Hayward Gordon CHOPX

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Hayward Gordon CHOPX
Submersible Chopper Pump Training Session Reno
Stead WWTP
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Training Outline

1. Introduction
2. Description of Pump
3. Pump overview (design features).
4. Submersible Motor overview.
5. Electrical Connections overview.
6. Guide rail and Quick-disconnect overview.

• Where is the pump being used?
• Review of pump performance curve.
• Maintenance pump end.
• Maintenance motor end.
• Installation / Start-up Checklist.
• Trouble Shooting.

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INTRODUCTION

• H.G. entered the process pump business in the
  early 1960s with the development of the small
  frame ANSI pumps.
• In the 1970s we designed our TORUS line of
  recessed impeller pumps, the cantilever pump line
  including the design of the slurry wet ends and
  the first sulfur pumps.
• In the late 1980s we started on our next major
  design phase with the development of the XCS
  screw centrifugal pumps.
• At the end of the 1990s we started on the CHOPX
  design.

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Description of Pump
What is a CHOPX chopper pump? The Hayward Gordon
CHOPX centrifugal chopper pump combines chopping
and pumping capability into one unit. The design
features a unique high efficiency, anti-fouling
impeller intended for services requiring
conditioning and size reduction of solid material
in the the pumped fluid. The dual function of
chopping and pumping provided by the CHOPX
chopper pump eliminates the need for separate
grinding or comminution equipment.
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Pump Wet End Design
Back plate in volute
Impeller
Cutter plate
Clearance adjustment shims
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Pump Wet End Design
Two bladed impeller in hardened steel (Rockwell
60) construction
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Pump Wet End Design
Backside of impeller c/w expelling grooves and
rear cutting teeth
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Pump Wet End Design
Volute c/w integral back plate (expelling grooves)
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Pump Wet End Design
Cutter plate assembly c/w expelling slots to
prevent binding (split shims used for clearance
adjustment).
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Pump Wet End Design
Carriage bolts for joining cutter plate assembly
to the volute.
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Pump Wet End Design
Impeller to cutter plate clearance adjustment
shims located here. Adjustment made by adding
or subtracting shims.
Impeller to cutter plate clearance checked
through this inspection port.
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Submersible Motor Overview
Motors are Reliance submersible which utilize a
UL approved Class 1, Groups C D tandem seal
design, with an oil chamber separate from the
winding area. Motors are designed to operate
continuously in fluid however may operate for up
to 15 minutes in air. NOTE The lower (outer)
shaft seal must be in liquid when motor
is operated, whether motor is submerged or in
air. Seals cannot be run in a dry environment
without a significant reduction in seal life.
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Submersible Motor Overview
Important Installation Notes 1. The user must
select a motor starter and over-current
protection suitable for this motor and its
application. 2. Thermal Protectors must be
connected. Leads marked P1 and P2 (see motor
manual Figure 2). 3. Moisture Sensing Probes
must be connected. Leads marked W1 and W2. (see
motor manual Figure 3). 4. Control leads
should not be installed in the same conduit as
power leads. Induced voltage can cause false
moisture detection signals. 5. Check your power
supply against final nameplate connection voltage.
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Submersible Motor Overview
Motor Lead Cable Assembly The motor lead cable
assembly for all Reliance submersible pump motors
has three marked power leads plus two ground
leads, two thermal leads and two moisture
sensing probe leads in standard cable lengths of
25 feet. Leads are brought through an epoxy
sealed connector providing a mechanically strong
water tight seal.
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Submersible Motor Overview
Thermal Protection System Reliance submersible
pump motors are equipped with thermal
protection devices. Failure to properly connect
or utilize this system voids motor
warranty. Thermostat leads marked P1 P2 must
be connected in series with the stop button of
the 3-wire pilot circuit of the magnetic motor
controller, so that the thermostat will open the
circuit before dangerous temperatures are
reached. Refer to Figure 2 (Thermal
Protector Wiring Diagram) on Pg. 6 of Reliance
motor OM manual
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Submersible Motor Overview
Moisture Detection System Reliance submersible
pump motors are equipped with moisture
detection devices. Failure to properly connect or
utilize this system voids motor
warranty. Moisture sensing probes, leads marked
W1, and W2, must be used in conjunction with an
induction relay. This device will detect
moisture entering the oil chamber due to failure
of the lower (outer) seal and, when properly
connected to a warning device, will provide
notification of needed maintenance. Integrity of
system requires periodic test. Refer to Page
6, 7 and 8 of the Reliance motor OM manual.
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Electrical Connections Overview
CAUTION! Make sure that power supply to control
panel is the same as on the motor
nameplate. CONTROL PANEL To assure
non-voidance of warranty and proper protection
of the motor, the control panel must as a minimum
contain the following components - Thermal
Protection System See Motor Manual - Moisture
Detection System See Motor Manual In addition
to the above, the control panel shall contain the
following components - Isolation switch,
lockable one preferred - Slow Trip Fuses or
Circuit Breakers in each incoming phase. -
Lightning Arrestor or each incoming phase (if
lightning is possible) - Start Switch - Seal
Failure Alarm Light
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Electrical Connections Overview
Follow motor Wiring Diagram and Instructions for
proper component selection and
connections. Level Switches For high-level
alarm a floating ball type is recommended as most
reliable switch. Level Control ON and OFF
levels to be set in such a manner as to avoid
switching pump on more than 10 times per hour to
prevent any possible damage to motor.
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Guide Rail Quick Disconnect System Overview

• Guide rails (pipes)
• - must be vertical and parallel and their
• top ends held in place with a bracket.
• Lifting winch
• Mounted directly over centerline of
• the motor. Lifting cable remains
• attached to the lifting yoke at all times.
• Quick-disconnect
• lubricate mating faces with grease.
• the weight of the pump seals the faces

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Where is this pump being used in the plant?
Operations Building Sump Pump Application Plant
Drainage
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Plant Drainage Pump Qty. 1
Pump model CHOPX4A-S s/n 297119 c/w 10 hp 1800
rpm motor Pump is operating off a guide rail
system c/w quick disconnect. Duty point of 700
usgpm _at_ 25 tdh
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Pump Performance Curve
700 usgpm _at_ 25 tdh
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Maintenance
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Maintenance Pump End

• Disassembly of Pump Wet End
• Refer to O M manual and GA drawing during
  dismantling
• Remove carriage bolts to separate cutter plate
  from volute.
• Remove cutter plate o-ring and clearance
  adjustment shims (located
• between cutter plate and volute).
• 4. Remove impeller screw washer (shroud)
  allowing for the removal
• of the impeller and impeller key.
• Remove shaft adapter, back clearance adjustment
  shims and motor
• shaft key.
• 6. Remove carriage bolts to separate volute
  from motor adapter.

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Maintenance Pump End
Carriage bolts for joining cutter plate assembly
to the volute.
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Maintenance Pump End
Impeller to cutter plate clearance adjustment
shims located here. Adjustment made by adding
or subtracting shims.
Impeller to cutter plate clearance checked
through this inspection port.
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Maintenance Pump End
Impeller against cutter plate
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Maintenance Pump End
Cutter plate assembly c/w expelling slots to
prevent binding (split shims used for clearance
adjustment).
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Maintenance Pump End
Two bladed impeller in hardened steel (Rockwell
60) construction
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Maintenance Pump End
Backside of impeller c/w expelling grooves and
rear cutting teeth
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Maintenance Pump End

• Disassembly of Motor Lower End
• Refer to GA drawing during dismantling
• Remove nut and lockwasher from quill shaft.
• Slide quill shaft collar toward motor (tap it
  with rubber mallet to
• disengage it from locked position).
• 4. Remove quill shaft from motor shaft
• Follow motor instructions (see Reliance OM
  manual).

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Maintenance - Submersible Motor

• Mechanical Repairs
• U/L listed motors must be returned to an
  authorized Reliance Electric
• Service Facility for repairs other than to
  replace the lower seal.
• The nearest Reliance facility is in Stockton, CA
  (209-464-7321).
• To inspect the lower (outer) seal proceed as
  follows
• Remove outer snap ring, replace as needed.
• Remove rotating outer seal, replace as needed.
• Approved lubricating and insulating oil shall
  meet Reliance approved
• source sheet 4824-18-AF. (I.e. Shell
  Rotella Oil SAE 10W)
• Refer to Page 4 5 of the Reliance motor OM
  manual.

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Maintenance - Submersible Motor

• Mechanical Repairs
• To inspect or replace the oil proceed as follows
• Remove outer snap ring, replace as needed.
• Remove rotating outer seal, replace as needed.
• Oil drains through seal opening. Oil added
  through same opening.
• Approved lubricating and insulating oil shall
  meet Reliance approved
• source sheet 4824-18-AF. (I.e. Shell
  Rotella Oil SAE 10W)
• 5. For 210TY frame motor oil quantity of 2 ½
  quarts.
• Refer to Page 4 of the Reliance motor OM
  manual.

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Maintenance - Submersible Motor
Electrical Repairs Lead Reconnect The cable
connector assembly may be removed to reconnect
the leads without negating the U/L listing or the
warranty. Warning the motor may contain
gas under pressure due to high temperatures from
operation without being submerged. Disassembly
may cause bodily injury. For assistance contact a
Reliance office. Refer to Page 5 of the
Reliance motor OM manual.
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Installation/Start-up Checklist

• Shipment
• Was there any damage in transit? (Check Cables)
• b) Were all items received?

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Installation Start-up Checklist

• 2. STORAGE
• Has equipment been protected from the elements?
• Are cable ends protected from moisture?
• Was equipment subject to flooding?
• Have storage instructions been followed?

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Installation Start-up Checklist

• 3. INSTALLATION
• Is the quick-disconnect level?
• Is a proper lifting device being used to raise
  and lower the pump?
• Have proper anchor bolts been used?
• Have the bolts been properly tightened?
• Is the discharge pipe properly supported?
• Are the guide rails and supports properly
  installed?
• Is the quick-disconnect properly seated?
• Are the power and control cables routed through
  separate conduits?
• Is the Thermal Protection System properly
  connected?

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Installation Start-up Checklist

• 3. INSTALLATION Continued
• j) Is the Moisture Detection System properly
  connected and tested?
• k) Are accessory items, level switches,
  vibration sensors, etc., properly mounted and
  properly installed?
• l) Are all safety labels in place?
• Has impeller been rotated by hand to ensure free
  rotation? This also helps ensure that the
  mechanical seals are seated correctly.
• n) VFDs has the VFD been properly set up and
  have all settings been checked with the
  pump/motor manufacturer?

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Installation Start-up Checklist

• 4. ROTATION
• Has the rotation of the motor been checked for
  correctness? (Jog VERY briefly)

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Installation Start-up Checklist

• 5. SYSTEM
• Has the system been checked to insure that it is
  free of foreign matter and purged of air, which
  could be damaging to the pump?
• Is discharge valve 25 open (open to 100
  immediately after start-up)?
• Is liquid available to the pump?
• Is the pump submerged?
• Has assurance been obtained from responsible
  parties that all piping is secure and that the
  routing of flow has been established and is
  correct?

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Installation Start-up Checklist

• 6. START-UP (Record as many as possible)
• Flow rate
• Discharge pressure gauge readings
• Height of pressure gauge above sump pump liquid
  level
• Motor amp draws
• Power Factor
• Other observations.

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Installation Start-up Checklist

• 7. SAFETY
• Have all safety/warning labels been read and
  understood?

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Trouble Shooting

• Vibration Noise
• Loose foundation bolts Tighten bolts, take
  care not to distort base.
• Bent shaft Inspect shaft, replace if bent.
• Binding rotating equipment Ensure pump rotates
  freely.
• Pumps too much liquid, head lower than rated
  Restrict discharge by
• partly closing discharge valve.
• Cavitation on the suction side due to lower NPSH
  available Raise
• suction/liquid level.

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Trouble Shooting

• No Discharge Flow
• Pump not primed fluid too low Prime pump
  raise liquid level.
• Speed too low Check voltage and frequency.
• Required discharge head too high Reduce head,
  increase speed or
• possibly install larger diameter impeller. Take
  care not to overload the
• motor
• Impeller or volute is blocked Clear blockage.
• Suction port is blocked Clear blockage.
• Wrong rotation direction Reverse any 2 leads
  on 3-phase motor.

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Trouble Shooting

• Not Enough Discharge Flow
• Speed too low Check voltage and frequency.
  Increase pump speed.
• Air or gas in liquid.
• Imposed discharge head too high Reduce head,
  increase speed or
• possibly install larger diameter impeller. Take
  care not to overload the
• motor
• Impeller or volute is blocked Clear blockage.
• Suction port is blocked Clear blockage.
• Insufficient NPSH available Raise
  suction/liquid level.
• Wrong rotation direction Reverse any 2 leads
  on 3-phase motor.

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Trouble Shooting

• Speed Too Low
• Incorrect wiring Check electrical connections
  of motor (is it receiving
• full voltage.
• Check motor

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Trouble Shooting

• High Power Consumption
• Speed to high Lower pump speed.
• Pumps too much liquid, head lower than rating
  Restrict discharge by
• partly closing valve.
• Specific gravity or viscosity of liquid pumped
  higher then rated Reduce
• pump speed. Reduce liquid specific gravity or
  viscosity.
• - Bent shaft Inspect shaft, replace if bent.
• Binding rotating element Ensure pump rotates
  freely

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Trouble Shooting

• Moisture detection light illuminated immediately
  after start-up
• Check that motor control wiring is not run
  through the same conduit as the
• the power cable. Control and power wires MUST
  be isolated.
• Possible residual moisture in seal chamber. Let
  pump run for approx. 48
• hours to see if moisture dissipates.
• If light says on, pump must be removed to check
  for failure of seal, cable
• or cable cap assembly.
• - Repair any damaged parts.
• Drain oil from seal chamber and replace with new
  oil per motor manual.

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Trouble Shooting

• Moisture detection light stays illuminated but no
  problems found
• with seals or cable cap assembly
• Check that motor control wiring is not run
  through the same conduit as the
• the power cable. Control and power wires MUST
  be isolated.
• Contact Hayward Gordon

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