275-400 - ANSI Centrifugal Pump Maintenance and Operations Training Pod

Product Dimensions
(L x W x H) 60" x 34" x 84" (1500 x 850 x 2100 mm)
450 lbs. (205 kg)

Shipping Dimensions

450 lbs. (205 kg)

Standardized, overhung, centrifugal pumps are among the most commonly encountered components found in refineries, chemical plants, power plants, and other similar process facilities. ANSI-type standard centrifugal pumps are among the most commonly-specified pump type found in industrial applications, worldwide. Operation, maintenance, and troubleshooting of these pumps are a primary responsibility for operators and maintenance technicians working in these environments.

This operational, multi-purpose, hands-on module, intended to be integrated into an optional working supply and return system, allows for a variety of maintenance activities and operational checks to be performed, realistically, by the student or student team in a realistic, plant-like environment.

A full-size 1" X 1-1/2" X 6" ANSI centrifugal pump is provided, allowing for, common maintenance activities such as alignment pre-checks, coupling/shaft alignment, leveling, oil level and condition checks, mechanical seal and/or packing installation, as well as preventive/predictive maintenance activities and checks. Additional operations-type activities can be performed such as pump start-up procedures and the monitoring/cataloging/trending of operating variables including, flow rates, pump speed, suction/outlet pressures, temperature, amperage load, as well as periodic forma/informal vibration checks, and valve position verification. All procedures are outlined in accompanying documentation, with safe work practices encouraged at each step.

Electrically, the assembly includes a three-phase reversing motor starter, hand-off-auto control station, pilot lights, system E-stop, power meter, and (8), instructor fault switches, all mounted inside and on the front panel of a NEMA type-4 enclosure.

Structurally, a welded structural steel baseplate structure allows for mounting of a variety of ANSI pump models from well-known manufacturers. The assembly can easily be leveled to match local conditions, via leveling feet. Through adjustable pipe support structures and pipe support hardware, connection to, and support of, the related optional overhead supply and return system is facilitated, along with stabilization of the assembly’s suction and discharge piping.

The primary connecting piping is steel and has been chosen in order to increase realism, and to provide a suitable, stable connecting point to the associated, optional, overhead supply and return system.

Shipped knock-down and organized for trouble-free assembly and installation, this large-scale teaching workstation will make pump-related training more realistic for both maintenance and operations trainees.
Welded, structural steel, and plate steel baseplate assembly allowing for stable mounting of all system components.
Four adjustable leveling feet, assuring precise system fit-up.
Provision for baseplate positioning via fork truck.
Provision for mounting of alternate centrifugal pump types incorporating a removable, and movable universal motor mounting base subassembly, outfitted for conventional shaft alignment activities.
Formed-steel and welded motor subbase, allowing for repositioning, and accurate motor alignment moves, using jacking bolts.
(1) 1" X 1-1/2" X 6" ANSI centrifugal pump with associated three-phase motor, guard, and standard elastomeric element coupling.
Adjustable, universal pipe support assembly fabricated from 1.5" X 1.5" X 12-gauge perforated steel tubing, and allowing for supply and discharge piping stabilization as well as stabilization of optional overhead supply and return system.
Provision for, and hardware for, permanent mounting of baseplate assembly.
NEMA-type control and power enclosure/assembly, with welded support frame, and including a magnetic motor starter, hand-off-auto control station, digital power meter, pilot lights, emergency stop switch, and 4 instructor fault switches. (Silk-screened control panel nomenclature.)
Control Assembly mounting structure incorporating 1.5" X 1.5" X 12-gauge perforated steel tubing and u-channel mounting hardware.
Welded steel schedule 40 piping and 150 pound fittings throughout.
Steel discharge piping assembly including flanged end connections, in-line flow meter, concentric reducer, throttling/isolation valve, swing-type check valve, and pressure gauge.
In-line, variable-area, flow meter (rotameter), in pump discharge assembly
Steel suction piping assembly including flanged end connections, in-line removable strainer, baseplate-mounted pipe support elbow, eccentric reducer, throttling/isolation valve, and pressure gauge.
Extensive spares and maintenance parts inventory. (See Accessories)
Powder-coated surfaces throughout.
Packaging for shipment via motor freight or sea freight.
#208-018 - Continuous sleeve gear coupling.
#210-002 - Preventive/predictive maintenance tool kit (includes vibration meter, infrared thermometer, and non-contact tachometer).
#275-001 - Standard Packing Tool Assortment, including: inspection mirror, cutting mandrel, (2) 10" long packing pullers, (2) 10" long lantern ring pullers, 6" pocket depth scale, (6) pairs latex gloves, 2 additional spools of packing and toolbox.
#275-004 - Type-1, mechanical "non-pusher" seal with elastomer bellows (includes acrylic gland adapter).
#275-005 - Type-8, mechanical "pusher" seal (o-ring type) (includes acrylic gland adapter).
#275-009 - 5-Star, series 84, cartridge seal.
#275-025 - Steel grid coupling (Additional).
#275-028 - Chain-type coupling.
#275-400-PAC - Quick-Start Package (Including #275-400, #275-001 #208-001, #208-003 #275-004, #210-002)
#275-4005 - Use/Exercise Guide, 3-part (additional printed copy).
#275-4005C - Use/Exercise Guide, 3-part (additional CD-ROM copy).
#275-499 - Supply and Return System, Basic
* Original pump installation and maintenance manual.
* Pump maintenance spares kit.
* 16-piece preliminary baseplate leveling Shim kit.
* 4-piece floor anchor installation kit.
* Lock-out/tag-out accessory kit.
* Combination wrench short set (4-piece).
* Spare packing set and bulk braided packing.
* Supplemental, replacement 7-piece flange gasket set.
* Supplemental temporary strainer.
* Sample trending charts
240/360 VAC, 3-phase,50/60 Hz Electrical supply, water source, instrument air source.
The courseware, useful in both a instructor-led and or a self-directed format, references one of several optional textbooks, and includes a use guide and multiple hands-on exercises.

Exercises include:
Dedicated use/exercise guide - Coming July 2015.

This device has been designed for professionals for use under controlled circumstances for training only. DAC assumes no liability for injury resulting from the use or misuse of this product.
This device is being offered for training purposes only, and components cannot be used as replacement hardware in actual applications.
For Economy, this product is shipped knock down. Some basic assembly with hand tool is required.
Working process systems and related equipment have inherent dangers.
In accordance with DAC’s established policy of continuous improvement, these specifications and product descriptions are subject to change without notice. This information is the latest technical information as of the time of viewing or printing.
This product may require installation by local mechanical and electrical contractors, ensuring conformance with