Et Pn Iso Pump Instruction Manual-Org

Mather + Platt Installation, Operating and Maintenance Instruction Manual for End Suction Pumps ET ISO/PN ISO

These instructions must be read prior to installing, operating, using and maintaining this equipment

MPPL/IM/ESP/ET/PNISO/2006/0

Mather + Platt

Table of Content

EC declaration of incorporation (QA02-45) for, pumps without prime mover EC declaration of conformity (QA02-46) for, pumps with CE prime mover. 1

Preface and Copyright Information

1-1

Preface Copyright Manufacturer Rights of alteration

1-1 1-1 1-1 1-1

General safety information

2-1

Safety symbols used in the man

2-1

Guides lines used and CE certification Declaration of Incorporation or Conformity Duty conditions Safety & control devices Safety instructions Safety instruction for the operator Electrical connection and electrical work Operation with different pump fluid Sound pressure Prime mover selection Warranty Remarks

2-1 2-1 2-2 2-2 2-2 2-3 2-4 2-4 2-4 2-5 2-5 2-6

Product description

3-1

General product information Proper use and fields of application Conditions of use Construction

3-1 3-1 3-1 3-2

Handling, transportation and storage

4-1

Handling Delivery Transport Storage Returning to supplier

4-1 4-1 4-2 4-2 4.2

Installation

5-1

5.1

Introduction

5-1

5.2

Requirements for the operating area

5-1

5.3 5.4 5.5 5.6 5.7 5.8

Cleaning Foundations Bedplate Alignment of pump and driving unit Pipe work Use of diesel engine as prime mover

5-1 5-2 5-2 5-4 5-7 5-8

1.1 1.2 1.3 1.4

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

3 3.1 3.2 3.3 3.4

4 4.1 4.2 4.3 4.4 4.5

5

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Table of Content

Mather + Platt

Start up

6-1

Introduction Pipe work flushing Cleaning of bearing Direction of rotation Priming Pump operating on flooded suction

6-1 6-1 6-1 6-1 6-1 6-1

Pump operating on negative suction Pump operating on hot liquid Pre-starting checks Normal starting checks Running checks Normal shut down Emergency shut down

6-2 6-2 6-2 6-3 6-4 6-4 6-4

Maintenance

7-1

Routine maintenance & frequency of inspection Overhaul maintenance Spares Lubrication

7-1 7-2 7-8 7-9

8

Troubleshooting

8-1

A

Lists, Tables & Type Plates

A-1

List of machine operators Maintenance and inspection log Type plates Leveling Records Alignment Protocol Pre-Starting checks Pump commissioning report Issue/Feed back report

A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8

Machine data sheet

B-1

Performance

B-1 B-1 B-1 B-1 B-3 B-4 B-5

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13

7 7.1 7.2 7.3 7.4

A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8

B B.1 B.2 B.3 B.4 B.5 B.6 B.7

Pressure limits Temperature limitation Flange loads Bearing, lubrication & gland packing data etc Recommended bolting & screw torques Interchangeability charts

MPPL/IM/ESP/ET/PNISO/2006/0

Mather + Platt

EC declaration of incorporation

EC declaration of incorporation According to annexure V of machinery directive 98 /37 /EC, We hereby state that this product (Pump without prime mover) Product designation Type designation

: :

Pump serial no Prime mover designation Type designation Prime mover (CE) serial no

: : : :

End suction pump Refer section B5 serial No 1 to 34 of the manual & the name plate on the pump Refer the name plate on the pump Not applicable. Not applicable. Not applicable.

fulfills the following relevant legal requirements: EC – Machinery directive 98 / 37 / EC Harmonized standards used, in particular: EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050 Manufacturer Address

: :

Telephone Fax e-mail

: : :

Representative (within EEA) Address

: :

Telephone Fax e-mail

: : :

Mather and Platt Pumps Ltd., Mumbai –Pune Road, Chinchwad, Pune411019, India. +91 (0)20 27442100. +91 (0)20 27442211. [email protected] WILO AG, NortkirchenstraBe 100, 44263 Dortmund, Germany +49 231 4102-0 +49 231 4102-363 [email protected]

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune A. V. Joshi Deputy General Manager - Quality Assurance

QA02-45 REV 0

Mather + Platt

EC declaration of conformity

EC declaration of conformity According to annexure V of machinery directive 98 /37 /EC, We hereby state that the Mather & Platt product (Pump with prime mover), refer prime mover manual name plate, instruction manual & CE declaration of conformity Product designation Type designation

: :

Pump serial no Prime mover designation Type designation Prime mover (CE) serial no

: : : :

End suction pump

Refer Section B5 Serial No 1 to 34 of the manual & the name plate on the pump Refer the name plate on the pump Refer the name plate on the prime mover Refer the name plate on the prime mover Refer the name plate on the prime mover

fulfills the following relevant legal requirements: EC – Machinery directive 98 / 37 / EC Harmonized standards used, in particular: EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050 Manufacturer Address

: :

Telephone Fax e-mail

: : :

Representative (within EEA) Address

: :

Telephone Fax e-mail

: : :

Mather and Platt Pumps Ltd Mumbai –Pune Road, Chinchwad, Pune411019, India. +91 (0)20 27442100 +91 (0)20 27442211 [email protected] WILO AG, NortkirchenstraBe 100, 44263 Dortmund, Germany +49 231 4102-0 +49 231 4102-363 [email protected]

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune A. V. Joshi Deputy General Manager - Quality Assurance QA02-46 REV 0

Mather + Platt

Preface and Copyright Information

1

Preface and Copyright Information

1.1

Preface

Dear Customer Thank you for purchasing one of our company's products. This operating and maintenance manual must be read carefully before installation & initial start-up to ensure safe and efficient use. This documentation contains all the necessary information for the product, allowing you to use it properly. In addition, you will also find helpful information, which will enable you to recognize potential dangers, reduce repair costs, down times and increase the reliability and working life of the product. The operating company is responsible for ensuring that all persons working with or on this product are at least 18 years of age and have read and understood this manual. Only qualified and trained personnel should be assigned to work on the product. All safety requirements and specific manufacturer's requirements must be fulfilled before the product is put into operation. This operating and maintenance manual supplements any existing national regulations on industrial safety and accident prevention. This manual must be made accessible to personnel working at all times and also be made available where the product is used. In a case where there is any doubt as to the functioning or adjustment of any parts of the equipment, or in the event of any trouble which cannot be remedied by reference to the information contained in this manual, MATHER & PLATT PUMPS LTD. should be consulted immediately at their Pune address mentioned below. In communicating with the Company, the Pump Serial Number should always be quoted.

1.2

Copyright

This operation and maintenance manual has been copyrighted by, the manufacturer. The operation and maintenance handbook is intended for, the use by assembly, operating and maintenance personnel. It contains technical information and diagrams which may not be reproduced or distributed, either completely or in part, or used for any other purpose without the expressed consent of the manufacturer.

1.3

Manufacturer

Mather and Platt Pumps Ltd Mumbai-pune Road Chinchwad Pune-411019 India Tel.: +91 (0) 20 27442100 Fax: +91 (0) 20 27442111 Internet: www.matherplatt.com e-Mail: [email protected]

1.4

Rights of alteration

The manufacturer reserves the right to make technical alterations to systems or components and contents of the manual.

This operating and maintenance manual refers to the product indicated on the title page.

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General Safety Information

General Safety Information

This operation and maintenance manual contains basic information, which must be strictly observed during operation and maintenance. Not only the safety instructions listed in this chapter must be followed but also those contained in other chapters, which refer to specific parts and procedures. The operator is responsible for ensuring that personnel follow these instructions and guidelines.

2.1

Safety symbols used in the Instruction manual This symbol indicates danger from general causes where noncompliance with safety instructions would affect personnel safety. This symbol indicates danger from electrical causes where noncompliance with electrical safety instructions will involve a high risk to personnel safety or loss of life. This note symbol refers to safety requirements or notes that are of critical importance to the user where non-compliance could damage the pump or installation or cause it to malfunction.

2.2

Guidelines used and CE certification

Our products conform to the following EU guidelines: -

Machinery directive 98 / 37 / EC.

In addition, several harmonized standards have been applied, e.g. EN 809, ISO 12100-1& ISO 12100-2, EN 1050 (Risk assessment). Please consult the EU Declaration of Conformity for the precise information and the guidelines in effect The EU Declaration of Conformity is issued in accordance with EU Directive 98/37/EC, Appendix II A. The CE symbol is found on the pump nameplate and motor & electrical panel nameplate when in M&P’s scope of supply.

2.3

Declaration of Incorporation or conformity.

Since Mather & Platt does not manufacture prime mover, following conditions will apply. It is recommended that customers should opt for CE marked prime mover. When customer takes only bare pump, or pump with accessories without prime mover, Declaration of Incorporation will be applicable. For unitized pumps with CE prime mover, Declaration of Conformity will be applicable. Where customer opts for pumps with prime mover without CE, or supplies his prime mover for unitization, which is not CE, Declaration of incorporation will be applicable.

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General Safety Information 2.4

Duty conditions

This product has been supplied as per specifications in your purchase order/ approved data sheet & drawings. A copy of these specifications / approved data sheet should be kept with these instructions.

The product must not be operated beyond the parameters specified for the application. In case of any doubts, contact Mather & Platt for advice, quoting Pump serial number. If the duty conditions of pump are going to be different than the specifications in purchase order / approve data sheet (e.g. liquid pumped, temperature or duty) it is requested the user seeks the written agreement of Mather & Platt pumps Ltd., before start up.

2.5

Safety & control devices

Direct controls are applicable when pump is supplied along with motor/panels. When motor/panel are in end user’s scope, it is advised to go for CE approved motors/panels.

These devices whether on pump/motor/electrical panels must never be dismantled or disabled. They must be checked by an authorized technician for proper functioning before, start-up. Refer to motor & Electrical panel instruction manuals for electrical safety & control devices information.

2.6

Safety instructions -

Installation & service should be done by, qualified personnel only.

-

The installation / removal of the product must not be performed by one person alone.

-

Failure to comply with safety precautions could result in personnel injury or damage to the equipment or installation. Failure to comply with safety precautions could also invalidate any claim for warranty.

-

The operator is required to know mechanical/electrical specifications of the machine and how to cut off the supply.

-

The operator must inform his/her superior immediately should any defects irregularities occur. This applies to both the electrical and mechanical devices.

-

If fastening devices are separated from the pump after use, they should be marked as fastening devices. Otherwise they should be carefully stored.

-

It is of vital importance that the system is shut down immediately by the operator if any problems arise which may endanger the safety of personnel and/or plant. Problems of this kind include: -

or

expressly

Failure of the safety and/or control devices. Damage to critical parts. Damage to electric installations, cables and insulation.

-

Main controls for the pumps should be located for easy view of the operator from the control position.

-

The removable and/or mobile equipment for lifting loads should be used in a manner that ensures the stability of -the equipment during operation.

-

Measures should be taken to bar persons from standing beneath a suspended load. Furthermore, it is also prohibited to move suspended loads over exposed workplaces where people are present.

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General Safety Information

-

The fastening devices should be adapted to the conditions at hand (weather, hooking system, load, etc.) If these are separated from the pump after use, they should be expressly marked as fastening devices. Otherwise they should be carefully stored.

-

Only fastening devices, which are legally designated as such and officially approved, may be used.

-

When using mobile working equipment for lifting non-guided loads, measures should be taken to prevent them from tipping, sliding, slipping etc.

-

If mobile working equipment is used for lifting loads, a second person should be present to coordinate the procedure if needed (for example, if the operator's field of vision is blocked).

-

While unloading the pump from the truck lift the pump by passing wire rope beneath the box containing the pump or pump assembly.

-

The load to be lifted must be transported in such a way that there is no danger of injury in the event of a power failure. Additionally, when working outdoors, such procedures must be interrupted immediately if weather conditions worsen.

-

When working in enclosed spaces care should be taken to provide sufficient fresh air. Provide sufficient ventilation.

-

When welding or working with electronic devices, ensure that there is no danger of explosion.

-

When working with pumps using hot liquid appropriate care should be taken. It is advised to use PPE irrespective of warning signs on pump/insulation provided depending upon the temperature of liquid handled.

-

Environmental safety: Disposal of any unwanted/scrap material should be disposed in appropriate way so as not to cause any harm to the environment. No hazardous material is used in M & P pumps.

These instructions must be strictly observed. Non- compliance can lead to serious personal injury and/or damage to the machine.

2.7

Safety instructions for the operator -

Local regulations for the prevention of accidents must be observed. Dangers resulting from electrical energy are to be prevented. National/local energy supply company regulations must be followed.

-

Guards for moving parts (e.g. coupling) must not be removed from the machine while in operation.

For safety reasons, safety and control devices must not be removed without authorization. Personnel must have the requisite specialist knowledge.

Use Standard Personnel protective equipments against sharp corners for protection of hands, for eyes when using grinders, Special PPE against electrical shocks, against sound (Cl 2.8) etc.

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General Safety Information 2.8

Electrical connection and electrical work

Refer to the motor and panels instruction manual at the time of installation and connection. Motors or electrical control panels are operated with alternating or industrial high-voltage current. It is recommended to use CE marked motor and / or electrical panel if they are not in M&P’s scope of supply. The local regulations must be adhered to. The "Electrical connection" data sheet in the respective motor and panel instruction manual must be followed when connecting the product. The technical specifications on the nameplate and in the machine data sheet must be strictly observed. Ensure that there is a provision for isolation of all energy sources and locking. If the machine has been switched off by, a protective device, it must not be switched on again until the error has been corrected. The electrical system (machine including protective devices and operating position) must always be grounded. Refer pump GA drawing & respective manuals of motor/electrical control panel for connecting earthing suitable as per motor rating and relevant regulations and standards including proper earthing lug size and fasteners.. If there is a possibility that people can come into contact with the machine and the pumped liquid (e.g. at construction sites), the grounded connection must be additionally equipped with a fault current protection device.

Electrical work (connection, maintenance and repair work) may only, be carried out by a qualified electrician. Any unused wires must be disconnected! The cable ends must never be immersed in the pumped liquid! Refer instruction manual of respective equipments like motor, panels etc for safety instruction to be followed when connecting these equipments to the pump and power supply and for the operation.

2.9

Operation with different pumped fluids

The pump supplied is intended for specific fluid. Refer pump data sheet and order confirmation. For any change in pumped fluid refer M&P before hand.

2.10

Sound pressure

Depending on the size and capacity (kW), the products produce a sound pressure of approximately 75dB (A) to 110dB (A). The actual sound pressure, however, depends on several factors. These include, for example, the installation type, fastening of accessories and pipeline, operating site condition, background noise, etc. Once the product has been installed, we recommend that the operator makes additional measurements under all operating conditions.

In accordance with the laws in effect, guidelines, standards and regulations, ear protection must be worn if the sound pressure is greater than 85dB (A). The operator is responsible for ensuring that this is observed! For actual values on sound level & vibration at the time of pump testing on test bed refer to the Pump performance test certificate submitted along with other certificates.

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Mather + Platt 2.11

General Safety Information

Prime mover selection

When prime mover is in M&P’s scope of supply, Electrical motors/diesel engines/steam turbines etc. are selected mutually with the customer/end user depending upon his requirements & absorbed power by the pump at duty point. Prime mover will be with CE marking. When pump is supplied along with prime mover and/or with control panel when in M&P’s scope, manufacturers’ instruction manual for respective equipment will be provided to the customer/end user along with the pump instruction manual.

2.12

Warranty

This chapter contains the general information on the warranty. Contractual agreements have the highest priority and are not superseded by the information in this chapter! The manufacturer is obliged to correct any defects found in the products it sells, provided that the following requirements have been fulfilled:

General information -

The materials used, caused the defects or the way the product was manufactured or designed.

-

The defects were reported in writing immediately to the manufacturer within the agreed warranty period.

-

The product was used only as prescribed.

-

All safety and control devices were connected and inspected by authorized personnel.

Warranty period If no other provisions have been made, the warranty period applies to the first 12 months from the date of delivery / installation or 18 months from the date of dispatch from the works which ever is earlier. For details refer the warranty certificate provided. Other agreements must be made in writing in the order confirmation.

Spare parts, add-ons and conversions Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, add-ons and conversions. Only these parts guarantee a long working life and the highest level of safety. These parts have been specially designed for our products. Self-made add-ons and conversions or the use of non-original spare parts can seriously damage the product and/or injure personnel.

Maintenance The prescribed maintenance and inspection work should be carried out regularly. This work may only, be carried out by qualified, trained and authorized personnel. The maintenance and inspection log supplied must be properly updated. This enables you to monitor the status of inspections and maintenance work. Quick repairs not listed in this operation and maintenance manual and all types of repair work may only be performed by the manufacturer and its authorized service centers.

List of machine operators The machine operator list must be filled out completely. By signing this list, all persons working on or with the product confirms that they have received, read and understood this operating & maintenance manual.

Damage to the product Damage as well as malfunctions that endanger safety must be eliminated immediately by, authorized personnel. The product should only be operated if it is in proper working order. During the agreed warranty period, the product may only be repaired by, the manufacturer or an authorized service workshop. The manufacturer reserved the right to recall the damaged product to the factory for inspection.

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General Safety Information Exclusion from liability

No liability will be assumed for product damage if one or more of the following points apply: -

Incorrect design on our part due to faulty and/or incorrect information provided by the customer.

-

Operation of product different/beyond the parameters specified in purchase order/approved data sheet.

-

Non-compliance with the safety instructions, the regulations and the requirements and this operating and maintenance manual.

-

Improper installation & pipe work.

-

Faulty construction site and/or construction work.

-

Chemical, electrochemical and electrical influences.

-

Improper assembly/dismantling.

-

Improper maintenance.

-

Unqualified repairs.

-

Wear.

This means the manufacturer’s liability excludes all liability for personal, material or financial injury.

2.13

REMARKS

To avoid ambiguity in the use of the word `replace' the words `replace' and ‘renew' are used in this manual in the following context: Replace - To put back, in its existing state, a part or component that has previously been removed. Renew

- To substitute a new part of component for a worn or damaged one.

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Mather + Platt 3

Product description

3.1

General product information

Product description

The machine is manufactured with great care and is subject to constant quality controls. Trouble-free operation is guaranteed if it is installed and maintained correctly.

3.2

Proper use and fields of application

These pumps are used for general water service, Chemical process, Sprinkler and drip irrigation, and condensate transfer, Drainage & Fire fighting, Juices/syrups etc.

3.3

Conditions of use All End suction models are for use in non-hazardous area. For precise details about the model of the pump and design operating conditions, see Pump nameplate, motor nameplate & panel name plate when in supply scope and the pump data sheet. Do not operate the pump away from specified operating range. Operating beyond duty point may not pose a risk to the operator but will reduce the efficiency of the pump or damage the pump itself. Operation more than 5 minutes, at close valve condition is not recommended. For hot liquids this is not recommended at all. Please also note that these pumps are not self-priming, which means that the impeller & casing must always be fully filled with fluid to be handled before putting in operation. A dry run must be avoided at all cost. Ensure that always site NPSH-A is more than NPSH-R.

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Mather + Platt

Product description 3.4

Construction

3.4.1 General description ET-ISO/PN ISO is a Mather + Platt end suction, back pullout pump. This pump is interchangeable with other ISO pumps of the same size, conforming to the international standard ISO 2858. The flow of liquid passes through the suction pipe & enters suction branch and reaches the eye of impeller or center of the impeller. The rotating impeller transfers liquid at high pressure and velocity in to the pump casing where the specially designed volute brings about a reduction in the velocity of the liquid. In this way the kinetic energy to the liquid by the rotating impeller is converted into additional pressure energy and the liquid is discharged through the delivery pipe. ET ISO is with grease lubrication. PN ISO is with oil lubrication.

3.4.2 Detailed description (Ref Fig. 14/15) 3.4.2.1 Casing (029) The pump casing is highly efficient of the volute type, designed with computer technology for high stress resistance and maximum performance. It features an anti-swirl vane in the inlet branch for Improved stability of head with a vertical centerline outlet branch as standard.

3.4.2.2 Impeller (031) The impeller is of the fully enclosed type, with twisted vane design for maximum performance, giving higher efficiencies and suction lifts. Sweptback clearing vanes are provided to balance the axial thrust and protect the gland packing and shaft from wear by abrasive particles. Impeller is hydraulically and dynamically balanced. It is keyed at the end of the shaft and secured by means of an impeller nut. Open impeller with wear plate option is available.

3.4.2.3 Back Cover (011) It features an 'O' seal for positive leak proof joint with the pump casing. Positive location is maintained between casing and housing because of the metal-to-metal face contact thus ensuring that the pump is a rigid structure unit.

3.4.2.4 Mechanical seal/ Gland packing (044/581) Extra deep stuffing box has been provided and it accommodates five packing rings and features a solid gland. The stuffing box is liquid sealed through a logging ring. The clearing vanes provide liquid under pressure at the logging ring. Alternatively clear water supply at 1.5 to 2.0 kg/sq cm pressure can be given as sealing liquid. Approximate quantity required 2 to 2.5 Lpm. The clear water sealing gives maximum seal life thus reducing the cost of maintenance. Mechanical seal can be provided in place gland packing arrangement.

3.4.2.5 Shaft (049) The shaft is ground all-over and sturdily proportioned to minimize deflection and provide long-term reliable service. As a standard arrangement deep groove single row ball bearings have been provided. The coupling end bearing has been precisely located by means of a snap ring. A cast iron cover, which houses a lip seal to prevent ingress of dust etc, protects each bearing. A deflector is also provided on the shaft to prevent entry of water in the bearing from gland leakage.

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Product description

3.4.2.6 Bearing housing (008) It is a rigid single piece casting and features a positive no gap location with the casing and ensures accurate coupling realignment. A lifting ring has been incorporated in the casting itself to facilitate handling and assembly. A generously sized drain has been provided to lead the gland leakage away to waste.

3.4.2.7 Bearings (464-1, 464) 3.4.2.8 Interchangeability These pumps are made as per ISO standard and many components are interchangeable over a wide range of pumps. The interchangeability charts are as per Annexure IV.

3.4.2.9 Driving coupling Flexible coupling is used to transmit the power from motor to pump shaft. The type of coupling used is indicated in the G.A. drawing.

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Mather + Platt 4

Handling, transport & storage

Handling, transport and storage

In order to prevent damage or serious injury when handling & transporting the product, the following points must be observed: -

Handling & transport work may only be carried out by, qualified personnel. The safety instructions must be followed at all times.

-

Only suitable lifting gear and load carrying equipment with valid test certificates and adequate lifting capacity for the loads involved (such as belts/wire ropes/slings) should be used for lifting & transporting the product. If chains are used, they should be secured against slipping along with protective cover to prevent damage to the product, paint and/or injury to personnel.

-

When lifting the pump in combination with the bedplate, the lifting tackle should be attached to the lifting lugs provided on the base plate side member. To lift the pump the lifting slings should pass beneath the pump body at suction and delivery flanges. See lifting diagrams.

-

See also "General Safety Information", section 2.

Fig. 1 Lifting diagrams Pumps should never be lifted with slings engaged below the bearing housing. Lifting hole in the top rib of bearing housing is only for lifting/handling the bearing housing during assembly of the pump. Never use this lifting hole for lifting the complete pump or pump unit with motor and bedplate (Refer figure 1). Safe working load of wire ropes reduces with increase in included angle Reduction of lifting Capacity with increase in included angle between legs Included angle Lifting Capacity

4.1

0° 100%

30

60

90

120

95%

75%

70%

50%

Delivery

On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of delivery. Any claim made at a later date will be deemed invalid. Damage to parts must be noted on the delivery or freight documentation.

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Handling, transport & storage 4.2

Transport

Only the appropriate and approved fastening devices, transportation means and lifting equipment may be used. These must have sufficient load bearing capacity to ensure that the product can be transported safely. The product is delivered by the manufacturer / shipping agency in suitable packaging. This normally precludes the possibility of damage occurring during transport and storage. The packaging should be stored in a safe place if the location used is changed frequently.

4.3

Storage

Short-term storage The equipments as shipped have adequate protection for short-term storage in a covered, dry and ventilated location at the job site prior to installation.

Long-term storage If the equipment will be subject to extended storage condition prior to installation, then the manufacturer must be informed about storage duration, so that special protection can be recommended. The following should be taken into consideration for storage: -

Place the product on firm foundation and secure it against falling. HSC pumps, End suction pumps and multistage pumps should be stored horizontally and Vertical pump assemblies vertically.

Never put down or pick up the product when it is not secured. Bending the product should be avoided at all costs. It can cause major damage to the product and/or serious injury to persons. -

Any suction or delivery pressure connections on products should be closed tightly before storage to prevent impurities.

-

The machine must be protected from direct sunlight, heat, dust, and frost.

-

The rotors or propellers must be turned at regular intervals. This prevents the bearing from locking and the film of lubricant on the mechanical shaft seal is renewed.

If product is to be stored for a longer period, contact M&P for preservation measures to be taken.

4.4

Returning to the supplier

Products, which are delivered to the plant, must be clean and correctly packaged. In this context, clean means that impurities have been removed and decontaminated if it has been used with materials, which are hazardous to health. The packaging must protect the product against damage. If you should have any questions please contact M&P.

Products, which are not suitably packaged on delivery, are no longer covered by guarantee!

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Installation

Installation

In order to prevent damage to the machine or serious injury during installation the following points must be observed:

5.1

-

Installation work – assembly and installation of the machine – may only be carried out by, qualified persons. Any errors in fitting or refitting will not pose risks to persons but pump will malfunction or performance of pump will be affected or internals will be affected. The safety instructions must be followed at all times.

-

Before any installation work is carried out, the machine should be inspected for damage that may have occurred during handling, transport & storage.

-

See also “General Safety information”, Section 2.

Introduction

This section provides instructions on the recommended methods of installing pumping sets on to concrete foundations. Careful attention must be paid to the customer and contractor’s installation drawings during the installation procedures to ensure that the pumping set is accurately positioned on the correct datum levels. The installation of the pump set may be divided into five stages, namely preparing the foundations, installing the pump, installing the drive unit, alignment, connecting the pipe work and coupling the drive.

5.2

Requirements for the operating area Pumping machinery should have adequate access and working room for maintenance operations. Adequate overhead space for lifting devices and working clearance must be provided.

5.3

Cleaning

Clean any anticorrosive protection from the mounting surfaces using a rag moistened with white spirit.

Do not use any chlorinated solvents such as carbon tetrachloride and trichloroethylene. Bearings, shafts etc should be cleaned and coated with lubricant till such time they are actually taken for installation.

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Installation 5.4

Foundations

Installation of the pump cannot be done in continuous sequence because two time periods are required to permit to grout to set. The first period occurs after bedplate has been leveled and foundation bolts half grouted. The second time lag occurs after full grouting of bedplate, which is after final alignment of pump and driving unit after piping. A suitable foundation for the pump must be prepared with pockets to accommodate the foundation bolts. The strength of the foundations must be adequate for the static & dynamic loads imposed and depend upon the local soil conditions. The top surface over which the bedplate rests must be left rough to assist in keying of the final grout and sufficient allowance must be made for the thickness of the steel packing and leveling shims beneath the bedplate, the requirement being approximately 25 mm. Foundation work is usually completed before the pump arrives on site but it is mentioned here because it is logical to begin the installation procedure sequentially.

Indicative drawing for foundation For details of dimension refer General Assembly drawing. Fig. 2

5.5

Bedplate Pumps and drivers that are received with both machines mounted on a common bedplate are checked for alignment before shipment. However during shipment, storage it may get disturbed. Also bedplates are flexible to some extent and may get distorted during transport and storage. Therefore it is necessary to remove the pump and driver from the bedplate and adapt procedure as given in section 5.5.1, 5.5.2 & 5.6.

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Installation

5.5.1 Bedplate checks It is insufficient to check level on the machined pads of bedplate (figure 3) with a spirit level because it is possible that some types of errors will not be revealed or will be accepted as being within acceptable limits. These distortions as showed in figs. 4, 5, 6 & 7. Therefore it is necessary to use I beam straight edge along with engineers master level (figure 8).

5.5.2 Installation & leveling of bedplate 5.5.2.1.

If the base frame is installed directly on the uneven surface of foundation, it could distort. To avoid this distortion and to provide suitable base for leveling, the packer plates should be provided on mother concrete. Minimum requirement being one on each side of foundation bolts. Intermediate packers should be placed at 250 mm center to center. Thickness of MS plates can be between 25 and 35 mm.

5.5.2.2.

Once the packer plates are positioned and leveled, place the base frame on them. Insert foundation bolts through hole in the base frame and insert nut. Ensure that bolts protrude sufficiently to accommodate lock nut and they are centrally disposed in the holes.

5.5.2.3.

Level the bedplate as follows.

a.

Use “I” beam straight edge and an engineers master level (with accuracy of 0.02 mm / meter) for leveling the bedplate. I-beam should rest on the machined surfaces of the bedplate, or on the leveling pads if provided.

These machined surfaces where level is being checked must be clean and free from paint, burrs etc. b.

Check datum position of base frame as given in G.A. Adjust the level of the bedplate by inserting shims between the bed plate and the packer plate until the bed plate is leveled and supported on all the packing plates at the height required for the connection of suction and discharge branches. For checking the levels across two pads, I-beam type straight edge should be used extensively in conjunctions with engineer’s master level. Level should be achieved within 0.05 mm per 250 mm.

5.5.2.4.

When the bedplate is leveled, grout the foundation bolts only. Care should be taken so as not to disturb the verticality of foundation bolts. For grouting use rich mix of 1: 1:2 of cement, sand and gravel below 12 mm. Alternatively quick setting grout mix can be used.

5.5.2.5.

When the grout has set, gently but firmly tighten the foundation bolts. Care must be taken not to distort the bedplate or loosen the foundation bolts in the grout by excessive tightening.

5.5.2.6.

Carefully re-check the level of the bed and make adjustments that are necessary by fine shimming.

5.5.2.7.

Position the pump and motor on the bedplate.

5.5.2.8.

Refer instruction manual of coupling & motor manufacturer.

5.5.2.9.

When the bedplate is leveled and the satisfactory-alignment is completed, proceed with connection of suction & delivery piping. Recheck the alignment after piping and run the final grout beneath the bedplate. Allow minimum seven days time for curing. Grout mix in the proportion specified earlier for foundation bolt grouting should be used. It is further recommend that all hollow pockets in the bedplate shall be filled after curing of earlier grout.

5.5.2.10. Pumps, which operate at high temperature, e.g. boiler feed duty, are supported on feet machined in line with the center of the shaft, which prevents expansion causing misalignment. Transverse and longitudinal keys are provided to locate the pump on the bedplate. The holding down bolts securing the pumps to the bedplate are arranged to allow the feet to slide during expansion either by using spring washers or by locating the nuts on the bolts without nitting the feet.

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Installation 5.6

Alignment of pump and driving units:

The following procedures outline recommended practice given in BS-3170 in 1972 (Appendix A) for checking shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected by canted coupling faces or eccentricity of the outside diameter of the coupling. Before commencing the alignment, rotate each shaft independently to check that the bearings run freely and that the shaft is true to 0.1mm or better. Check that no damage can be caused when the shaft of the driven unit is turned. Coupling should be loosely coupled and the halves must be free to move relative to each other, otherwise gauge Indicators can be incorrect. Where, tightly fitting pins or spring prevent loose coupling, the springs or pins should be removed and a line scribed across both half couplings and readings taken only when the two marks are aligned.

Before proceeding for alignment please ensure: a. For bush bearing protective paper between bearing and shaft is removed, bearing housing is cleaned and flushed with oil. b. Bearings are properly lubricated. c. Pumps with stainless steel internals shaft should be rotated only after taking pump liquid inside the casing. Any dry rotation may cause severe damages to pump internals.

5.6.1

Angular alignment

After isolating the driven unit from its power supply, clamp two dial indicators are dramatically opposite points on one half coupling or to the shaft behind it with the plunger resting on the back of the other half coupling. (See figure 10) Rotate the coupling unit the gauges are in line vertically and set the dial to read zero. Rotate the coupling by 180 and record the readings on each gauge. The readings should be identical, though not necessarily zero. Either positive or negative readings are acceptable provided they are equally positive or negative. Adjust the position of one of the units if necessary. Rotate the couplings unit the gauges are in the line horizontally and adjust the dial to zero. Repeat the operation outlined above by rotating the coupling by 180°.

5.6.2

Radial alignment

Clamp a dial gauge on one of the couplings or to the shaft as shown in figure 3 with the plunger resting on the rim of the other half coupling. Set the dial zero. Rotate the coupling and note the reading at each quarter revolution. Any variation in the readings indicates the deviation from alignment and the position of one of the units must be adjusted until the readings at each quarter revolution are identical or within the tolerances given below.

5.5.3 Alignment tolerances a b c

Pump speed < 1000 rpm > 1000 rpm to 1800 rpm 1800 rpm to 3000 rpm

Angular alignment 0.15 mm TIR 0.1 mm TIR 0.05 mm TIR

Radial alignment 0.15 mm TIR 0.15 mm TIR 0.1 mm TIR

TIR- Total indicated reading The above tolerances are general guidelines since it may very with different types of coupling and its manufacturer’s standards. However it is recommended that for higher speeds greater degree of accuracy must be observed. If the pumps are used for hot liquid or there is chance of disturbance in the alignment due to piping temperatures, hot alignment should be carried out. All the alignments (angular as well as radial) have to be carried out by using 3 dial indicators, simultaneously. MPPL/IM/ESP/ET/PNISO/2006/0

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Installation

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

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Fig. 8

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Installation

Couplings Flexible couplings

Pin Bush Coupling

Spacer coupling

Fig. 9

Alignment of Coupling

For detecting this type of error

To check the parallelism of axis (Angular alignment)

Fig. 10

For detecting this type of error To check intersection of axis (Shafts inline at coupling end)

Fig. 11

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Installation 5.7

Pipe work

No stress must be imposed on the pump casing by the pipe work; either by the weight of the pipes or by the tightening of badly fitting pipes. Experience has showed that such stress can seriously affect the alignment of the pump unit. All pipe worked attached to the pump must be fully supported and the mating faces of the pipe flanges must be parallel and all bolt holes coinciding with each other. It is important therefore that alignment of the pump and motor should be re-checked after the pipes are finally fitted. Resetting or supporting the pipes must correct any deviations in the alignment.

Alignment of pump casing with pipe work Fig. 12

5.7.1 Suction condition Intake design Pump intake by way of open channel, tunnel, sump or a tank should supply evenly distributed vortices free flow with adequate submergence of pump suction pipe. A centrifugal pump can perform properly only if it is supplied with a steady flow of liquid at the suction flange with sufficient pressure to provide adequate NPSH to the pump and with a uniform, non-swirling velocity profile. The failure of suction piping to deliver the liquid to the pump in this condition can lead to noisy operation, random axial load oscillations, premature bearing failures, cavitations damage to the impeller and casing inlet portion. It may also damage discharge side due to liquid separation. Suction pipe velocity: Suction pipe velocity should not exceed the velocity in pump suction nozzle. Pipe velocity may need to be reduced further to satisfy pump NPSH requirements and to control suction pipe losses. With pipe velocity in the 5 to 10 ft/sec range, and with suction piping containing valves fitting and bends, straight pipe length of minimum five diameters may be required to ensure uniform flow to pump suction. Use of strainer in suction piping: If strainer is used it should have opening area which is three times the area of the upstream pipe. Differential pressure gauge / switch should be fitted across strainer to monitor any chocking and resultant pressure drop. It is advisable to connect this to operation logic of pump. The suction pipes should be as short as possible and when dealing with cold liquids, the total suction including friction should not normally exceed 15 feet. Mather & Platt pumps will deal with a suction lift as great that dealt with by similar pump of any other make but extensive experience has proved that it is not advisable to exceed 15 feet suction lift under working conditions without the approval of Mather & Platt design department. MPPL/IM/ESP/ET/PNISO/2006/0

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Installation

An arrangement of suction pipe work, which is common to two or more pumps operating on suction lift, is not recommended. If such an arrangement is unavoidable, any possible points of air ingress, such as valve and glands should be liquid sealed and isolating valves should be fitted at the appropriate points. The arrangement of a pump, which is to handle hot liquids, should be such that the liquid flows into the pump under pressure. The pressure must be increased with temperature of the liquid. When the diameter of the suction pipe is bigger than that of pump suction branch, the form of taper pipe used must not allow the formation of air pocket. To avoid the formation of air pocket, the installation of suction pipe work must be arranged under the following conditions: a b c

With as few bends as possible. Suction pipe work must be perfectly air tight. There must be a gradual rise in the suction pipe work.

Typical good and bad arrangements are shown in figure 13. The inlet of the suction pipe must lie well below the lowest possible water level and it must be fitted with a foot valve and strainer. The strainer must be clear of the bottom and sides of the well or sump, so that deposits of sediments or grit are not drawn into the pump. The foot valve should be of the free opening type preferably of the hinge flap design to work in a horizontal or vertical position. Velocity of water should not be greater than 6 feet per second for a 6" bore valve, 7 feet per second for valves between 6" and 14" bore and 8 feet per second for valves above 14" bore. The strainer should be of rugged construction with holes in the sides, suitable for the type of the liquid to be passed. For clean liquid the cumulative area of these holes should not be less than twice the area of the bore of the pump suction branch. Where the liquid is known to contain a high percentage of solids, the area of the holes should be much greater. It may even be necessary to provide special apparatus, such as traveling screens, to ensure that the pump is kept free of solid foreign matter. When pumps are expected to operate on positive suction head, foot valve is not necessary. However, at site, if liquid level falls below the minimum water level mentioned in the drawing, the pump should not be started.

If required suction sump model study should be done.

5.7.2 Delivery conditions A suitable sluice valve should be fitted in the delivery pipe as near to the pump as possible, along with non-return valve. Pump casings have sometimes been cracked by pressure surges imposed on them through the absence a non-return valve. It is often an advantage to provide these valves with by-pass connections, although these are not always required.

5.7.3 Stuffing box packing Pumps are dispatched from our Works with the stuffing boxes unpacked; otherwise packing will be aged. The packing is packed with greaseproof paper and dispatched with the pump. The softest possible packing i.e. plaited cotton impregnated with oil and colloidal graphite is recommended for most duties. Required number of lengths of packing should be cut off so that each length will pass once round the shaft sleeve line and meet to end. The ends of packing must be cut square. After cleaning the stuffing box and shaft sleeves the packing should be inserted into the stuffing box. Each ring should be pushed into position individually using the glands joint of each ring must be positioned 180 from joints of its neighbor. if a logging ring is included in them arrangement should be inserted into the stuffing box at the appropriate time during the packing sequence so that it is aligned with the cooling water connection. The gland should now be fitted square with the pump casing and the nut should be screwed up to little more than finger tightness.

Packing should be handled with care and it should not be allowed to pick up the dust or abrasive matter by coming into contact with floors or dirty benches. It is bad practice to hammer packing to facilitate the insertion.

5.8

Use of diesel engine as prime mover The location of installation should have facility for disposal of exhaust gases and supply of continuous air. Pump house should have acoustic design.

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Installation

Examples of good & bad suction layout

Fig. 13

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Start-up

6.1

Introduction

Start-up

This chapter covers the commissioning and operation of pump only. For commissioning of motor, engine, turbine & electrical panels respective instruction manuals should be referred. This procedure also should be adapted after each major overhaul. See also “General Safety information”, Section 2.

6.2

Pipe work flushing

Before the pumps are brought into service, either on initial commissioning or on re-commissioning after overhaul, the pipe work associated with the pumps must be flushed through. This will clear deposits or scales which may have accumulated in the pipes, and which could damage the internal components of the pumps.

6.3

Cleaning of bearings

Where possible, especially if the unit has been in store for a long period before commissioning, the bearings should be cleaned and flushed out with clean white spirit or good quality paraffin. Waste should not be used for this purpose, as particles of foreign matter may be left behind which would cause damage when the bearing is in service. Bearings should be then filled with recommended grade and quality of fresh lubricant to the level. Refer list of lubricants at the end of this manual. Ball and roller bearings are given an initial charge of grease before leaving Mather & Platt Works and do not require any attention beyond the normal greasing routine before the first servicing period. Only greases selected from the table at the end of the manual or their equivalent should be used. Bearings should never be over greased.

Pumps fitted with prelubricated, sealed bearings do not require external lubrication for life.

6.4

Direction of rotation

Disconnect the drive coupling and run the motor to check its direction of rotation. A directional arrow is provided on the pump unit.

6.5

Priming

These centrifugal pumps are not self-priming type. The efficient operation of a centrifugal pump depends upon fine running clearances, which are lubricated by the pumped liquid. Priming can be done either by running vacuum pump or by external water supply.

Any attempt to run the pump dry or partially full may result in seizure of the rotating internal components. These pumps must therefore be properly primed before starting, with venting of all the air, gases, vapor etc.

6.6

Pumps Operating on Flooded Suction Head

When these pumps operate on a flooded suction head, all that is required to prime them is to open the air release valve situated on top of the pump casing, open the pump inlet isolating valve and vent the air out of the casing. When the liquid issues from the air vent, free of air, the pump is properly primed. The air vent must be closed after priming and before the pumping set is started.

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Start-up 6.7

Pumps Operating on Negative Suction Head

There are two methods of priming pumps that draw their liquid from an elevation lower than the pump inlet branch: 6.7.1

If the inlet pipe work is fitted with a non-return foot valve, the pump casing and inlet pipe work can be filled with liquid from an external source under pressure. The pressure imposed on the pump by this method must not exceed that for which the pump is designed. In certain cases priming can be achieved by flooding back from the delivery side of the pump.

6.7.2

By exhausting air or gas from the pump casing. To enable this method to be used, the gland arrangement must be sufficiently gas-tight or they should be liquid sealed from an external supply. For operation details of gas exhausts reference should be made to the manufacturer’s instructions. Some form of priming indicator is usually fitted to indicate when the priming operation is complete.

6.8

Pumps operating on hot liquids

As stated in Section 5.5.1, pumps operating on hot liquids are usually so arranged that the liquid flow into the pump under pressure. If the saturation pressure of such liquids is above atmospheric pressure, any attempt to prime the pump will result in the liquid "flashing" from the air cocks. For these reasons, the air cocks at the top of the pump casing should be left slightly open when priming boiler circulating pumps until all air has been driven out of the casing. The cooling water services of a pump handling hot liquids should be turned on before the pump is primed. These services may supply cooling water to the bearings and / or stuffing boxes. Where the services are functioning, open the inlet valves and start warming the pump throughout. Never cut off the water services while the pump is "on temperature". Where bearings are water-cooled, adjust the cooling water supply until the bearings have a running heat. Over-cooling may lead to condensation of moisture from the atmosphere inside the bearing with consequent contamination of the oil. The suction sluice valve, if provided, must be fully open and the delivery sluice valve must be closed.

6.9

Pre-starting checks

6.9.1.

Ensure that sufficient fluid is available at the pump suction for satisfactory operation of the pump. Efficient operation of the pump depends upon the running clearance, which are lubricated by pumped liquid. Any attempt to run the pumps dry or partially full will result in seizure of internal rotating components.

6.9.2.

Check that the inlet isolating valve is open and that the delivery valve is closed.

6.9.3.

Ensure that bearings have been filled with proper grade of lubricant.

6.9.4.

Check that there is no blockage in the strainer at the end of the suction line.

6.9.5.

Check for free rotation of the unit when coupled.

6.9.6.

Check that suction and delivery pressure gauges are connected. Test and make available any alarm, signals, interlock systems and any of the protective devices incorporated in the auxiliary and main pumping control system.

6.9.7.

Ensure that all electrical checks on motor, relay setting in panel etc have been carried out in accordance with the instructions of motor manufacturer.

6.9.8.

Ensure that stuffing box sealing water seal connection is provided as shown in GA Drawing.

6.9.9.

Check that priming procedure detailed in 6.5 has been carried out.

Refer checklist A.6 for recording the data.

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Start-up

6.10

Normal Starting checks

6.10.1.

When all the foregoing pre-start checks are satisfactory, depress the appropriate `START' button on the control panel and run the pump at its rated speed.

6.10.2.

Check that the pump is rotating in the correct direction. This is indicated by, a direction arrow on the pump casing.

6.10.3.

Check the ammeter reading to ensure that the motor is not being

6.10.4.

Check that the pumping unit is generating not less than its rated delivery pressure indicated in the data sheet/name plate.

overloaded.

If the pumping unit fails to generate at least it’s rated delivery pressure it must be stopped immediately, the cause ascertained, the fault rectified and the pumping unit re-primed before restarting. 6.10.5.

Ensure that the stuffing box is not overheating and that there is slight leakage from the gland. There may be at first a tendency for the stuffing boxes to run warm because of the high viscosity lubricant in the packing. During the first few minutes of running with new packing, a small quantity of very viscous fluid will be extruded, but the flow should cease when the packing has settled down.

6.10.6.

Check that the oil is being carried to the bearing bushes by the oil rings in case of bush bearing.

6.10.7.

Check that the bearing is not overheating. The ideal running temperature of bearings is 40 ˚C to 60 ˚C for ball bearings and 40 ˚C to 55 ˚C for bush bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 ˚C for all bearings and 75 ˚C for bush bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

If the bearings are overheating its cause should be investigated immediately. 6.10.8.

If the foregoing checks are satisfactory, open the delivery valve slowly and bring the pump gradually up-to its rated parameters based on pressure gauge and ammeter readings. Unless the pump is fitted with a special leak-off device, it should not be run for a long period against a closed delivery valve. Check that the driving unit is not being overloaded during valve opening.

6.10.9.

Check that the driving unit is not being overloaded during valve

opening.

Overloading may occur if the pump is discharging into an empty system when the delivery head will be temporarily lower than that for which the pump is designed. Careful regulation of the discharge valve until the system is fully charged will prevent this. 6.10.10.

Check vibration of pump set and ensure that vibration level is within limits specified in Hydraulic Institute Standard of America. Check that noise level is within stipulated limits.

6.10.11.

Check the pump and motor for overheating, excessive vibration and noise. Report any faults. During first commissioning, the pumps may be run for 8 hours trial operation and all the parameters like delivery pressure, current, bearing temperature, etc. Be recorded periodically.

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Start-up 6.11

Running Checks

Once the pump is started and duty conditions are set, operator intervention is not required except running checks and unless pump is to be stopped. Make the following checks at regular intervals. It is recommended that they be made at every change of shift. 6.11.1.

Check the suction and discharge pressure gauge for normal operating pressure, if there is significant drop in the suction or discharge pressure the pump may have lost its supply. In the event of this fault occurring, the pump must be stopped immediately and the cause of liquid loss eliminated.

6.11.2.

Check the stuffing box assembly for overheating.

6.12

Normal Shutdown

6.12.1

Close the delivery valve to reduce the load on the driving unit.

6.12.2

Depress the appropriate STOP button on the control panel.

6.12.3

When the pump has come to rest, close the suction-isolating valve.

6.12.4

Isolate any ancillary supplies.

6.13

Emergency Shutdown

In the event of any malfunction of the equipment, trip the pump set. When the pump has come to rest, close the suction & discharge valves, isolate the driving unit power supply & rectify the fault.

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Start-up

Fig. 14 cross sectional drawing for ET ISO pump

Ref

Description

Ref

Description

4580 775-1 775 729 584 581 464-1 464 454 442 363 287

Safety Guard ‘O’ ring for sleeve ‘O’ ring for casing Water deflector Lip seal Mechanical seal Bearing (Coupling end) Bearing (Impeller end) External circlip Impeller nut Bearing end cover Spacer sleeve

286 084 054 049 032 031 029 023 017 011 088

Shaft sleeve Key (Impeller) Key (Impeller) Shaft Neck ring Impeller Casing Support foot Gland plate Back cover Bearing housing

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Start-up

Fig. 15 cross sectional drawing for PN ISO pump

Ref

Description

Ref

Description

4580 775-1 775 729 584 571 477 464-1 464 454 442 363 287

Safety Guard ‘O’ ring for sleeve ‘O’ ring for casing Water deflector Lip seal Breather plug Oil thrower Bearing (Coupling end) Bearing (Impeller end) External circlip Impeller nut Bearing end cover Spacer sleeve

286 084 067 054 049 581 032 031 029 023 017 011 088

Shaft sleeve Key (Impeller) Constant level oiler Key (Coupling) Shaft Mechanical seal Neck ring Impeller Casing Support foot Gland plate Back cover Bearing housing

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Maintenance

Maintenance

See also “General Safety information”, Section 2.

7.1

Routine maintenance & frequency of inspection

Centrifugal pump requires very little routine maintenance beyond periodic replenishing of grease in the bearing assemblies. However, serious troubles can be often avoided by regular observation and analysis of various working parameters. Some of the routine maintenance checks for this purpose are as under:

7.1.1

To keep daily logbook records of working parameters like suction and discharge pressure, flow rate, current drawn, bearing temperature, etc. These parameters should be recorded twice a shift. Any sudden change should be a signal for investigation. Refer Section A.2 for Maintenance & Inspection log.

7.1.2

Bearings will normally run at a temperature of 30˚C -35˚C above ambient temp. The ideal running temperature of bearings is 40 ˚C to 60 ˚C for ball bearings and 40 ˚C to 55 ˚C for bush bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 ˚C for all bearings and 75 ˚C for bush bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

7.1.3

Vibration & sound level readings should be taken once in a fortnight and values compared with that of previous records.

7.1.4

Check that there is sufficient leakage from the gland packing to ensure proper cooling and lubrication.

7.1.5

Pump bearings should be replenished with correct grade of grease after every 1000 Hrs. Grease should be changed completely after every 3000 hours or as required by site condition. Recommended type and grade of grease is indicated in section 7.4.

7.1.6

For any abnormality observed from the visual/manual inspection and through maintenance & inspection logs, stop the pump and investigate.

7.1.7

Fault Finding - Many of the common faults which occur on centrifugal pumps and which can be diagnosed by observations are given in the chart under section 8.

In case fault can not be diagnosed, please fill up the Issue/Feed back report no SR01-02 and send to service department at Mather & Platt headquarters at Pune / nearby regional office or the representative within EEA. After a long period of service, wear will occur in parts of the pump, necessitating the renewal of a few components. Parts, those are most likely to be affected are impeller/ wearing ring, bearing, impeller distance sleeves. Logbook records will indicate wear as gradual deterioration of performance is noticed. Once this is known, pumps should be taken for overhaul. It is recommended that yearly stripping & checking of wear & tear and clearances should be done and overhauling where required.

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Maintenance 7.2

Overhaul maintenance

7.2.1 General information It is inevitable after long service that certain components will become worn. Frequently it is more economical to renew the worn components completely, but where site machining and engineering facilities are available most components can be restored if wear is not too far advanced. It is impossible to be mandatory regarding the periods at which major overhauls should be undertaken as this will be dependent upon the fluid being pumped, the site operating conditions, and the length of operational availability required. The determination of when major overhaul should be carried out will depend upon the performance of the pump, i.e. its rate of deterioration by reference to instrumentation, during the current operational period. If the hydraulic or mechanical performance has deteriorated to such an extent that no further deterioration can be tolerated during the next operational period, wearable components should be renewed. If related pair of components show a marked degree of wear in relation to the rest of the unit, then it may be sufficient to renew only the heavily worn components. If the wear is uniform throughout the pump, then all wearable components may require renewal. Measurements should be taken and recorded of all wearable components at the first, and every subsequent overhaul period. Reference to these records will enable an accurate assessment of the rate of wear to be made, and a reasonably accurate forecast regarding when a particular component may require renewal can be made. Information regarding original design dimensions and clearances is furnished in data sheet. Any other information if needed can be obtained on application from Service Department, Mather & Platt Pumps Ltd., Chinchwad, Pune 19 India. Such request must quote nameplate number and type of the pump in question. The parts most likely to be affected are: 1. 2. 3. 4.

Impeller Necks. Ball Bearings. Wear Rings. Impeller.

Before commencing dismantling operations, ensure that the following tools and tackles are available: 1.

A crane / chain pulley block suitable for handling the weight of pumping unit.

2.

A selection of ring and open-ended spanners in British, American, and Metric sizes.

3.

Eyebolts in British and Metric sizes.

4.

Cotton rope, wire rope and slings.

5.

Hardwood and metal packing blocks.

6.

Miscellaneous tools including a set of Allen keys, drills, pin

7.

Extractor / puller for bearing and coupling.

drivers, files etc.

After a long service, wear will occur in parts of the pump necessitating the renewal of the parts. Those most likely to be affected are impeller, Wear rings, bearings, and sleeves.

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Maintenance

7.2.2 Dismantling the pump (Refer Fig. 14/15) a.

Isolate the pump motor electrically.

b.

Isolate the pump system by closing suction and delivery valve.

c.

Strip the coupling and remove the spacer if fitted.

d.

Unfasten nuts holding bearing housing (088) to pump casing (029) and lift off rotating element with bearing housing.

Where coupling without spacer is fitted, it will be necessary to move driving unit away from the pump before this operation can be carried out. e.

Strip the coupling and remove the spacer if fitted.

f.

Unfasten nuts holding bearing housing (088) to pump casing (029) and lift off rotating element with bearing housing.

g.

Impeller (031) can be drawn off after removing impeller nut.

h.

Remove gland and back cover (011).

i.

Draw shaft sleeve off the shaft.

7.2.3 Dismantling shaft assembly Shaft assembly can be withdrawn from the bearing housing after removing the screws securing the bearing and covers.

Unnecessary removal of the bearings should be avoided because removal of the bearing can damage it and cause deterioration of the interference fit. Except where removal is necessary to give access to the other parts, bearing should be removed only if they need close inspection. Symptoms, which will indicate the state of bearing, are the condition of the lubricant, the bearing running temperature, noise level and vibration during operation.

7.2.4 Examination Of Internal Components With the pump and rotating element dismantled, the internal components and clearances can be checked.

7.2.5 Casing neck ring Use an internal micrometer to measure the bore of casing ring, taking measurements at intervals around the circumference to check for uneven wear. A comparison between this dimension and that of the impeller neck will indicate the amount of diametrical clearance between the casing neck ring and the impeller neck. If this clearance is 150% or more than the original design clearance, or if the deterioration in hydraulic performances has been such that no further deterioration can be tolerated during the next operation period, The impeller-wearing ring to casing neck ring clearance must be restored to the original design value by fitting small- in-bore neck rings, bored out to suit the diameter of the impeller.

7.2.6 Shaft Sleeves (where ever applicable) The shaft sleeve should be examined to see if it is grooved or generally worn. The outside diameter of the sleeve should be measured and a comparison made with the bore of the stuffing box bush through which the sleeve passes. The amount of clearance between the two can thus be checked to determine whether or not it is within acceptable limits. MPPL/IM/ESP/ET/PNISO/2006/0

7-3

Mather + Platt

Maintenance 7.2.7 Impeller a.

Inspect the impeller as follows: i.

Examine the impeller for damage.

ii.

For corrosive /erosion pitting.

iii.

Cavitations pitting.

iv.

Bent or cracked vanes, inlet and outlet vane end wear.

Any of the above may be repaired, or if damage is extensive, impeller may need replacement. Further information should be sought from M + P, Service Dept. Chinchwad, Pune before any decision on repair work is taken. b.

Around the eye, wearing rings protects the impeller. Examine around the eye at neck portion for grooving in alignment with spindle axis; slight grooving is acceptable but deep or profuse grooving must be remedied by machining the impeller by taking a polish cut on wearing ring. Spare wear rings are supplied with excess outside diameter to facilitate machining after fitting. The wear rings are shrink fitted on impeller neck and are screwed.

c.

To check wear, around the impeller neck, use precision instruments such as out side micrometer to accurately measure the outside diameter. Measurements should be taken at intervals around the circumference to check the uneven wear. Differences between the neck OD and the neck ring ID measured will give us the clearance between the two. Clearance thus obtained should not be more than 150% of maximum designed clearance.

7.2.8 Shaft & keys Shaft should be checked for the trueness, or any other mechanical damage and corrosion. If the shaft is not true within 0.1 mm TIR, it should be replaced / repaired. Examine the shaft keys and key ways. Remove damaged or worn out keys.

7.2.9 Bearings a.

Clean all the components using clean white spirit. Do not use chlorinated solvents such as trichloroethylene and carbon tetrachloride because they introduce a corrosion risk when used on ferrous materials.

If these chemicals are present for any reason a' No Smoking' rule must be strictly enforced. (CHLORINATED SOLVENT FUMES + TOBACCO SMOKE = TOXIC GAS). b.

Visually inspect the bearing. The balls, the inner and outer tracks must all be free from chipping cracks, abrasions or discoloration.

c.

Check that the parts of the cage are firmly fixed together.

d.

Visually inspect the bore for any sign of damage. Burrs or any scratches caused during bearing withdrawal should be carefully removed by hand application of a fine oilstone, the treatment being confined to the minimum possible area.

e.

Visually inspect the outside diameter for signs of fretting, any stains may be carefully polished off, but abrasion must be kept to the absolute minimum that is required, followed by cleaning.

f.

Check that bearing rotates freely and smoothly. If there is any doubt regarding the serviceability of the bearing it should be replaced.

MPPL/IM/ESP/ET/PNISO/2006/0

7-4

Mather + Platt

Maintenance

g.

Inspect the Bearing Cage as follows:

i

Visually inspect the bore for any signs of fretting, any stains may be carefully polished off, but abrasion must be kept to the absolute minimum that is required, followed by cleaning.

ii

Where fretting has occurred, bearing and housing should be cleaned and dry, and trial assembled. It is a transitional fit and may be described as a sucking fit without any detectable clearance or play between the outer race and the housing bore. Any assembly, which achieves this, may be considered as being acceptable, provided the bearing is serviceable. Assemblies, which do not achieve this degree.

An incorrect fit can allow one or both of the bearing tracks to creep, which will affect the running accuracy and the assembly and dismantling of a pump. Creep is the slow rotation of one track relative to its seating, it is undesirable since the spindle and the bore of the bearing or the housing and the outside -diameter of the bearing may become worn. Creep is not due to friction within a bearing but is generally caused due to radial loads rotating or oscillating in respect to fixed point on the track. If creep has occurred the interference fit of the bearing must be restored, either by metal spraying or chromium plating and regrinding the seating to the correct diameter; interference fits must not simulated by knurling, scoring or distortion of the seating on which creep has occurred because such practices are ineffective and creep will quickly reoccur. Even if the bearing is prevented from creeping it will usually be distorted by the seating, and failure will result caused by local overloading and high frequency vibration. h.

Examine the abutment. Abutment for ball bearings must be flat and square with the axis-of rotation. The radius at the root of an abutment must be smaller than the corner radius of the track located against the abutment. The edge of the abutment must be reduced or chamfered; a burred edge can tilt or distort a bearing track.

i.

If after inspection, the bearing is reusable, completely coat all parts with a rust preventive oil, working it well into the internal parts of the bearing. Wrap in clean greaseproof paper and store until required for replacement or refit on to the spindle if needed. In case of immediate use, coating of rust preventive oil is not necessary.

7.2.10 Stuffing box bush Check bore of stuffing box bush and compare with sleeve diameter. If "clearance is excessive, the bush should be renewed.

While assembling stainless steel component, molybdenum-disulphide paste should be applied to prevent galling / seizure and also to facilitate easy removal in future.

MPPL/IM/ESP/ET/PNISO/2006/0

7-5

Mather + Platt

Maintenance 7.2.11 Re-assembly of the pump For reassembly procedure refer to illustrated Annexure (A-K).

A 1.

Work in clean area.

2.

Follow main steps a-k and order of assembly numbers. Warning note: lifting holes is for rotating assembly only.

B

3. 4. 5. 6.

Heat bearing in oil @ 80 ° C for 15 minutes. Press on to shaft, pushing on inner ring Fit shaft circlip. Apply recommended grease at 45 ° angles shown.

C 7. 8.

Press in grease seals. Fit grease in nipples.

9.

Vacuum and blow out all cavities of bearing housing.

D

MPPL/IM/ESP/ET/PNISO/2006/0

7-6

Mather + Platt

Maintenance

E 10. Lifting hole for rotating assembly. 11. Set bearing housing “D” vertical on flange. 12. Press in shaft assembly “B” as shown.

F 13. Fasten outer bearing cover assembly “C”. 14. Secure inner bearing cover assembly ”C”. 15. Fit deflectors to both sides. 16. Fit coupling key. 17. Add PVC tape to secure.

G 18. Place back cover on bench. 19. Insert the packing / logging ring set into this stuffing box. 20. Fit gland studs. 21. Fit gland in to stuffing box. 22. Hold gland with nuts adjusted to finger tightness.

H 23. Fasten back cover assembly “G” to bearing housing assembly. 24. Rotate shaft & check for rubbing. 25. Fit impeller key tightly and apply. “Locktite” anti seize compound to shaft 26. Tap impeller lightly into place. 27. Tighten impeller nut, holding the shaft steady at coupling end. 28. Check operating gap 0-5-1-5 mm. 29. Lightly grease” O” ring & fit.

MPPL/IM/ESP/ET/PNISO/2006/0

7-7

Mather + Platt

Maintenance I

30. Stand casing on suction flange. 31. Vacuum & blow out all cavities. 32. Grease seal ring area all around.

J 33. Place the assembly in vertical position. 34. Lower rotating element assembly “H” in to casing “I” taking care of “O” ring. 35. Fit all screws and pull up evenly with 4 screws @ 90 °. 36. Shaft must rotate freely. 37. Bolt on support foot finger tight.

K 38. 39. 40. 41.

7.3

Stand pump on feet. Adjust support foot and tighten bolt. Fit casing plug using PTFE. tape on thread.

Spares

We recommended the following spares for various periods normally desired by pump users : a. b. c.

For two years operation: Gland packing and bearings. For three years operation: Gland packing, bearings, neck rings, sleeves-nuts, glands and logging rings. For five years operation: One rotating element.

MPPL/IM/ESP/ET/PNISO/2006/0

7-8

Mather + Platt

Maintenance 7.4

Lubrication

RECOMMENDATIONS FOR CENTRIFUGAL PUMPS ARE GIVEN BELOW:

International Manufacturers Where pumps are fitted with stainless shafts, we recommend that a colloidal graphite lubricant, e.g. Oil Dag (Achesons) be added by an amount corresponding to 1 ½ % to 2% by volume of lubricating oil as shown in the schedule. MANUFACTURER

OIL

GREASE

GREASE

Ring oil Bush type Bearings

Ball & Roller Bearings

For use with Mechanical Grease pumps

Alexander Duckham Co. Ltd.

Duckhams H2

Duckhams LB 15

Duckhams, LB 10

Esso Petroleum Co. Ltd.

Thresso 47

T.S.D. 807, (U.K.)

Firmax 1

Esoo multi Purpose Grease H. (0verseas) Germ Lubricants Ltd

Normal shafts,

Germac Neo Astra

Germ Gun Grease

Crem Dyno bear MH Mobile Companies throughout the world

Mobil' DTE oil Medium

Mobil Grease No.3

Mobil Grease No 2

National Benzole Co. Ltd

TCC-2

MPG - 1

MO- 1

BP Energol TH 80HB /

BP Energrease LS3

Power Petroleum Co. Ltd

BP Energol TH 100 HB

BP Energrease PR 3 OR LS 3

Regent Oil Co. Ltd.

Caltex Regal OIL B (R&O)

Caltex Multifac 2

Caltex Multifac 2

Shell Companies throughout the world

Shell Tube, Oil 29 / or Vltrea 31

Shell Nerita Grease 3 / or Shell Alvania Grease 3

Shell Unedo Grease 1

Sternol Ltd

Deotoyl M

Stemoline LHT

Sternoline T

Valvoline Oil Co

Valvoline No 1 or No.2 Turbine Oil

Volvine No. G.LI. Ball & Roller Bearing grease

Valvoline F.V 18

Wakefield-Dick Industrial Oils Ltd

Perfecto Light

Spheerol A.P. 3

Spheerol A.P. 2 OR impervia T

Perfecto Special X Hyspin 70

MPPL/IM/ESP/ET/PNISO/2006/0

7-9

Mather + Platt

Maintenance

Indian Manufacturers MANUFACTURER

Ring oil/Bush type Bearings

Grease

Indian Oil Corporation

Servo System-46

Servogem-2/3

Hindustan Petroleum

Enclo-46

Lithon-2/3

Bharat Petroleum

Hydral-46

Multipurpose Grease-3

Grease Lubricated Bearing

For oil Lubrication: 1.

ISO Grade 46 oil.

2.

All above oils are compatible with each other when fresh.

3.

It is unsafe to mix oil of two or more grades for use in Bearings.

4.

Number 46 is Viscosity at 40 degree centigrade in centistokes.

For Grease Lubrication: 1.

Only lithium base Grease to be used.

2.

Numbers mentioned stands for consistency.

3.

Grease of two different grades should not be used.

MPPL/IM/ESP/ET/PNISO/2006/0

7-10

Mather + Platt 8

Trouble shooting

Trouble shooting Chart

Sl No

Symptoms

Possible cause of trouble and remedies (Each number is defined in the list below)

--

Pump does not deliver water.

1,2,3,4,6,11,14,16,17,22,23

--

Insufficient capacity delivered.

2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31

--

Insufficient pressure developed

5,14,16,17,20,22,29,30,31

--

Pump loses prime after starting.

2,3,5,6,7,8,11,12,13

--

Pump requires excessive power.

15,16,17,18,19,20,23,24.26,27,29,33,34,37

--

Stuffing box leaks excessively.

12,13,24,26,32,33,34,35,36,38.39,40

--

Pump vibrates or it is noisy.

2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43, 44, 45,46,47

--

Bearings have short life.

24,26,27,28,35,36,41,42,43,44,45,46,47

--

Pump overheats and seizes.

1,4,21,22,24.27,28,35,36,41

Suction troubles

Remedies

1

Pump not primed

Ensure that casing is fully filled and water comes out from air-cock.

2

Pump or suction pipe not completely filled with liquid

Check leaking foot valve in case of negative suction

3

Suction lift too high.

Reduce by lowering pump elevation or increase

I

Water level. 4

Insufficient margin between pressure and vapor pressure.

Check that NPSH available is at least 1 meter more 1 meter more than NPSH required.

5

Excessive amount of air in liquid.

Check the reasons and eliminate. Gas gets entrapped in liquid. Air may be entering through suction joints.

6

Air pocket in suction line.

Ensure pipe fully filled and there is no bend for negative suction.

7

Air leaks into suction line

Tighten pipe joints with solution.

8

Air leaks into pump through stuffing boxes.

Ensure stuffing box sealing.

9

Foot valve too small or leaking.

Replace I Attend.

10

Foot valve partially clogged.

Clean

11

Inlet of suction pipe insufficiently submerged.

Ensure adequate submergence such that foot valve is not exposed.

12

Water seal pipe clogged.

Clean or change.

13

Logging ring is improperly located

Position logging ring centrally under sealing holes of

in stuffing box, preventing sealing

stuffing box.

fluid from entering to form seal.

MPPL/IM/ESP/ET/PNISO/2006/0

8-1

Mather + Platt

Trouble shooting Suction Troubles (contd.)

Remedies

14

Speed too low.

Check motor RPM, supply frequency, Motor nameplate speed should be as specified on pump nameplate.

15

Speed too high.

Check motor RPM and supply frequency.

16

Direction of rotating wrong.

Check correct direction of rotation for motor before coupling to motor.

17

Total head of system higher than design head of pump.

Check the causes and refer to M&P. Measure with pressure gauge.

18

Total head of system lower than pump design head.

Check the causes and refer to M&P. Measure with pressure gauge.

19

Specific gravity of liquid different from design.

Refer to M&P.

20

Viscosity of liquid different from design.

Refer to M&P

21

0peration at very low capacity.

Check the causes and refer to M&P, Operate pump at rated duty.

22

Parallel operation of pumps unsuitable for such operation.

Refer to M&P with characteristics curves of pump.

Mechanical troubles

Remedies

23

Foreign matter in impeller.

Open and clean.

24

Misalignment.

Check with Dial gauge should be within limits and without undue pipe stresses.

25

Foundations not rigid.

Check, vibration on Bedplate, check hollowness.

26

Shaft bent.

Dismantle and check, Replace shaft.

27

Rotating part rubbing on stationary part.

Incorrect assembly, correct the assembly.

28

Bearing worn.

Check lubrication, shaft run out, alignment, replace if required

29

Wearing rings worn.

Replace.

30

Impeller damaged.

Replace.

31

Casing gasket defective, permitting internal leakage.

Replace.

Shaft or shaft sleeves worn

Replace.

32

or scored at packing. 33

Packing improperly installed.

Use correct grade and size of packing

34

Type of packing incorrect for operating condition.

Use correct grade and size of packing.

35

Shaft running' out of center because of worn bearings or misalignment.

Rectify.

36

Rotor out of balance, causing vibration.

Balance the rotor.

MPPL/IM/ESP/ET/PNISO/2006/0

8-2

Mather + Platt

Trouble shooting

37

Gland too tight, resulting in no flow of liquid to lubricate packing

Adjust gland. Ensure sealing water flow

38

Cooling liquid not being provided to water-cooled stuffing boxes.

Provide.

39

Excessive clearance at bottom of stuffing box between shaft and casing, causing packing to be forced into the pump.

Check pumps assembly.

40

Dirt or grit in sealing, liquid leading to scoring of shaft or shaft sleeve.

Provide clean liquid for flushing.

41

Excessive thrust caused by mechanical failure inside pump or by failure of hydraulic balancing device, if any (in case of multistage pump etc.)

Check pump operation and assembly

42

Excessive grease or oil in antifriction bearing housing or lack of cooling, causing excessive bearing temperature.

Attend.

43

Lack of lubrication.

Provide proper lubrication.

44

Improper installation of antifriction bearings (damage, incorrect assembly of stacked bearings, use of unmatched bearings as a pair I etc.)

Rectify or replace bearing.

45

Dirt in bearings

Investigate the cause and clean bearing.

46

Rusting of bearings from water in housing

Arrest water ingress.

47

Excessive cooling of water- cooled bearing, resulting in condensation of atmospheric moisture in bearing housing.

Reduce cooling water flow.

For any occurrence of any abnormal symptoms stop the pump and investigate the cause for corrective action without delay. For trouble shooting of prime mover, electrical panels, mechanical seals refer the respective manufacturers instruction manual.

MPPL/IM/ESP/ET/PNISO/2006/0

8-3

Mather + Plat

Lists, Tables, Type Plates & Checklists

A Lists, Tables, Type plates & Checklists A.1

List of machine operators

All persons working on or with the product confirms with their signatures that they have received, read and understood this operating and maintenance manual. In addition they obligate themselves to conscientiously follow the instructions provided. Non-observation releases the manufacturer from any warranty obligations.

Name

Starting date

Table 1: List of machine operators.

MPPL/IM/ESP/ET/PNISO/2006/0

A-1

Signature

Lists, Tables, Type Plates & Checklists A.2 Sl. No.

Mather + Platt

Maintenance and inspection log Date

Equipment No

MPPL/IM/ESP/ET/PNISO/2006/0

Details

Signature Name

A-2

Remarks

Mather + Platt

Lists, Tables, Type Plates & Checklists

A.3

Type Plates

3.3.1

Type plate for unitized pump set

11

Sr. no.

1

Typ

2

KW

3

RPM

4

M3/hr

5

H (m)

6

P(max) Bar

7

T( º C )

9

Year of mfg

10

Total Set wt

8

1-Machine Serial Number 2-Machine type 3-Rated power 4-Rated speed 5-Rated discharge 6-Rated head 7- Maximum head 8- Total Set weight (Pump+Motor+Bedplate) 9- Operating temperature 10-Year of manufacture 11-CE mark

MATHER & PLATT PUMPS LTD CHINCHWAD, PUNE 411019, INDIA

3.3.2

Type plate for bare pump

11

Sr. no.

1

Typ

2

KW

3

RPM

4

M3/hr

5

H (m)

6

P(max) Bar

7

T( º C )

9

Year of mfg

10

Pump Wt

8

MATHER & PLATT PUMPS LTD CHINCHWAD, PUNE 411019, INDIA

MPPL/IM/ESP/ET/PNISO/2006/0

A-3

1-Machine Serial Number 2-Machine type 3-Rated power 4-Rated speed 5-Rated discharge 6-Rated head 7- Maximum head 8- Pump weight 9- Operating temperature 10-Year of manufacture 11-CE mark

Lists, Tables, Type Plates & Checklists A.4

Leveling Records

Required accuracy of level is 0.05 mm / 250 mm.

Level achieved:

Level Bottle used: Straight Edge used:

Checked by:

Verified by:

MPPL/IM/ESP/ET/PNISO/2006/0

A-4

Mather + Platt

Mather + Platt A.5

Lists, Tables, Type Plates & Checklists

Alignment Protocol

PUMP & MOTOR / ENGINE/ TURBINE ALIGNMENT READINGS. PUMP SR. NO:

PUMP TYPE :

DRIVER SR. NO:

MAKE:

A)

TYPE:

Before connecting Suction & Delivery Piping: RADIAL

AXIAL

Gap between coupling halves: B)

After connecting Suction & Delivery Piping: RADIAL

AXIAL

Gap between coupling halves: Required: Acceptable Limit:

Checked by: Verified by:

MPPL/IM/ESP/ET/PNISO/2006/0

A-5

Lists, Tables, Type Plates & Checklists A.6

Mather + Platt

Pre-Starting Checks for Pump set Checked on

Sl No

Activities

1

Alignment with and without piping

2

Flushing of pipe lines and ensure no leakages

3

Availability of sufficient liquid in sump / suction as per specifications.

4

Installation of all instruments a. Suction and delivery pressure gauges b. Pressure switches c. Temperature gauges d. Any other as supplied / specified.

5

Operation of suction, delivery and inline valves

6

Proper supports for piping and other allied equipments.

7

Availability of flushing / sealing liquid for stuffing box.

8

Availability of sufficient cooling liquid for bearings as specified

9

Free rotation of pump and drive shafts

10

Lubrication of bearings

11

Checking of insulation resistance of motor

12

Proper cable termination

13

Motor protection relay settings

14

Check all interlocks as specified / provided

15

No a. b. c.

16

Coupling of pump and drive and free rotation of shafts in coupled condition

17

Suction valve is fully opened

18

Pump is fully primed and all air is vented

19

Delivery valve is closed (if required)

20

Emergency shut down is possible.

load trial operation of drive Direction of rotation is ok Noise and vibration within limits Bearing temperatures and winding temperatures are within limits d. Overall operation is satisfactory

MPPL/IM/ESP/ET/PNISO/2006/0

A-6

Remarks

Mather + Platt A.7

Lists, Tables, Type Plates & Checklists

Pump commissioning report

SR02-04

Date: Pump Details a. Pump Sr.No. b. Type of pump c. Head d. Capacity e. Rpm f. Construction

Details of Motor a. Motor make b. Sr. no. c. Motor frame size d. KW / HP e. RPM f. Voltage

Details of System a. Application b. Liquid c. pH Value d. Suction

PIPING DETAILS a. Suction pipe size b. Delivery pipe size c. Valves d. Expansion joints

Pump operating parameters a. Suction pressure b. Discharge pressure c. RPM d. DE bearing temperature e. NDE bearing temperature f. Duration of trial run

Flooded/Lift

Motor operating parameters a. Current b. Voltage c. RPM d. DE bearing temperature e. NDE bearing temperature f. Winding temperature (maximum)

Observations & Remarks:

Checked by: Verified by:

MPPL/IM/ESP/ET/PNISO/2006/0

A-7

Lists, Tables, Type Plates & Checklists A.8

Mather + Platt

Issue / Feedback report

SR01-O2 Page 1

Date: To Mather and Platt Pumps Ltd. P.O. Box No. 7, Chinchwad, Mumbai-Pune Road, Pune-411019, India. 1 Client / Site

:

2

Nature of complaint

:

3

Date of receipt of pump at site & date of commissioning Was erection/commissioning in M & P’s scope Pump details Pump type: P.D. No: Flow:

:

4 5

:

Head: RPM: Efficiency:

6

Prime mover details Make: Sr. No.: Frame size / Type: KW/HP rating:

Motor / Engine RPM: Volts: Full load current: Insulating class:

7 a b c d e

Site layout Suction pipe details, valves Discharge pipe details, valves Expansion joints, strainer etc. Suction sump details Suction conditions

f

Static head (Elevation difference between pump centreline & discharge point)

(Enclose drawings / Sketch / photographs) : : : : : Flooded / Suction lift Details: :

8

Installation details

a

Base frame

Loose

b

Base frame levelling readings

:

c

No of packers below base frame

:

d

Alignment readings

e

-With pipe connection

:

-Without pipe connection

:

Coupling type & gap between couplings halves

:

MPPL/IM/ASCCP/2006/0

A-8

/ Turbine

/Anchored with foundation bolts

Mather + Platt

Lists, Tables, Type Plates & Checklists SR01-O2 Page 2

9 a b

Operation details Application of pump Solo / parallel / series operation

c

Liquid specification (Chemical analysis report)

Specific gravity: Temperature : Solid contents :

pH value : Viscosity :

d

Operation parameters

Suction Pr. : Discharge : Motor current : Frequency : VibrationsOverall readings: Bearing temp. : Suction pr. : Motor current :

Delivery Pr. Speed Volts

e

Parameters at close valve / minimum flow condition

: :

Filtered readings: Discharge Pr. Volts

Minimum flow : 10

Routine or major overhauls carried out if any (Give details)

:

11

Any other details or observation

:

12

Investigation engineers report

:

13

Spare requirement

:

14

Course of action finalized

:

15

Service Charges

:

Any other observation:

Prepared by:

MPPL/IM/ASCCP/2006/0

Checked by:

A-9

: : :

: :

Mather + Platt B

Machine data sheet

Pump Technical data

B.1 Performance Mather & Platt pumps are furnished for a particular duty and service conditions advised on your order / data sheet. Changes in hydraulic system will affect the pumps performance. See Safety, Sec 2, duty condition.clause 2.3.

B.2 Pressure limits The operating pressure has been selected to meet your specific requirements. See Safety, Sec 2, duty condition -clause 2.3.

B.3 Temperature limitation Refer the order specification/Data sheet.

B.4 Flange loads Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH NOZZLE

EACH END NOZZLE

EACH SIDE NOZZLE

EACH TOP NOZZLE

Nominal size of the Nozzle Plate (INCHES) FX FY FZ FR FX FY FZ FR FX FY FZ FR FX FY FZ FR

1’’ 117 145 95 210 117 95 145 210 145 95 117 210 163 124 81 220

1¼ ‘’ 135 166 109 240 135 109 166 240 166 109 135 240 192 147 96 260

1½ ‘’ 142 176 116 255 142 116 176 255 176 116 142 255 247 189 124 335

2’’ 160 200 130 290 160 130 200 290 200 130 160 290 340 260 170 460

2½ ‘’ 200 255 160 370 200 160 255 370 255 160 200 370 510 390 325 720

3’’ 240 300 200 430 240 200 300 430 300 200 240 430 700 530 350 950

4’’ 320 400 280 570 320 280 400 570 400 280 320 570 980 740 500 1330

5’’ 440 560 360 800 440 360 560 800 560 360 440 800 1300 1000 750 1800

(Ref API 610) 6’’ 560 700 460 1010 560 460 700 1010 700 460 560 1010 1700 1300 870 2310

7’’ 700 900 580 1300 700 580 900 1300 900 580 700 1300 2100 1600 1070 2850

8’’ 850 1100 700 1560 850 700 1100 1560 1100 700 850 1560 2600 1900 1300 3500

9" 1000 1300 850 1900 1000 850 1300 1900 1300 850 1000 1900 3100 2400 1500 4000

10’’ 1200 1500 1000 2200 1200 1000 1500 2200 1500 1000 1200 2200 3700 2800 1800 5000

11’’ 1350 1650 1100 2400 1350 1100 1650 2400 1650 1100 1350 2400 4050 3100 2050 5550

12’’ 1500 1800 1200 2600 1500 1200 1800 2600 1800 1200 1500 2600 4500 3400 2200 6100

14’’ 1600 2000 1300 2900 1600 1300 2000 2900 2000 1300 1600 2900 4700 3500 2300 6300

Forces – lb Moments – lb ft Each Top Side Nozzle Each Nozzle

2.2 = Kg

7.22 = Kg m

END SUCTION PUMPS: ET/PN ISO MPPL/IM/ESP/ET/PNISO/2006/0

B-1

15’’ 1800 2200 1400 3100 1800 1400 2200 3100 2200 1400 1800 3100 5200 3900 2600 7000

16’’ 1900 2300 1500 3300 1900 1500 2300 3300 2300 1500 1900 3300 5400 4000 2700 7200

Mather + Platt

Machine data sheet

Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH TOP NOZZLE

FX FY FZ FR

EACH NOZZLE

EACH END NOZZLE

FX FY FZ FR

EACH SIDE NOZZLE

Nominal size of the Nozzle Plate (INCHES)

FX FY FZ FR FX FY FZ FR

18" 2100 2500 1650 3650 2100 1650 2500 3650 2500 1650 2100 3650 5700 4250 2900 7600

20" 2250 2750 1775 3970 2250 1775 1750 3970 2750 1775 2250 3970 5900 4500 3100 8000

22" 2425 2950 1850 4250 2425 1850 2950 4250 2950 1850 2425 4250 6050 4650 3175 8250

24" 2550 3100 2025 4500 2550 2025 3100 4500 3100 2025 2550 4500 6200 4750 3250 8450

26" 2675 3300 2125 4750 2675 2125 3300 4750 3300 2125 2675 4750 6400 4900 3400 8750

(Ref API 610)

28" 30" 32" 33" 36" 2775 2825 2875 2900 2950 3400 3500 3600 3625 3675 2200 2775 2300 2325 2400 4900 5000 5150 5250 5300 2775 2825 2875 2900 2950 2200 2275 2300 2375 2400 3400 3500 3600 3625 3675 4900 5000 5150 5200 5300 3400 3500 3600 3625 3675 2200 2275 2300 2325 2400 2775 2825 2875 2900 2950 4900 5000 5150 5200 5300 6600 6800 7000 7200 7400 5000 5125 5150 5175 5400 3550 3600 3650 3675 3800 9000 9200 9400 9600 9900

38" 3000 3740 2470 5400 3000 2480 3740 5400 3740 2480 3000 5400 7620 5570 3930 --

40" 3055 3810 2545 5515 3055 2560 3810 5515 3810 2560 3055 5515 7845 5745 4065 --

42" 3110 3875 2525 5630 3110 2645 3875 5630 3875 2645 3110 5630 8075 5925 4200 --

44" 3170 3945 2700 5755 3170 2735 3945 5755 3945 2735 3170 5755 8315 6115 4345 --

46" 3225 4015 2780 5875 3225 2825 4015 5875 4015 2825 3225 5875 8560 6305 4490 --

48" 3285 4090 2865 6000 3285 2915 4090 6000 4090 2915 3285 6000 8810 6505 4645 --

Forces – lb Moments – lb ft Each Top Side Nozzle Each Nozzle

2.2 = Kg

7.22 = Kg m

END SUCTION PUMPS: ET/PN ISO

MPPL/IM/ESP/ET/PNISO/2006/0

B-2

50" 3340 4165 2950 6130 3340 3010 4165 6130 4165 3010 3340 6130 9070 6710 4800 --

52" 3400 4240 3040 6260 3400 3110 4240 6260 4240 3110 3400 6260 9340 6920 4965 --

Mather + Platt B.5

Machine data sheet

Bearings, Lubrication, Gland packing

End suction pumps SL NO

PUMP MODEL

MAX RPM

ELEMENT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

ET/PN ISO-A ( O/T) ET/PN ISO-B ( O/T) ET/PN ISO -1 ET/PN ISO-2 ET/PN ISO-3 ET/PN ISO-4 ET/PN ISO-5 ET/PN ISO-6 ET/PN ISO-7 ET/PN ISO-8 ET/PN ISO-9 ET/PN ISO-10 ET/PN ISO-11 ET/PN ISO-12 ET/PN ISO-13 ET/PN ISO-14 ET/PN ISO-15 ET/PN ISO-16 ET/PN ISO-17 ET/PN ISO-18 ET/PN ISO-19 ET/PN ISO-20 ET/PN ISO-21 ET/PN ISO-22 ET/PN ISO-23 ET/PN ISO-24 ET/PN ISO-25 ET/PN ISO-26 ET/PN ISO-27 ET/PN ISO-29 ET/PN ISO-30 ET/PN ISO-31 ET/PN ISO-32 ET/PN ISO-35

3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500

0 0 1 1 1 2 1 1 1 2 2 1 1 1 2 2 2 2 3 & 3H 2 3 3 & 3H 3 4 3 3 3 & 3H 3 4 3 4 4 4 4

BRG. DE

6305 ZZ 6305 ZZ 6306 NR 6306 NR 6306 NR 6310 NR 6306 NR 6306 NR 6306 NR 6310 NR 6310 NR 6306 NR 6306 NR 6306 NR 6310 NR 6310 NR 6310 NR 6310 NR 6310 OR 3310 6310 NR 6310 NR 6310 OR 3310 6310 NR 6313 NR 6310 NR 6310 NR 6310 OR 3310 6310 NR 6313 NR 6310 NR 6313 NR 6313 NR 6313 NR 6313 NR

BRG. NDE

NU 305 NU 305 NU 306 EC, 6306 NU 306 EC, 6306 NU 306 EC, 6306 NU 310 EC, 6310 NU 306 EC, 6306 NU 306 EC, 6306 NU 306 EC, 6306 NU 310 EC, 6310 NU 310 EC, 6310 NU 306 EC, 6306 NU 306 EC, 6306 NU 306 EC, 6306 NU 310 EC, 6310 NU 310 EC, 6310 NU 310 EC, 6310 NU 310 EC, 6310 N.A., 6310 NU 310 EC, 6310 N.A., 6310 N.A., 6310 N.A., 6310 NA., 6313 N.A., 6310 N.A., 6310 N.A., 6310 N.A., 6310 NA. , 6313 N.A., 6310 NA. , 6313 NA, 6313 NA. , 6313 NA. , 6313

BRG LUB ET / PN

Grease Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil Grease/oil

BRG LIFE HRS

40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000

SHAFT DIA AT CPLG MM

GLAND PACK ING SIZE

24 24 24 24 24 32 24 24 24 32 32 24 24 24 32 32 32 32 42 32 42 42 42 48 42 42 42 42 48 42 48 48 48 48

8 8 8 8 8 10 8 8 8 10 10 8 8 8 10 10 10 10 10 10 10 10 10 12 10 10 10 10 12 10 12 12 12 12

Bearing numbers sufficed with ZZ are shielded and pre lubricated bearings.

MPPL/IM/ESP/ET/PNISO/2006/0

B-3

ST BOX NO OF RINGS

5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

Mather + Platt

Machine data sheet

B.6 Recommended bolting & screw torques Failure of threaded fasteners due to over-tightening can occur by bolt shank fracture or by stripping of the nut and / or bolt’s thread. a bolt or screw assembled with a nut of appropriate class is intended to provide an assembly capable of being tightened to the bolt proof load without thread stripping occurring. The torque value to be set for a particular size of screw is dependent upon: 1. 2. 3. 4. 5.

Material of screw. Parent metal. Whether the screw is untreated or plated. Whether the screw is dry or lubricated. The depth of the thread.

Tightening Torques – Untreated Screw (Black finish) Friction of coefficient 0.14. Property Class 5.6 8.8 10.9 12.9

Torque Nm Ft. lb Nm Ft. lb Nm Ft. lb Nm Ft. lb

M6 4.6 3.3 10.5 7.7 15 11 18 13

M8 11 8.1 26 19 36 26 43 31

M10 22 16 51 37 72 53 87 64

M12 39 28 89 65 125 92 150 110

Nominal M16 95 70 215 158 305 224 365 269

diameter – Coarse thread M20 M24 M27 M30 184 315 470 636 135 232 346 468 420 725 1070 1450 309 534 789 1069 590 1020 1510 2050 435 752 1113 1511 710 1220 1810 2450 523 899 1334 1805

M33 865 637 1970 1452 2770 2042 3330 2455

M36 1111 819 2530 1865 3680 2625 4260 3156

M39 1440 1062 3290 2426 4520 3407 5550 4093

M33 800 590 1830 1349 2580 1902 3090 2276

M36 1030 768 2360 1740 3310 2441 3880 2535

M39 1340 988 3050 2249 4290 3163 5150 3798

Tightening Torques – Electrically Zink plated Friction of coefficient 0.125. Property Class 5.6 8.8 10.9 12.9

Torque Nm Ft. lb Nm Ft. lb Nm Ft. lb Nm Ft. lb

M6 4.3 3.1 9.9 7.3 14 10.3 16.5 12.1

MPPL/IM/ESP/ET/PNISO/2006/0

M8 10.5 7.7 24 17.7 34 25 40 29

M10 21 15 48 35 67 49 81 59

M12 36 25 83 61 117 86.2 140 103

Nominal M16 88 64 200 147 285 210 340 260

B-4

diameter – Coarse thread M20 M24 M27 M30 171 295 435 560 126 217 320 435 390 675 995 1350 297 497 733 995 550 960 1400 1900 405 708 1032 1401 650 1140 1660 2280 485 84o 1239 1681

Mather + Platt

Machine data sheet

B.7 Interchangeability Charts Shaft Element No. 1 BEARING & SHAFT SEAL GROUP CONSISTING OF BEARINGS BEARING COVERS SHAFT SEALS DEFLECTORS

PACKED SEAL WITH GLAND/ MECHANICAL SEAL

SHAFT

HOUSING

BACK COVER

Shaft Element No 4

MPPL/IM/ESP/ET/PNISO/2006/0

B-5

IMPELLER

CASING

Mather + Platt

Machine data sheet Shaft Element No 2 & 3 BEARING & SHAFT SEAL GROUP CONSISTING OF BEARINGS BEARING COVERS SHAFT SEALS DEFLECTORS

PACKED SEAL WITH GLAND/ MECHANICAL SEAL

MPPL/IM/ESP/ET/PNISO/2006/0

SHAFT

HOUSING

B-6

BACK COVER

IMPELLER

CASING