

avoid formation of air pockets.

11. Permanently mounted suction ﬁlters are not recommended.

12. Pump casing, bowl area, and circulation piping must be insu-

lated. Do not insulate motor section of pump.

Teikoku USA | Chempump Instruction Manual IOM-22-ALP13SE-1122

It is extremely important to design and size the suction system to

minimize pressure losses and to be sure that the pump will not be

starved for liquid during operation. NPSH problems are a result of

improper suction systems.

The suction pipe should be one or two sizes larger than pump

suction port, depending on piping length. Use the largest pipe

size practical on suction piping and keep piping short and free

from elbows, tees or other sources of pressure drop.

If elbows, tees or valves must be used, locate them 10 pipe diam-

eters upstream from the pump suction inlet. When reducing to

pump suction port diameter, use eccentric reducers with ﬂat side

on top to avoid air pockets.

On most Type-R (Plan 13-SE) reverse circulation ALP multi-stage

pumps there is a restriction oriﬁce that must be installed on the

reverse circulation ﬂange of the rear bearing housing.

The design and installation of the reverse circulation line must

be in accordance with reverse piping layout drawing shown it

Appx. A and Figure 1-3.

A vent line back to the suction vessel is required in the discharge

pipe. The connection for the vent line in the discharge pipe must

be between the pump discharge ﬂange and the ﬁrst block valve

and/or check valve. Install a block valve in the vent line. When a

solenoid valve is used for the start vent, the solenoid valve should

be the direct acting type. Program the solenoid valve to be open

when the pump is off and closed when the pump is on. Refer to

Appx. D piping layout for the Type-R (Plan 13-SE) reverse circula-

tion ALP multi-stage pump.

If discharge pipe length is normal, pipe diameter can be the same

size as the pump discharge port diameter. If discharge piping is

of considerable length, use one or two size larger diameter pipe.

If the pump is to discharge into a closed system, an elevated tank

or if there are multiple pumps connected together, place a check

valve in the discharge line close to the pump.

NOTE: Install properly sized pressure gauges in suction and dis-

charge lines between the pump and the ﬁrst block and/or check

valve so that operation of the pump and system can be easily

observed. Should cavitation, vapor lock, or unstable operation oc-

cur, widely ﬂuctuating discharge pressures will be observed. Such

gauges provide a positive means of determining actual system

conditions and can be used to great advantage in evaluating sys-

tem problems.

Figure 2-1. Teikoku TRG Bearing Wear Monitor

Table 2-1. Conditions indicated on the TRG Meter

The TRG meter has a colored scale which is divided into three zones: Green (0 to 0.5), Yellow (0.5 to 0.75), Red (0.75 to 1)

AT TRIAL OPERATION DURING OPERATION

Indication Condition Solution Indication Diagnosis User Actions

Full scale or 1-Volt incorrect wiring change power cable

connection Green Good No action

Yellow to Red phase failure check connection of

cables

Yellow or voltage increase of

> 0.3 V from initial indication

Bearings worn to

caution level

Plan routine

maintenance

Green normal connection is correct Red or voltage increased of

> 0.5 V from initial indication

Immediate

maintenance required

Shutdown immediately

and replace worn parts

Hazard! Do not operate if TRG meter condition is RED.

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