Horizontal & SuHorizontal & Sump Pumpmp Pumps

CENTRIFUGAL PUMPS

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A-5, Sector XXII, Meerut road, Ghaziabad – 201002, (U.P), India Phone:+91-120-3015784

WPIL Limited Trinity Plaza,3rd floor 84/1 a, Topsia road (south) Kolkata 700046, India

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WPE ES IOM Manual

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WPIL designs are being regularly improved and are thus subject to changes.The pumps designed as per customer’s requirement will not exactly match data provided in this manual.

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WPE ES IOM Manual

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The booklet covers the instructions for the following models of Brg.Frame unit 11 15 12 18 22

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pumps.

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Pump models 32/130,40/130,50/130,65/130,32/200,40/200,50/200,65/200 32/160,40/160,50/160,65/160,80/160,32/260,40/260,50/260 80/200,100/200,65/260,80/260,100/260,125/260,40/320,50/320,65/320,80/320,100/320 150/260,125/320,150/320,100/400,125/400,150/400


This manual contains important and useful information for the proper functioning and maintenance of this pump. It also contains important instructions to prevent possible accidents and serious damage and to ensure the safe and smooth functioning of this pump.
Read this manual carefully before commissioning the pump. Familiarize your self with the operation of the pump and strictly obey the instructions! a

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shall not be bound to any Guarantee other than the guarantee accepted by . In particular, will not assume any liability for explicit and/ or suitability of the articles supplied. P

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The guarantee shall forthwith and legally defunct in case:
Service and/ or maintenance has not been carried out strictly in accordance with the instructions.
Installations and/ or commissioning has not been carried out in accordance with the instructions.
Necessary repairs have not been carried out by our personal or have been carried out without our prior written consent.
The articles supplied have been changed without our prior written consent.
The spare parts used are not original WPIL Pump parts.
The articles supplied are used amateurishly, carelessly, improperly and/or negligently.
The articles supplied become defective due to out side circumstances beyond our control. e

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Furthermore, all deliveries are subject our “ “, which will be forwarded to you, free of charge and request. G

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Check the consignment immediately on arrival for damage and conformity with the advice note.
In case of damage and/or missing parts, have a report drawn up by the carrier at once. 3

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WPE ES IOM Manual

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If a pump or a complete pump unit has to be lifted, the slings should be fixed as shown in figure 1. And figure 2.

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WPE ES IOM Manual

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In case the pump is not immediately being used, the pump shaft has to be rotated manually twice a week. E

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Every WPIL pump has a name plate giving following details: WPIL PUMPS Ghaziabad CENTRIFUGAL PUMP SL.NO : SIZE :

MM

SPEED:

RPM

DRIVE :

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TYPE : TOTAL HEAD CAPACITY : M³/HR JOB NO :

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While you correspond with us for your requirements of spare parts or for any technical information, please always quote this details in your letter.

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WPIL water pumps are single volute casing pumps with axial suction branch and top centre line delivery branch. All pumps supported by integrally cast foot in the casing and all water pumps are centerline mounted. Bearings are cooled when liquids are handled at temperatures above 100˚c i

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Clockwise, pump viewed from driven end. i

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All the WPE models are suitable for the speed of 1450 rpm. Besides that the following speeds are recommended.

Max speed Upto 3600 rpm Upto 2900 rpm Upto 1800 rpm

Pump Models 32/130,40/130,50/130,65/130,32/160,40/160,50/160,65/160,32/200,40/200 50/200,80/160,80/200,100/200,32/260,40/260,50/260,65/260,80/260,100/260 125/260,150/260,40/320,50/320,65/320,80/320,100/320,125/320,150/320, 80/400,100/400,125/400,150/400

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WPE ES IOM Manual

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1.1 If the assembly of the pump with the driver on a common base plate is done in our works, the whole set will be carefully mounted and aligned. It is necessary to check once more the alignment of the coupling before putting the pump into operation. The eye bolts which may be fitted to the driver must never be used to lift the complete set as they are meant to carry the weight of the driver only. 1.2. If you furnish the driver yourselves, the clearance between the motor and pump coupling halves as shown on the arrangement drawing must be strictly observed. Difference in level between the shaft centre lines of pump and driver must be equalized by suitable pickings (plain parallel shims). When the pump and motor holding – down bolts are finally secured, care must be taken to avoid distortion. l

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Place a ruler (A) on the coupling. The ruler should touch both coupling halves across the whole width( see figure ).
Do the same check against both sides of the coupling near the axis.

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For all security the alignment is also checked with a pair of out side caliper (B) at 2 – diametrically opposite points of the side surfaces of the coupling halves.

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WPE ES IOM Manual

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Construction with stuffing box: check whether the gland nuts have not been over tightened. If necessary, loosen the gland nuts and retighten them by hand.
Check whether the shaft turns freely. Do this turning the shaft end at the coupling a few times by hand. P

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The bearings of pumps provided with grease-lubricated bearings are filled with grease at the time of delivery. Pump provided with oil lubricated bearings are supplied without oil. See the enclosed chart for specifications of oil to be used.
Fill the oil sump through the oil filling orifice up to the bottom of the constant level oiller.
After that fill the constant level oiller entirely. P

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Proceed as follows, both when the unit is put into operation for the first time and after the pump has been overhauled.
Fully open the stop value in the suction pipe. Closed the delivery stop value.
Fill the pump and the suction pipe with liquid to be pumped.
Turn the pump shaft a few times by hand and more liquid, if necessary. h

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The sense of rotation of the pump is indicated the arrow. Check whether the sense of rotation of the motor corresponds with that of the pump.
Let the motor run for only a short time and check the sense of rotation.
If the sense of rotation is not correct, change connecting wire of motor so as to match with rotation of the pump.
Mount coupling guard. t

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Open the stop valve in the supply piping for flushing for flushing or cooling liquid, if the pump is supplied with a flushing or cooling system.
Start the pump. 7

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WPE ES IOM Manual


As soon as the pump is under pressure, slowly open delivery stop valve until the working pressure is attained. d

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After the pump is started, the stuffing box will show a certain amount of leakage. Because of the expansion of the packing fibers, this leakage will gradually decrease. Make sure that the packing never runs dry. To prevent this, loosen that gland nut to the extent that the stuffing box leaks drop wise. As soon as the pump has reached the proper temperature (and leakage is still too much) the gland can be adjusted permanently.  Tighten both gland nuts, one after the other, a quarter turn.  Wait 15 minutes after each adjustment before making the next adjustment.  Continue in this way until an acceptable drop wise leakage has been attained (20-30 drops/ minutes). e

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A mechanical seal may never show visible leakage. o

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If a pump is in operation pay attention to the following:
The pump should never run dry.
Never use a stop valve in the suction pipe to control pump capacity. The stop valve should always be fully opened during operation.
Check whether the absolute inlet pressure is sufficient, so that no vapour can be formed.
Check whether the pressure difference between suction and delivery pressure corresponds with the specifications for the duty point of the pump. I

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Since the pumps are offered of back pull out type of design. While dismantling the pump, casing will remain in its place with the suction and delivery piping. The rotating Assembly can be pulled back easily. If spacer coupling is used, then the driver also Need not to be removed, enabling easy re-assembling of the pump without affecting the alignment. We recommend to mach-mark the parts before removing the spacer so as to ensure the original state of mounting when reassembling. • Drain the liquid handled by the volute casing(C 1) and oil from bearing bed(C 27). 8

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WPE ES IOM Manual

Remove spacer coupling or if there is no such coupling, loosen driver and move it aside. Loosen sealing liquid and coolant pipes if it is there and undo the fastening bolt on the support foot. Undo stud nuts on volute casing (C 1). Using the 2 forcing screws on the stuffing box(C 11) with draw the volute casing.. After undoing the impeller nut (C 6) withdraw the impeller with gasket. After that undo the stuffing box studs from lantern(C 34), withdraw the stuffing box along with packing, Lantern ring( C 4),Pressure Ring(C 33) and Gland ( C 13) . Remove the Shaft sleeve (C 14). Remove the lantern from bearing housing. Remove Deflector (C 31 ) and Inner Bearing Cap(C15) from bearing housing. Remove the Outer Bearing Cap(C 20).Remove pump shaft(C 24) with Bearings towards drive side.

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For assembly proceed with reverse sequence. After mounting the shaft, check the axial flow of the rotor from 0.01mm to 0.7mm. If new bearings are mounted on the shaft, they must first to be heated up to 80˚c in an oil bath. The bearings if installed in our works, have normal clearances, however, use of bearings with C3 play is permissible. L

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The pump is furnished with two deep groove ball bearings (table 1.) r

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The grease lubricated bearing have been lubricated before shipment. For this bearings following bearing greases are recommended which are available in the market. r

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Name of the firm Indian oil Caltex Hindustan petroleum

Speed 1450 rpm Servo gem 3 Starfak 3 Natra 3

Speed 2900 rpm/3600 rpm Servo gem 2 Starfak 2 Natra 2

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WPE ES IOM Manual

Bearings

Amount of oil in liters

Qty of grease for relubr of each bearing (g)

15

6305 – 2 Nos

0.550

100

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6307 - 2 Nos

0.700

150

22

6309 - 1 No 3309 – 1 No

0.850

200

Frame unit

Table – 1 The lubrication in Table 1 apply if the temperature is below 70˚C. Each temperature rise of 15˚C will reduce the lubrication interval to a half. O

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The bearing housing has been emptied of oil prior to shipment and must be refilled before starting.
Pour oil in the bearing housing half way up the sight glass.
During operation the level may slightly fall. Refilling during operation.
When the pump is put into operation after prolonged shut down, flush bearings and bearing housing with petrol or benzyl in order to remove impurities. During the flushing procedure rotate the shaft slowly.

For lubrication of our pumps we recommend the lubricants shown on this lubrication table L

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Firm Indian Oil Hindustan Petroleum

Mobil

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Speed up to 1500 rpm Servo System 150 Esstic 55, Terresso 56 Mobil Vactra oil Heavy Mobile D.T.E. oil Heavy Vac HLP 49

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Speed above 1500 rpm Servo system 68, 46 Esstic 50, Terresso 52 Mobil Vactra oil Medium Mobile D.T.E. oil Medium Vac HLP 36

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It is recommended that for a new pump the oil should be changed after 100 hours of operation for the first time and thereafter at intervals of 6-12 months add oil when necessary.

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WPE ES IOM Manual

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When a new pump is being put into service or the stuffing box has just been re-packed, watch the packing performance more closely than normal. Shut off the cooling water to the gland (if applicable). During the first hours, the stuffing box is allowed to leak quite a good deal, about 100 drops a minute. If the leakage degreases, slack the packing gland. If you want to reduce the leakage, tighten the packing stepwise at intervals of about 10 minutes and continue until packing performance is satisfactory. A small leakage of single drops should be allowed from the stuffing box for ascertainment of lubrication and of the correct packing tightness. A suitable leakage is 5 – 30 drops a minute. If the packing cannot be made to seal without intense tightening, it is best to re-pack. When re-packing remove all the old packing rings and cleans the stuffing box thoroughly. At the same time check to see that the water channels are clear and the shaft is free of warpage and score marks. When selecting the packing type, observe the quality and temperature of the liquid being pumped and the shaft sleeve material. Carefully form the packing into the right shape over the shaft sleeve. First insert the cut ends into the stuffing box and then push the whole ring to the bottom of the stuffing box. Put the rings one by one in the stuffing box, with the cut ends spaced 90 degrees apart. (See figure)

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Frame unit 15 18 22

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Packing ring a x d / L in mm 8 x 8 x 150 10 x 10 x 188.5 10 x 10 x 220

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: No of packing ring 4 (1 x L x 3) 4 (1 x L x 3) 4 (1 x L x 3)

Size in mm 8 10 10

Total length of packing in mm 600 754 880 11

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WPE ES IOM Manual

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Frame unit

– DIN 3760

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Because of design and manufacturing tolerances it is recommended to use metric Oil seals according to the following tables. a

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Size of Oil seal used in Bearing cap

15

Drive end 25 x 37 x 7

Non drive end 25 x 37 x 7

18

35 x 47 x 7

35 x 47 x 7

22

45 x 60 x 10

45 x 60 x 10

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Regularly check the outlet pressure. Bearing Temperature. Noise and Vibration. Voltage and Current. Check the pressure of the flushing liquid. This pressure must be 1.5 bar higher than the pressure at the impeller hub.

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Do not tighten the gland nuts any more after the running in period and adjustment.
If in time in gland packing starts to leak excessively, new packing rings have to be mounted instead further tightening the gland nuts. e

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A mechanical seal generally requires no maintenances. However, it should never be allowed to run dry. If there are no problems it is not advisable to dismantle the seal as the facing surfaces are running one another. Dismantling always means replacement of the mechanical seal. When the mechanical seal is leaking it has to be replaced. L

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Bearing housings with grease packed deep – groove ball bearings require no maintenance.. The bearings are filled with grease during assembly. In case the pump is overhauled, the bearing housing and the bearings have to be cleaned and provided with new grease.

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WPE ES IOM Manual

During operation the constant level oiler should never be empty, so take care to top up timely. The oil should be changed once a year. If the oil temperature is higher than 80 ˚C, the oil should be change more often. E

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WPE ES IOM Manual

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W1 W2* W3 * W4* W5* W6 * W7* W8 * W9 W 10 * W 11 * W 12 W 13 * W 14 W15 W 16 W 17 W 18 W 19 W 20 * W 21 W 22 W 23 W 24 * W 25 * W 26 W 27 * W 28 W 29 * W 30 W 31 W 32 * W 33 e

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Volute Casing Impeller Stuffing Box Gasket – Shaft/ Sleeve Impeller Nut Impeller Key Lantern Ring Wear Ring Casing Drain Plug Gasket - Stuffing Box/Casing Sleeve Stud – Gland/Stuffing Box Oil Seal – Inner Bearing Cap Plug – Oil Drain Bearing Bed Oil Level Sight Glass Support Foot Hex Bolt – Support Foot Outer Bearing Cap Oil Seal – Outer Bearing Cap Key – Coupling Shaft Hex Bolt – Outer cover/Bed Gaskets – Outer Bearing Cap Bearing - Coupling End Vent Bearing – Pump End Bearing Cap Inner Deflector Gland Stud – Bed/Stuffing BOx Gland Packing Stud – Stuffing Box / Casing. s

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In general failures in a pump unit are attributable to the following causes:





Failures in the pump Failures or faults in the piping systems Faults due to a wrong installation or commissioning Faults due to a wrong pump selections

A number of the most frequently occurring failures as well as their possible causes are set forth in the below table. o

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Pump doesn't deliver any liquid Volume flow of the pump is insufficient The discharge head of the pump is insufficient Pump stalls after it has been put into operation The power consumption of the pump is higher than normal The power consumption of the pump is lower than normal The stuffing box is leaking excessively Shaft packing or mechanical seal have to be replaced to often Pump vibrates or makes noise Bearings wear too soon or gets hot Pump runs with difficulty, gets hot or stuck P

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1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20 21 29 1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20 21 28 29 2 4 5 13 14 17 19 28 29 1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 18 22 23 24 25 26 27 32 34 38 39 13 14 15 16 17 18 20 21 28 29 6 7 23 25 26 30 31 32 33 43 6 7 23 25 26 30 31 32 33 34 35 36 41 1 9 10 11 15 18 19 20 22 23 24 25 26 27 29 37 38 39 40 23 24 25 26 27 37 38 39 40 42 23 24 25 26 27 34 37 38 39 40 42

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1. 2. 3. 4. 5. 6. 7. 8. 9.

Pump or suction pipe not sufficiently filled or de-aerated. Gas or air coming from the liquid. Air lock in the suction pipe. Suction pipe leaks air. The pump sucks in air through the stuffing box. The sealing or flush water pipe to the stuffing box is not connected or blocked. The lantern ring in the stuffing box has been mounted wrongly. The manometric suction head is too high. Suction pipe or suction strainer is blocked. 15

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WPE ES IOM Manual

10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

Insufficient immersion of foot valve or suction pipe during operation of the pump. NPSH available too low. Speed too high. Speed too low. Wrong sense of rotation. Pump doesn't work at the right duty point. Liquid density differs from the calculated liquid density. Liquid viscosity differs from the calculated liquid viscosity. Pumps works when the liquid flow is too low. Wrong pump selection. Obstruction in impeller or pump housing. Obstruction in the piping. Wong installation of the pump unit. Pump and motor nor well alignment. Rotating part running out of true. Imbalance in rotating parts (for instance impeller, coupling). Pump shaft is running out of true. Bearing faulty or worn out. Seals rings faulty or worn out. Damaged impeller. Pump shaft or shaft sleeve at shaft packing or running surfaces of the mechanical seal are worn out or damaged. 31. Worn or dried up shaft packing. 32. Not well packed stuffing box or bad mounting of the mechanical seal. 33. Packing type of the mechanical seal not suitable for the operation liquid or operation circumstances. 34. Gland of seal cover has been tightened too much or crookedly. 35. No water cooling of stuffing box at high temperatures. 36. The sealing or flushing liquid to the stuffing box or the mechanical seal is polluted. 37. Axial retaining of impeller or pump shaft is defective. 38. The bearings have been mounted wrongly. 39. Too much or too little bearing lubrication. 40. Wrong or polluted lubricant. 41. Impurities in the liquid get into the stuffing box. 42. Too high axial force because worn dorsal blades or excessive inlet pressure. 43. Excessive pressure in packing space due to much play in the smothering bush, blocked by-pass pipe or worn dorsal blades.

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WPE ES IOM Manual

For any correspondence / ordering spares , please quote the following CUSTOMER : PROJECT : WPIL REF. : PUMP MODEL : PUMP SERIAL NO. :

Contact WPIL For any complaints and suggestion regarding Pumps Email us: [email protected] Phone: +91-120-3015784 Fax : +91-120-3015740 Factory Address : WPIL LIMITED A-5, Sector XXII, Meerut road, Ghaziabad – 201002, (U.P), India

Corporate office address : WPIL limited Trinity Plaza, 3rd Floor, 84/1 a, Topsia Road (South) Kolkata 700046, India P: +91.33.3021.6800 F:+91.33.3021.6835

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WPE ES IOM Manual

WPIL PUMP BASKET

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL CENTRIFUGAL PUMPS TYPE U

Factory Address:

Corporate Address:

A-5, Sector XXII, Meerut Road,

WPIL Limited

Ghaziabad - 201002, (U.P.), India

Trinity Plaza, 3rd Floor,

Phone:+91-120-3015784

84/1 A, Topsia Road (South) Kolkata 700 046, India

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What do you want to do?

• Foreword & safety regulations • Receiving & Checking • Storage & Shifting • Preparation for installation • Installation Procedure • Pump start-up and operation • Maintenance of the pump • Contact Us

Click on the option you need above, for any further assistance, contact WPIL on [email protected]

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Foreword & safety regulations

Foreword & safety regulations 1.

Foreword

2.

Safety regulations

3.

Safety instructions

4.

Manufacturer’s regulations Go Back to Main Menu

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Receiving & Checking

Receiving & Checking 1. Unloading & inspection. 2. Shortages & damages. Go Back to Main Menu

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Storage & Shifting

Storage & Shifting 1. Environmental briefing. 2. Recommended storage procedure. 3. Recommended shifting procedure.

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Preparation for installation Preparation for installation 1. Required tools, material & equipment. 2. Installation drawings. 3. Preparing the pump foundation. 4. Layout & inspection of pump parts for installation. 5. Hoisting instructions. 6. Layout of pipe work valves and accessories

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Installation Procedure Installation Procedure 5.1

Leveling & grout type 5.1.1 Leveling of base plate

5.2

Installing the pump assembly

5.3

Couplings 5.3.1 Flexible coupling 5.3.2 Coupling alignment

5.4

5.3.2.1

Radial Alignment

5.3.2.2

Angular Alignment

5.3.2.3

Alternative Method for Alignment

Installing the accessories 5.4.1 Priming connection 5.4.2 Air vent connection 5.4.3 5.4.4 5.4.5

Pressure gauge connections Stuffing box packing Mechanical seal Go Back to Main Menu

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Pump start-up and operation

Pump start-up and operation 1. Pre-start checks. 2. Important operating instructions. 3. Trouble shooting chart.

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Maintenance of the pump Maintenance of the pump

7.1

Preventive maintenance table.

7.2

Recommended spare parts & ordering procedure. 7.2.1 Procedure for Odering Spare Part 7.2.2 Recommended list of spare parts subject to most wear 7.2.3 Recommended list of spare parts to be stocked if down time is critical

7.3

Major maintenance of pump. 7.3.1 Packing box assembly/Mechanical Seal 7.3.2 Bearings 7.3.3 Pump assembly (U) removal 7.3.3.1

Complete rotating assembly removal

7.3.3.2

Dismantling of rotor shaft

7.3.3.3

Method of removing dowel bushing

7.3.3.4

Re-Assembly of the rotor assembly

7.3.4

Re-Assembly of the pump unit

7.3.5

Dismantling of Re-Assembly of U pumps

7.3.6

Lubrication chart

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Maintenance of the pump

7.4

7.3.6.1

Recommended grease lubricants

7.3.6.2

Recommended oil lubricants

Reference drawings, material of construction & technical details. Go Back to Main Menu

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FOREWORD 1.1 FOREWORD This manual provides instructions for installing, operating and maintaining WPIL Horizontal Centrifugal Pumps. These instructions are written only for those who have a working knowledge of Horizontal

pumps and a familiarity with both the terminology and proper field practices used in

pump industry. Cautions and warnings are included, but they are not substitutes for the careful work of the experienced. If installation & maintenance work is neglected, or carried out incorrectly, we will not be able to fulfill our warranty obligations as agreed and documented in the purchase contract. Although we used the most current information available at the time this manual was published, all information contained herein is subject to change without notice. We have made every effort to avoid errors, but we cannot guarantee that this manual is error-free. We appreciate your interest in our product. If you have questions about the contents of this manual, please contact our field service department.

By furnishing this manual, WPIL does not accept liability for successful pump installation, operation or maintenance; that liability belongs to those who actuallyinstall, operate and maintain the pump.

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SAFETY REGULATIONS 1.2. SAFETY REGULATIONS

WARNING We wish to point out that we accept no liability for damage and operatrional faults arising from nonadherence to the instructions in the operating and maintenance manual.

This section contains safety regulations which must be always followed when operating our pumps. The regulations are highlighted in the text using the following symbols:

=Working safety symbol = “WARNING” For working and operating procedures which is must.

= CAUTION To prevent damage to the EQUIPMENT.

The words WARNING and CAUTION are always in front of the text to which they refer. The word NOTE is after the associated text. Go Back to Menu

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SAFETY REGULATIONS It is essential to observe the regulations highlighted this way. Particular attention must be paid to the safety equipment installed in the pump. If the safety equipment is not working or malfunctioning, the pump must not be operated. The following instructions for guaranteeing protection at work and safety must be observed:

-

Operators must have the necessary specialist knowledge.

-

Maintenance work may only be carried out by authorized persons.

-

The laws and regulations valid at the place of use must be observed when operating the pump. In the interest of occupational safety, operators, supervisors and machine operators are responsible for observing the regulations.

-

Perform functional inspections before starting work.

-

Tools and other objects may only be kept in their correct places; otherwise they can jeopardize safe operation.

-

Operating media (e.g. oils, lubricants and cleaning agents) for maintenance, servicing and repair work and oil changes must be collected in suitable containers and disposed of correctly, (in accordance with statutory guidelines applicable in the country).

-

Wear protective gloves when carrying out cleaning work, particularly when using solvents or petroleum ether. Avoid naked flamers and smoking during cleaning.

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SAFETY INSTRUCTIONS 1.3. SAFETY INSTRUCTIONS 1. The pumps may only be operated and maintained by persons who are qualified and competent to operate such machines.

WARNING The electrical machines and units are equipment with an industrial heavy-current connection. These items of equipment have dangerous conductive with rotating parts during operation. Serious material or health damage may be caused by removal of safety facilities, incorrect use and wrong operation. The persons responsible for the pump must therefore guarantee that: 1. Only qualified persons are assigned to work on the pump. 2. This manual is available to operating persons and that they follow it. 3. Non-qualified persons do not operate the pump and are not allowed in its proximity.

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SAFETY INSTRUCTIONS

WARNING The electrical connection must be made by a qualified electrician in accordance with the local regulations. The mains voltage must be the same as the voltage stated on the rating plate. The “electrical circuit diagrams” must be observed with regard to electrical connection of the pump. If the motor was switched off by the triggering of a safety element, it should not be switched back on again. The fault must be located and remedied. Switching back on without fault correction presents a risk of explosion. 2. The operator must be instructed about his pump’s power supply and how to switch it off. 3. The operational reliability of the safety equipment must be checked daily. 4. The operator must report to his superior as quickly as possible for any fault or irregularity which occurs. This applies to both the mechanical and electrical units. 5. It is absolutely essential that the operator shuts down the pump immediately if faults occur which jeopardize safety. These include: 1. Failure of the safety facilities 2. Damage to important pump components 3. Damage to electrical units and lines as well as insulation Go Back to Menu

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SAFETY INSTRUCTIONS 6. The operator is forbidden to modify electrical connections. Only trained specialists may perform this work.

Dry running is not permissible. Briefly switching on for maximum 10 seconds is possible without any danger. Do not switch on if there’s a fault.

7. Work on the pump may only be carried out if the current is switched off and when the moving parts are no longer turning. Unauthorized switching-on must be prevented by suitable measures. WARNING Never put hands and objects into the pump while turning. 8. The pump may only be switched on when it is installed and flooded.

WARNING Wear protective gloves when carrying out cleaning work, particularly when using solvents or petroleum ether. Naked flames and smoking are forbidden.

Operating media (e.g. gear oils, transformer oils, lubricants and cleaning agents) for maintenance work and servicing and oil changes must be collected in suitable containers and disposed off correctly.

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MANUFACTURER’S REGULATIONS 1.4. MANUFACTURER’S REGULATIONS 1.4.1 General These instructions must always be kept at hand where the pump is in use. It is essential that these instructions be read before work is started by all persons involved in working with or on the pump (make entry in the machine operator list). Person(s) who will only occasionally work on the pump (e.g. for assembly and maintenance) must also read and understand the operating and maintenance manual. It is essential to follow the instructions in the operating and maintenance manual of the pump. This applies strictly to the general and special safety instructions at the start of this manual and in the appropriate chapters. If in doubt, consult the person responsible for safety and accident prevention in your division.

1.4.2 Correct behavior Use the pump only for the intended liquids and data sheet parameters. Any other use is regarded as a special application which must be clarified with the manufacturer. The manufacturer is not liable for use of the pump for purposes other than those for which it was designed. The pump is operated from the control unit intended for this purpose. Go Back to Menu

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MANUFACTURER’S REGULATIONS Faults which can impair safety must be remedied immediately.

Unauthorized modification / application of the

pump

render the manufacturer’s liability VOID for any resulting damage.

1.4.3 Behavior during operation All accident prevention regulations must be observed. A further precondition for safe operation is that the additional instructions in this operating and maintenance manual are observed.

1.4.4 Original parts and safety Original parts and accessories are designed specially for the pump by WPIL Limited. We expressly point out that original parts and accessories not supplied by WPIL Limited are not tested and released by the company. The installation and/or use of such products can impair the active and/or passive performance / safety of the pump.

WPIL Limited shall not be liable for any damage arising from the use of non-original parts and accessories. 1.4.5 Maintenance and inspection list Keeping the maintenance and inspection list (Chapter 7 of the operating and maintenance manual) will help you to monitor the stipulated inspection and maintenance work.

1.4.6 Damage Damage must be immediately remedied by specialists only. Go Back to Menu

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RECEIVING & CHECKING 2.1 UNLOADING & INSPECTION All pump parts are precision machined parts. Unload with adequate care. Check the following:  Contents against packing list.  All components for damages.  Shafting for straightness and damage in case of broken crate or careless handling.

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RECEIVING & CHECKING 2.2 SHORTAGES AND DAMAGES Any shortages or damages should be immediately noted on the receipted documents of freight agent/carrier to facilitate prompt and satisfactory resolution.

REPORT ALL TRANSIT DAMAGE / SHORTAGE IMMEDIATELY ON FREIGHT AGENT / CARRIER RECEIPT. Late reports of shortage/transit damage will cause controversy and delay prompt & satisfactory resolution.

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STORAGE & SHIFTING 3.1 ENVIRONMENTAL BRIEFING All pump parts are precision machined. All parts supplied should be stored indoors in a dry (45% RH) and non-corrosive environment. The effective life of preservatives applied at the factory is 60 days including transportation period, unless specifically agreed other-wise.

HIGH-HUMIDITY / COASTAL & CORROSIVE ENVIRONMENTS A.) Inspect pump and parts periodically to ensure that preservatives are intact. B.) All machined surfaces and exposed shafting must be coated with rust preventive agents suitable for the local environment. C.) Turn pump rotor manually each week a few turns.

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STORAGE & SHIFTING 3.2 RECOMMENDED STORAGE PROCEDURE DO NOT DISCARD ORIGINAL PACKING BOXES. REPACK AND STORE & MOVE IN ORIGINAL PACKING BOXES.

•

Storage area must be level and not at risk of flooding.

•

All openings need to be sealed against ingress of dirt, particulate matter and water.

•

All small parts need to be stored in covered boxes with preservative paper.

•

Rubber parts like o-rings, gaskets and bearings need to be stored in closed containers.

•

Keep heavy components off the ground by using supports.

•

Shafting need to be removed from boxes, coated with preservative and then re-boxed with preservative paper.

INSPECT ALL PARTS PERIODICALLY TO ENSURE PRESERVATIVES ARE INTACT AND NO SIGN OF CORROSION IS VISIBLE.

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STORAGE & SHIFTING 3.3 RECOMMENDED MOVEMENT / SHIFTING PROCEDURE Pump assembly, thrust bearing assembly, all shaftings & small parts must be moved in boxed condition only.

DO NOT MOVE LOOSE PARTS. STICK TO ORIGINAL FACTORY PACKAGING METHODS FOR MOVEMENT.

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PREPARATION FOR INSTALLATION 4.1 REQUIRED TOOLS,MATERIALS AND EQUIPMENTS The materials and equipment necessary for installation of the pump will vary with the size of the pump and type of the installation. The list of lifting equipments and hand tools at Table below is offered as a guide only. The installation rig should be rated to hold at least 1.5 times the weight of the complete pumping unit i.e. the assembled pump and driver.

S.No.

TOOLS & MATERIALS

QUANTITY

REMARKS

1

Washing Oil, Kerosene

For washing of parts

2

Emery Cloth Paper

For cleaning of parts

3

Molycote (anti-galling grease)

For assembly

4

Sealing tape/Thread compound for pipe

For auxiliary piping

5

Line Marker

2 Sets

For alignment of foundation

6

Chisel

3 Sets

For foundation preparation

7

Lifting Nylon Slings of suitable capacity

2 nos.

For installation & rigging

2 nos.

For assembly

and 3 m long 8

1 / 5 / 10 lb Hammer

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PREPARATION FOR INSTALLATION 9

File Set

2 sets

For assembly

10

Screw Driver

2 each

For assembly

11

Adjustable Wrench

1 no.

For assembly

12

Pipe Wrench

2 nos.

For auxiliary piping / Line Shaft.

13

Allen Key(2 mm to 10 mm size)

14 15

1 set

For assembly

Wire Brush

2 nos.

For assembly

Single ended / double ended wrench(10mm

2 each

For assembly

to 36mm) 16

Plumb Bob with string

1 no.

For installation

17

Nylon hand hammer

2 nos.

For installation

18

Eye bolt of various sizes

19

D-shackle of various sizes (5 /7.5 M)

1 set

For rigging

20

Socket wrench

1 set

For assembly

21

Position marker punch

1 set

For assembly

22

Gap gauge (feeler gauge)

2 sets

For erection

23

Scraper

2 sets

For assembly

24

Marking String

-

For assembly

25

Ring spanner

2 nos. each

For assembly

For rigging

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PREPARATION FOR INSTALLATION 26

S.S. shims of various sizes (0.1 mm to 2 mm)

27

Mobile hoist/ travelling crane

1 no.

For assembly For assembly depending on size & weight of the pump

28

Bearing pullers

1 no.

For Bearing removal

Measuring tools required during installation:

Sno.

Tools & Materials

Quantity

1

Precision Class Spirit Level Gauge (Accuracy 0.02 1 no

Remarks For level checking

mm/ M) 2

Steel Tape (5, 10M)

1 each

For measurement of foundation

3

Dial Gauge with Magnet Holder & Clamps

1 set

For alignment checking

(Minimum division 0.01mm) 4

Gap Gauge (feeler gauge)

2 sets

For assembly

5

Edge 1.5 M long

1 No.

For Leveling

6

Straight Steel Scale (1 M)

1 each

For assembly

7

Straight Edge (I–beam type) 1.5 m long,

1 no.

For level checking

Accuracy-0.05mm/M

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PREPARATION FOR INSTALLATION 4.2

INSTALLATION DRAWINGS

Collect and arrange the following drawings:

• Foundation drawing (refer pump General Arrangement drawing), • Installation dimensional drawing (refer pump General Arrangement drawing & pump crosssectional drawing),

• Functional unit layout, (as per design by you), and • Piping diagram (as per design by you). Finalize the method of installation based on these documents before starting work.

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PREPARATION FOR INSTALLATION 4.3 PREPARING THE PUMP FOUNDATION The foundation must be built to support the weight of the entire pump unit when the pump is full of water. It should be rigid enough to withstand and prevent vibrations. The loading details of the pump are given in General Arrangement Drawing. WPIL recommends that a concrete foundation be used wherever possible. Steel I-beams or timbers may also be used, but they should be strong enough to prevent spring action and braced (tied together) to prevent lateral movement. In case of concrete foundation, the top surface of the foundation should be left rough to allow proper binding of final grout mixture. Also the top surface level should be lower in height by at least 20 to 35 mm to permit leveling of base plate. Go Back to Menu

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PREPARATION FOR INSTALLATION 4.4

LAYOUT & INSPECTION OF PUMP PARTS FOR INSTALLATION

•

All pump accessories should be checked for correctness and cleanliness.

•

All small components and fasteners should be separated assembly-wise as per crosssectional drawing & checked for correctness and cleanliness.

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PREPARATION FOR INSTALLATION 4.5 HOISTING INSTRUCTIONS Nylon slings (of rated load capacity) for lifting the pump assembly should pass at positions on the pump branches as shown in Fig. 4.5.a

Horizontal/Vertical Pump Lifting Arrangements Fig:- 4.5a Go Back to Menu

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PREPARATION FOR INSTALLATION To lift the prime-mover (electric motor), pass sling as shown in Fig 4.5.b

Fig: 4.5b

Never lift the entire pump assembly by the eye-bolts or from the bearing housing or from the shaft extension.

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PREPARATION FOR INSTALLATION 4.6 LAYOUT OF PIPE WORK, VALVES and ACCESSORIES It is important to ensure that pipe work, valves etc. connected to the pump are adequately supported. Ensure that the pump does not carry the weight of the pipe work when filled with water or tend to be dragged in any direction.

No strain is put on the pump casing flanges by the pipe work else would disturb the pump alignment leading to vibrations.

Never connect a pump to the piping; always connect pipe to the pump

4.6.1 SUCTION PIPING To avoid the formation of air pocket, the installation of suction pipe work must be arranged under the following conditions:

• Always as few bends as possible • Suction pipe work must be perfectly air tight • There must be a gradual rise in the suction pipe work towards the pump Go Back to Menu

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PREPARATION FOR INSTALLATION •

In case of an elbow is required at the pump suction flange, it should have a long radius. Location of the elbow from the pump flange should be more than 2D of straight pipe.

•

In case of an expander is required at the pump suction flange, it should be eccentric type to avoid the air pockets.

•

In case of strainer is provided, for clear water the total area of these holes should exceed three times the area of the bore of the pump suction branch.

Typical good and bad suction arrangements are shown in Fig 4.6.1.a & b and typical layouts are shown in Fig. 4.6.1.c & d

Good suction layouts, showing pipes rising all the way to the pump.

Bad suction layouts, which will cause air pockets and failure to pump. Fig. 4.6.1.a Go Back to Menu

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PREPARATION FOR INSTALLATION

Fig. 4.6.1.b Showing how the fault in the illustration on the left may be avoided.

Showing how an air pocket may be formed when the suction pipe is bigger than the pump branch. avoided.

Typical Layout – Flooded Suction (Fig. 4.6.1.c) Go Back to Menu

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PREPARATION FOR INSTALLATION

Typical Layout – Suction Lift (Fig. 4.6.1.d) 4.6.2 DELIVERY PIPING •

Pipe work, valve, fitting etc. are located in the delivery pipe line should be adequately supported to avoid any strains on the pump flange.

•

If an expansion joint is used it is recommended that this should be located at a distance not less than 2D from pump flange.

•

The intermediate spool piece between pump and expansion joint needs to be anchored.

•

Improper anchoring may subject to large reaction forces which could be detrimental to the installation.

•

A check valve is recommended in the case of back flow/high pressure surge is anticipated.

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INSTALLATION PROCEDURES 5.1 LEVELING & GROUT TYPE The purpose of grouting is to prevent lateral shifting of the base plate, not to fix irregularities in the foundation. Base plates are normally fabricated M.S. channel width plates at top and bottom accurately machined to have parallel plane surfaces. The base plate looks similar to as shown in Fig. 5.1.a

Base Frame with Channel (Fig. 5.1.a) 5.1.1 LEVELING OF BASE PLATE 1. Mark the base plate/base frame and foundation bolts position as per GA Drawing. 2. Grout foundation bolts, as per GA drawing, using quick setting cements. 3.WPIL recommends that 20-30 mm of epoxy grout is maintained under the base frame. 4.In case epoxy grout is not available, level using leveling wedges. Fill the gap between sole plate and foundation with quick setting concrete. Refer fig. 5.1.1.a & b 5.Level base plate/base plate with the help of straight edge and spirit level in two directions at 90 degrees by either leveling wedges or leveling nuts on anchor bolts. Go Back to Menu

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INSTALLATION PROCEDURES 6. Allow curing time for grout as per manufacturer’s recommendations. Setting time is usually 48 hrs and the grouting becomes hard in 72 hrs. 7. In case of vertical installation, the pump should be mounted following the practices outline for base plate mounted pumps similar to horizontal pumps. 8. If the pump is driven via a universal joint drive shaft, there may be a requirement to offset the pump shaft w.r.t. the driver. Optimal offset will typically be in the range 0 to 4º depending on shaft design. Consult the separate user instructions before installation. 9. Any support for the universal joint drive shaft, Plummer blocks must not exhibit resonant frequencies in the range of 0.8 to 1.2 of nominal pump speed. 10. In case of vertical pump, the alignment of the unit is achieved by adding or removing shims between the motor stool and the pump casing. The motor has a spigot fit in to the motor stool and it is therefore not possible to achieve any horizontal movement at this interface.

Before leveling, the sole plate should be high enough in grout thickness. Preferred levelness is dead-level. Maximum acceptable tolerance is 0.15 mm/meter.

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INSTALLATION PROCEDURES

Fig. 5.1.1.a

FOUNDATION BOLT FIXING DETAILS WITH BASE PLATE Fig. 5.1.1.b Go Back to Menu

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INSTALLATION PROCEDURES 5.2 INSTALLING THE PUMP ASSEMBLY The horizontal & vertical pumps are supplied in assembled condition from the works (as shown in Fig. 5.2.a & 5.2.b). The accessories like couplings, coupling guard, motor stool & pump stool (in vertical pump) etc. are supplied separately, are to be assembled with the pump and motor shaft respectively at site and to be installed on the base frame/base plate. The following steps shall be followed in installing the pump assembly. •

Sling and hoist the pump with its half coupling and gently lower in position on the leveled base plate.

•

Check that no gap exists between pump feet and the respective machined pads on the base plate.

•

Locate the pump fixing bolts and tighten down.

•

Similarly locate the prime mover with its coupling half in position on the leveled base plate.

•

Rotate each shaft independently by ensuring that the bearings run freely and that shafts are true within 0.1mm. Coupling pins should not be fixed during this check.

Fig. 5.2.a Go Back to Menu

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INSTALLATION PROCEDURES

Vertical Pump Assembly (Fig: 5.2b)

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INSTALLATION PROCEDURES 5.3 COUPLINGS 5.3.1 FLEXIBLE COUPLING For horizontal pumps, the couplings used are Flexible pin bush type similar to as shown in Fig. 5.3.1a & b. Both couplings are identical except 5.3.1b with the exception of bore and the pins can be inserted from either side. Ref.

Description

2

Coupling Pin

3

Coupling Bush

5

Distance Sleeve

272

Locking Washer

276

Flexible Coupling (Pin Half)

277

Flexible Coupling (Bush Half)

‘A’ Type Flexible Coupling Fig. 5.3.1.a

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INSTALLATION PROCEDURES

Ref. Description 2

Coupling Pin

3

Coupling Bush

54

Coupling Key

272

Retaining Washer

275

Locking Nut

276

Flexible Coupling (Pin Half)

277

Flexible Coupling (Bush Half)

‘B’ Type Flexible Coupling Fig. 5.3.1.b

5.3.2 COUPLING ALIGNMENT The pump unit has been manufactured to allow field alignment. The unit must be properly aligned at the time of installation. The importance of correct alignment can not be over emphasized. Alignment should be checked and corrected as required after: 1. Mounting 2. Piping is connected 3. Pump or driver is moved for any reason. Angular and parallel mis-alignment are corrected by shifting the motor and adding or removing shims from under the motor feet. Go Back to Menu

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INSTALLATION PROCEDURES 5.3.2.1 RADIAL ALIGNMENT The radial alignment (intersection of axis) refer fig. 5.3.2.1a, for the rotating unit are carried out with the help of dial gauge.

•

Clamp the dial indicator to one of couplings or to the shaft behind it, with the plunger resting on the rim of the other half coupling.

•

Set the pointer to zero.

•

Rotate the coupling and note the readings at each quarter revolution (90º).

•

Any variation in readings indicates a deviation in alignment. The position of one of the units must be adjusted until the readings at each quarter revolution are within the specified tolerances given below.

For detecting this type of error

To check intersection of axes (Shaft in line at coupling end)

Fig. 5.3.2.1.a Go Back to Menu

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INSTALLATION PROCEDURES 5.3.3.2 ANGULAR ALIGNMENT The angular alignment (parallelism of axis) refer fig. 5.3.2.2a, for the rotating unit are carried out with the help of dial gauge. 1.Clamp two dial gauge indicators at diametrically opposite points on one half of the coupling, on to the shaft behind it, with plungers resting on the back of the coupling. 2.Inscribe a line across both of couplings for reference, readings are to be taken only when the two marks coincide. 3.Rotate the couplings until the gauges are in line vertically and set the gauges to zero. 4.Rotate the coupling through half revolution. 5.If the alignment of the pump and its driving unit is correct the reading of both gauges should be the same, though not necessarily zero. 6.Equally positive or negative readings are acceptable. 7.Adjust the position of any one of the units to correct the readings. 8.Rotate the couplings until the gauges are in line horizontally and reset the dial so that the pointers are at zero. 9.Repeat the operations from point 4 to 7. Coupling up to Ø300mm Coupling > Ø300mm

0.05mm (0.002”)

0.07mm (0.003”)

RADIAL & ANGULAR ALIGNMENT NOT TO EXCEED 0.5mm (0.004”) ON DIAL GAUGE

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INSTALLATION PROCEDURES

For detecting this type of error

To check the parallelism of axes (Angular alignment) Fig. 5.3.2.2a 5.3.2.3 ALTERNATIVE METHOD FOR ALIGNMENT Angular and parallel misalignment can alternatively quickly be checked by using the straight edge and feeler gauge as described below.

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INSTALLATION PROCEDURES

Fig. 5.3.2.3a Check for angular alignment by inserting the taper or feeler gauges between the coupling faces at 90º intervals. The unit is in angular alignment when these four measurements are the same, or within recommended tolerances. Check for parallel alignment by placing a straight edge across both coupling rings on all four sides. The unit is in parallel alignment when the straight edge rests evenly across both coupling rings in all four directions.

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INSTALLATION PROCEDURES 5.4

INSTALLING THE ACCESSORIES

5.4.1 PRIMING CONNECTION Priming connection has been provided in the upper half of the casing to fill the casing with water from some outside source until suction pipe and casing are completely filled with the water. Priming may also be accomplished by the use of vacuum pump. Sometimes put valves are also used for priming purpose depending upon the size of the pump. 5.4.2 AIR VENT CONNECTION The air vent connection is provided at the top of the casing near the priming plug to provide the air release valve for the removal of air during priming. It is necessary to exhaust air from suction pipe and pump casing, as any air that remains in trapped will interfere with operation or hinder pump from lifting water and will loose the priming. 5.4.3 PRESSURE GAUGE CONNECTION Connect a compound gauge to suction of pump and pressure gauge to discharge flange of the pump. It is advisable to furnish shut-off valves between flange gauged connections and gauges. The gauges are necessary for an adequate check on pump performance. 5.4.4 STUFFING BOX PACKING Packing and repacking of stuffing box should be done with great skill and care. Normally the pump is dispatched from works along with packing. However, the time between the date the pump is dispatched from works and date it is commissioned is more than three months, replace the packing. For various pump models, refer the packing sizes as per the following Table 5.4.4. For installation purpose, refer the pump assembly drawing (Fig. 7.3.3). Mechanical seal is optional and factory assembled. THE PACKING RING JOINTS SHOULD BE STAGGERED AND EACH RING SHOULD BE PUSHED IN TO POSITION SEPARATELY. Go Back to Menu

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INSTALLATION PROCEDURES PUMP SIZE & TYPE

SHAFT SLEEVE

STUFFING BOX DATA

DIA. AT PACKING HORIZONTAL

VERTICAL

SIZE OF PACKING

No. OF RINGS PER BOX

SQ. (mm X mm) 8 LN 18

8 LNV 18

101.6

15.88

5

8 LN 21

8 LNV 21

114.3

15.88

5

8 LN 29

8 LNV 29

114.3

15.88

5

10 LN 18

10 LNV 18

88.9

15.88

5

10 LN 22

10 LNV 22

114.3

15.88

5

10 LN 26

10 LNV 26

114

15.88

5

12 LN 14

12 LNV 14

88.9

15.88

5

12 LN 17

12 LNV 17

101.6

15.88

5

12 LN 21

12 LNV 21

114.3

15.88

5

12 LNH 21

12 LNHV 21

114.3

15.88

5

14 LN 19

14 LNV 19

95

19.05

5

16 LN 23

16 LNV 23

114

15.88

5

16 LN 35

16 LNV 35

165.1

19.05

5

20 LN 26

20 LNV 26

152.4

19.05

5

20 LN 28

20 LNV 28

152.4

19.05

5

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INSTALLATION PROCEDURES 24 LN 34

24 LNV 34

140

19.05

5

24 LN 42

24 LNV 42

190.5

19.05

5

30 WLN 30

30 WLNV 30

130

20

5

30 LN 41

30 LNV 41

203.2

19.05

5

Table 5.4.4 5.4.5 MECHANICAL SEAL The typical mechanical seal assembly is shown in fig. 5.4.5.a The correct functioning of the seal must be checked regularly. No adjustment is possible locally. When leakage reaches an unacceptable level, the seal will need replacement. PART

DESCRIPTION

119

SEAL RING

220

MATING RING

301

O-RING

321

O-RING

412

SPRING

431

GRUB SCREW

449

SPRING HOLDER

554

DRIVE COLLAR

Fig. 5.4.5.a Go Back to Menu

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PUMP START-UP & OPERATION 6.1 PRE-START PROCEDURES Before the pump is brought in to the service, suction and delivery pipe work should be flushed and the sump clear of all debris like foreign material, silt and other deposits. This is done to prevent damage to the pump internals.

IF PUMP IS STORED FOR MORE THAN

ENSURE THE INLET PIPE AND PUMP

THREE MONTHS, THE BEARING SHOULD

CASING ARE COMPLETELY FULL OF

BE DISMANTLED, CLEANED & RE-

LIQUID BEFORE STARTING

GREASED.

CONTINUOUS DUTY OPERATION.

ENSURE THAT THE PUMP IS GIVEN THE

WHENEVER COUPLING GUARD IS

SAME ROTATION AS THE PUMP

REMOVED OR DISTURBED, ENSURE

DIRECTION ARROW CAST ON THE

THAT THE PROTECTIVE GUARD IS

PUMP CASING/ NAME PLATE.

SECURELY REFITTED PRIOR TO STARTUP.

Consult the applicable manufacturer’s instructions for detailed information for the prime mover (motor, engine or steam turbine) coupling, drive-shaft, electric driver, gear-head or mechanical seal applicable to the pump. Prior to start-up, check/do the following: 1. Open the vent connection on top of the pump upper casing to allow the trapped air to escape. Let liquid run out until casing is free from air bubbles. 2. In the case of vertical installation, open vent connection at the front of the upper half casing and disconnect the seal flush line at the mechanical seal/ stuffing box to allow the trapped air to escape. Let liquid run out until free from air bubbles.

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PUMP START-UP & OPERATION 3. That the pump operates with suction lift and is fitted with foot valve. Fill suction pipe and casing with liquid at a pressure of 1 to 2 bar from external source. 4. In case pump operates with suction lift without foot valve, the pump casing vents on suction volute must be connected to an external vacuum pump priming system. 5. In case of mechanical seal pump, all piping to the seal should be connected and properly lubricated. 6. Check that all cooling, heating and flushing lines are operating and are regulated for required flow. 7. Check that allowable runout shaft with seal is 0.050 mm. 8. Check wiring of the driver. 9. Check rotation of driver with the coupling halves disconnected i.e. under no-load condition. 10. Check that all connections to driver and starting device are as per the wiring diagram. 11. Check that voltage, phase, and frequency of the supply line are as per the motor name plate. 12. Rotate the shaft manually to ensure that the impellers rotate freely. 13. Check driver bearings for proper lubrication and oil level in housing. 14. Check that auxiliary seal components are properly vented. 15. Check discharge piping and pressure gages for proper operation.

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PUMP START-UP & OPERATION 6.2 IMPORTANT START-UP INSTRUCTIONS Following these helpful guidelines will assure longer life for your pump. 1.Check the tightness of pump set holding down bolts. (Refer torque as per the table 7.3.3.1) 2.Pump/base plate should not be used as pipe anchor. 3.Suction and discharge piping should be anchored as close as possible to the pump flanges to reduce vibration and prevent strain on the pump casing. 4.Expansion joints, if used, they must be properly tied and located on the side of the pipe anchor away from the pump. 5.Ensure adequate liquid is available in the sump and that sump levels are within the recommended values to meet NPSHR (Net positive suction head). 6.If the pump loses its prime or breaks suction, immediately shut it down and investigate the cause.

DO NOT RUN PUMP DRY! The impellers and bearing have small clearances and may bind / seize and cause serious trouble.

7.Ensure that suction valve is fully open. 8.Ensure that delivery valve is closed. The pump may be started with a fully open delivery valve provided the system operating pressure is standing on the discharge side of the pump NRV (if fitted). 9.Issue permission to startup after obtaining clearance from the concerned official to whom the essential system condition is known. 10.Start the pump through panel or local station. 11.Allow pump to reach its full speed and check the pressure gauge reading. 12.At this point the pump should generate a pressure higher or equal to its rated pressure. Go Back to Menu

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PUMP START-UP & OPERATION 13.If the generated pressure is lower the rated pressure stop the pump immediately and investigate. 14.Rectify the fault and re-prime the pump before restart. 15.If the pressure is within the satisfactory limits, slowly open the delivery valve to permit charging the line. 16.Care to be taken to avoid prolonged operation at near closed valve condition. It should not be more than five minutes. 17.Ascertain the pump total head from the pump test sheet or pump name plate. 18. If the pump capacity is much higher than the supplied pump, it is better to throttle the pump than to let it break suction. Only pumps may be throttled, however, the throttling should be limited to 50 percent of design flow. NOTE: Throttling may affect the driver load. 19.When the pump is stopped, the flow of liquid backing down through the pump will cause the pump to rotate backward. NEVER START THE PUMP AGAIN WHILE THIS BACKWARD ROTATION IS HAPPENING! If you do, you will place a severe strain on the shafting and it may break. Always allow the pump to stop completely before restarting it.

20.The bearing should be watched for signs of over heating. The bearing temperature may be allowed to rise 50ºC above ambient but not to exceed 80ºC for both oil & grease lubricated bearings. Normally recommended intervals between oil/grease changes are 4000 hours or at least every six months. The quality of grease should be of lithium soap base. Go Back to Menu

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PUMP START-UP & OPERATION NEVER MIX GREASES CONTAINING DIFFERENT BASES, THICKENERS OR ADDITIVES. 21. Do not operate the pump for long period at low capacity on account of overheating from churning. 22. If necessary, bypass arrangements may be adopted to save the pump operations at low capacity. 23. The gland should be checked to make sure that they are not cracked and rubbing on shaft sleeves causing overheating and overloading of motor. 24. When the pump is in operation, there should be some leakage at the stuffing box packing (Fig. 6.3.a). For cooling and lubrication, allow approximately 60 drops of liquid to escape each minute.

Fig. 6.3.a 25. In case of mechanical seal fitted with the pump, the seal leaks slightly at start-up, allow a reasonable amount of time for the seal to adjust itself. Liquids with good lubricating qualities normally take longer to wear in the seal than liquid with lesser qualities. When a seal starts out with a slight leak and gets progressively less with running, it indicates leakage across the seal faces and continued running will usually eliminate this. Where leakage occurs immediately and remains constant, unaffected by running, it usually indicates a secondary seal damage (shaft packing), or the seal faces are warped out of flat. See Section 6.3 (Troubleshooting), for possible causes and remedies. Go Back to Menu

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PUMP START-UP & OPERATION EXTERNAL FLUSH OR QUENCH SHOULD BE

NEVER RUN A MECHANICAL

STARTED BEFORE THE PUMP IS RUN AND

SEAL DRY EVEN FOR A

ALLOWED TO FLOW FOR A PERIOD OF FIVE

SHORT TIME.

MINUTES AFTER THE PUMP HAS STOPPED.

26. After the pump set has run out for an hour, all readings should be suitably logged in site records. 27. The pump set should be allowed to run for another hour or so to observe any undue change in parameters or until such time as the pump stabilizes.

TOLERANCE : VIBRATION LEVELS 95 Microns peak to peak when run at 1450 rpm. Measurement shall be on pump bearing housing. Refer Hydraulic Institute Standards (ANSI/HI-1994) for different speeds.

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PUMP START-UP & OPERATION

Trouble shooting chart

6.3.1

NO LIQUID DELIVERED

6.3.2

INSUFFICIENT PRESSURE

6.3.3

INSUFFICIENT CAPACITY

6.3.4

PUMP LOSES PRIME AFTER STARTING

6.3.5

PUMP OVERHEATS AND SEIZES

6.3.6

SHORT BEARING LIFE

6.3.7

VIBRATION AND NOISE

6.3.8

STUFFING BOX LEAKS EXCESSIVELY

6.3.9

SHORT SEAL LIFE

6.3.10 MECHANICAL SEAL LEAKS 6.3.11 USING TOO MUCH POWER

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.1 NO LIQUID DELIVERED TROUBLE INDICATOR NO LIQUID DELIVERED

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Lack of priming

• Pump or suction pipe not completely filled with liquid. Fill pump and suction pipe completely with liquid. • Check for leaks in suction pipe joints and fittings. Vent casing to remove accumulated air. Check and replace packing and shaft sleeve for wear if required.

• Loss of Prime or Air leaks

• Suction valve closed

• Open valve. • Open pump and inspect for obstruction.

• Impeller plugged • Suction lift too high

• Check the liquid level in the sump, static lift may be too high. Maintain the required level/suction pressure to meet the NPSHR of the pump. Measure with mercury column or vacuum gauge while pump is in operation. If static lift is too high, liquid to be pumped must be raised or pump lowered.

• Foot valve/strainer clogged

• Inspect and clean the foot valve and/or strainer. Area through foot valve should preferably 2 times, if strainer is used, area should be 3-4 times the area of suction pipe.

• Speed too slow

• Check motor voltage or frequency may be low. Check the pump’s speed is consistent with manufacturer’s recommendations.

• Wrong rotation

• Rotation must be as indicated by arrow on pump nameplate. Check engagement of motor coupling.

• Parallel operation of pumps unsuitable for operations

• Check the system head curve with the pump curve and see the suitability of the pump. Go Back to Menu

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.2 INSUFFICIENT PRESSURE TROUBLE INDICATOR INSUFFICIENT PRESSURE

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Speed too slow

• Check motor voltage or frequency may be low. Check the pump’s speed is consistent with manufacturer’s recommendations.

• Air leaks piping

in

suction

• Check the piping joints for air leakage. Check for gaskets in place and tighten the bolts to prevent air leakage.

• Mechanical defects

• Defective impeller, wearing rings or packing. Inspect impeller, wearing rings and packing. Replace if vane sections eroded or damaged. Replace wearing rings, packing if worn out.

• Wrong rotation

• Rotation must be as indicated by arrow on pump nameplate. Check engagement of motor coupling.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.3 INSUFFICIENT CAPACITY TROUBLE INDICATOR INSUFFICIENT CAPACITY

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Speed too slow

• Check motor voltage or frequency may be low. Check the pump’s speed is consistent with manufacturer’s recommendations.

• Lack of priming

• Pump or suction pipe not completely filled with liquid. Fill pump and suction pipe completely with liquid.

• Suction lift too high

• Check the liquid level in the sump, static lift may be too high. Maintain the required level/suction pressure to meet the NPSHR of the pump.

• Air leaks in suction piping

• Check the piping joints for air leakage. Check for gaskets in place and tighten the bolts to prevent air leakage.

• Air leaks in to pump through stuffing boxes

• Inspect and replace the incorrect/worn out packing.

• Foot valve/strainer partially clogged

• Inspect and clean the foot valve and/or strainer. Area through foot valve should preferably 2 times, if strainer is used, area should be 3-4 times the area of suction pipe.

• Excessive amount of air/gas in liquid

• Inlet of suction pipe insufficiently submerged. The inlet pipe to be sufficiently submerged at least 2-3 feet in liquid.

• Suction valve throttle

• Check and open valve.

• Impeller passage partially plugged • Total head of system higher than designed head of pump • Wrong rotation

• Dismantle the pump, inspect passage, clean if required.

• Parallel operation of pump unsuitable

• Check the system head curve with the pump curve and see the suitability of the pump.

• Take suitable measure to reduce the friction losses or static lift or replace the pump. • Rotation must be as indicated by arrow on pump nameplate. Check engagement of motor coupling.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.4 PUMP LOSES PRIME AFTER STARTING TROUBLE INDICATOR PUMP LOSES PRIME AFTER STARTING

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Pump or suction pipe not completely filled with liquid

• Check and fill liquid completely.

• Suction lift too high or water level too low

• Check NPSHA > NPSHR, proper submergence, loses at strainers and fittings.

• Excessive amount of air or gas in liquid

• Check and purge from pipes.

• Air or vapor pocket in suction line

• Check suction line design for pockets.

• Air leaks in to suction line

• Check air tight pipe then joints and gaskets.

• Air leaks in to pump through mechanical seal, sleeve joints, casing joint or pipe lugs • Inlet of suction pipe insufficiently submerged

• Check air tight assembly then joints and gaskets.

• Check cut out system design.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.5 PUMP OVERHEATS AND SEIZES TROUBLE INDICATOR PUMP OVERHEATS AND SEIZES

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Operation at very low capacity

• Lack of prime- Fill pump and suction pipe completely with liquid. Suction lift too high- If static lift is too high than liquid to be pumped must be raised or pump to be lowered.

• Parallel operation of pump unsuitable for operation • Misalignment

• Check the system head curve with the pump curve and see the suitability of the pump. • Check for misalignment both angular and radial and correct to tolerance limit.

• Rotor out of balance

• Check and balance the rotor with in the specified grade. • Check the bearing lubrication and replace the bearing.

• Bearing worn out

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.6 SHORT BEARING LIFE TROUBLE INDICATOR SHORT BEARING LIFE

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Operation at high capacity • Misalignment due to pipe strain

• Measure value and check maximum permitted. • Check the flange connections and eliminate strains using method permitted.

• Shaft bent

• Check shaft run-outs within acceptable values (0.05 mm). • Check for signs of this and correct it.

• Rotating part rubbing on stationary part internally • Bearings worn • Shaft running off centre because of worn bearings or misalignment • Impeller out of balance resulting in vibration • Excessive trust caused by mechanical failure inside the pump • Excessive grease in ball bearings • Lack of lubrication for bearings • Improper installation of bearings • Damage bearings due to contaminations • Wrong direction of rotation

• Replace bearings • Check misalignment and correct if necessary. Check bearings for excessive wear. • Check and balance the impeller to the required grade (ISO 6.3 Grade). • Check wear condition of impeller, its clearances and liquid passages. • Check method of re-greasing. • Check hours run since last change of lubricant. • Check method of assembly or state of cleanliness during assembly and type of bearing used. • Check contamination source and replace damaged bearings. • Reverse two phases on motor terminal box.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.7 VIBRATION AND NOISE TROUBLE INDICATOR VIBRATION AND NOISE

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Inadequate grouting

• Check base plate grouting, re grout if required. Also piping supports for anchoring.

• Misalignment

•

Check for misalignment both angular and radial. Correct to tolerance limits. • Isolate driver from pump unit, if vibration continues. Inspect driver and determine the cause utilizing vibration frequency analyzer and/or pump assembly. Consult motor/pump manufacturer.

• Motor imbalance Driver

• Foreign Material in unit

• Mechanical Defects

• Inspect volute, impeller and suction piping for foreign material and remove. Also repair any accompanying damage. • Shaft running off center because of worn bearings or misalignment. Inspect impeller bearings and shaft for damage and repair or replace as required.

• Rotor out of balance

• Balance the impeller to the specified grade.

• Clogged impeller or foreign material in pump • Foundation not rigid

• Back flush. Pull, check for damage and replace.

• Vortex problems in sump • Resonance • Excessive grease or oil in antifriction bearing housing • Motor noise • Cavitation due to low submergence or operation beyond maximum capacity rating • Foreign material in pump • Entrained air

• Check the proper tightness of the foundation bolts and check for no gap between the base plate and finished floor level. Re grouting is recommended. • Increase pump submergence. Apply sump modification such as; relocate pump in sump, lower the inlet velocity in sump. • System frequency at or near pump speed—Loosen anchor bolts. Change pipe loading. • Fill the quantity of grease as recommended. • Check for bearing failure. Install RTD’S in bearing housing. Monitor bearing oil level. • Insufficient NPSH available. Evaluate system head conditions and reduce pump capacity, if possible. Change pump’s impeller to lower NPSH design to meet the system NPSH available. • Back flush or pull and inspect. • Air separation can also cause hydraulic noise. Bleed off entrained air.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.8 STUFFING BOX LEAKS EXCESSIVELY TROUBLE INDICATOR STUFFING BOX LEAKS EXCESSIVELY

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Packing is worn out or not properly lubricated • Packing is improperly inserted

• Inspect packing, lubrication line and lantern ring location to ensure flow. • Inspect packing for correct size and avoid overlaps.

• Packing is not right kind for liquid handle

• Packing selection should be checked against manufacturer recommendation.

• Shaft scored

• If shaft/sleeve scored excessively, repacking alone may not stop excessive leakage. Hence replace shaft/sleeve.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.9 SHORT SEAL LIFE TROUBLE POSSIBLE CAUSES INDICATOR SHORT SEAL LIFE • Abrasive particles in fluid

RECOMMENDED REMEDIES • Prevent abrasives from accumulating at seal faces. Flush line maybe required. Use abrasive separator or filter.

• Seal running too hot

• Increase cooling of seal faces (for example, by increasing flush line flow). Check for obstructed flow in cooling lines.

• Equipment mechanical misaligned

• Align properly. Check for rubbing of seal on shaft.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.10 MECHANICAL SEAL LEAKS TROUBLE INDICATOR MECHANICAL SEAL LEAKS STEADILY (OPTIONAL)

SEAL LEAKS INTERMITTENTLY

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Faces not flat • Blistered carbon graphite seal faces

• Check for incorrect installation dimensions. • Check for gland plate distortion due to overtorquing of gland bolts. Improve cooling flush line, if overheated. Check gland gasket for proper compression. Clean out any foreign particles between seal faces and re-lap faces. Check for cracks and chips at seal faces during installation. Replace primary and mating rings, if damaged. • Replace secondary seals.

• Secondary seals nicked or scratched during installation • Worn out or damaged Orings • Compression set of secondary seal (hard and brittle) • Chemical attack (soft and sticky) • Spring failures • Erosion damage of hardware and/ or corrosion of drive mechanism • Faces not flat • Blistered carbon graphite seal faces

• Secondary seals nicked or scratched during installation • Worn out or damaged Orings • Compression set of secondary seal (hard and brittle) • Chemical attack (soft and sticky) • Spring failures • Erosion/Corrosion damage of hardware

• Check for proper seal selection with seal manufacturer. • Check for proper lead-in on chamfers, burrs, etc. • Review with seal manufacturer for alternate materials selection. • Replace parts. • Review with seal manufacturer for alternate materials selection. • Check for incorrect installation dimensions. • Check for gland plate distortion due to overtorquing of gland bolts. Improve cooling flush line, if overheated. Check gland gasket for proper compression. Clean out any foreign particles between seal faces and re-lap faces. Check for cracks and chips at seal faces during installation. Replace primary and mating rings, if damaged. • Replace secondary seals. • Check for proper seal selection with seal manufacturer. • Check for proper lead-in on chamfers, burrs, etc. • Review with seal manufacturer for alternate materials selection. • Replace parts. • Review with seal manufacturer for alternate materials selection. • Check for square-ness of stuffing box to shaft. • Align shaft, impeller and bearing to prevent shaft vibration and/or distortion of gland plate and/or mating ring.

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PUMP START-UP & OPERATION (Trouble shooting chart) 6.3.11 USING TOO MUCH POWER TROUBLE INDICATOR USING TOO MUCH POWER

POSSIBLE CAUSES

RECOMMENDED REMEDIES

• Speed too high

• Check voltage and frequency on motor.

• Improper impeller trim

• Pull pump and inspect. Modify existing impeller to provide actual system requirements. • Take suitable measure to reduce the friction losses or static lift or replace the pump. • Check alignment of pump and driver, also foundations.

• Total head of system lower or higher than pump design head • Pump out of alignment or shaft bent • Pumping sand, silt, or foreign material i.e. heavier liquid than allowed for

• Test liquid for viscosity and specific gravity.

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MAINTENANCE OF THE PUMP 7.1 PREVENTIVE MAINTENANCE TABLE It is recommended that a maintenance plan and schedule is adopted, in line with the user instructions. It should include the followings :

S#

Stage

1

Pump start-up

Preventive maintenance checks/actions •

Static lift/water level in the sump is adequate and that sump water level are within the recommended value.

•

If the pump sets have been stored for more than three months, the bearing housing should be cleaned and old grease should be washed out. Re-grease the bearing housing DE and NDE side as per recommendation specified in manual. Refer lubrication chart (7.3.6).

•

Ensure that the pump is properly primed by opening the vent on pump top casing and shut the vent after ensuring that the entrained air is removed.

•

Ensure that pump shaft is free in rotation.

•

Startup the prime mover on no load condition to check the direction of rotation.

•

Ensure that suction valve is fully open.

•

Ensure that delivery valve is closed. The pump may be started with a fully opened delivery valve in case NRV is fitted.

•

Start the pump through panel or local station.

•

Allow pump to reach its full speed and check the pressure gauge reading. At this point the pump should generate a pressure higher than its rated pressure. If the pressure is lower than rated pressure, stop the pump and investigate. Rectify the fault and re-prime the pump before re-start.

•

If pressure is within satisfactory limits than slowly open the delivery valve, to permit charging the line.

•

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•

Care to be taken to avoid prolonged operation at near close valve condition.

•

The pump set should be allowed to run for one hour or so to observe any undue change in performance parameter.

•

The delivery sluice valve should be closed prior to going in to STOP mode.

•

Do not go in to start mode when pump rotor is subjected to reverse flow or reverse rotation.

2.

3.

Pump operation

Temporary shut-

•

Change grease in bearing housing every 1000 hours running.

•

Grease motor bearings as per motor manufacturer’s instruction.

•

Adjustment of gland packing / change of gland packing in case of leakage.

•

Pack grease at every 500 hours of operation.

•

Check temperature of motor bearings, motor winding and pump bearing. Bearings will normally run between temperatures of 30º to 60ºC.

•

Any abrupt change in bearing temperature is much more indicative of trouble than a constant high temperature. If so than it is to be investigated and rectified.

•

Check input current, voltage, frequency, sump water level, suction and discharge pressure gauge readings and enter all the observations in log book with date and time at-least once in a day.

•

Tighten all loose bolts and check for excessive vibration.

•

Check for some excessive leakage through stuffing box while the pump is in operation. If the leakage can not be reduced by gland adjustment than replace the packing as per 7.3.1

•

The discharge valve should be closed before shutdown of the pump to prevent back flow.

•

If NRV is installed in the delivery line then discharge valve can be closed after shutdown the pump.

down

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MAINTENANCE OF THE PUMP 7.2 RECOMMENDED SPARE PARTS AND ORDERING PROCEDURE 7.2.1 PROCEDURE FOR ODERING SPARE PARTS: •

List the serial number and model of the pump (refer the name plate).

•

List the part number (from the Bill of Material in cross sectional drawing).

•

List the Quantity.

•

List the complete Part Description (from the Bill of Material in cross sectional drawing). To ensure continued satisfactory operation, replacement parts to the original design specifications should be obtained from WPIL. Any change to the original design specifications i.e. modifications or use of a non standard part will invalidate the pump safety certification.

7.2.2 RECOMMENDED LIST OF SPARE PARTS SUBJECT TO MOST WEAR. •

Impeller ring with grub screw/ casing ring.

•

Line bearing in case of vertical pump assembly.

•

Shaft sleeve with ‘O’ ring.

•

Gland Packing.

•

Complete Mechanical Seal (optional).

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MAINTENANCE OF THE PUMP 7.2.3 RECOMMENDED LIST OF SPARE PARTS TO BE STOCKED IF DOWN TIME IS CRITICAL. (Refer Sectional Drawing Fig. 7.3.3 for part no’s.)

NAME OF PART Casing ring with anti rotation pin Stuffing box packing rings (Sets) Shaft sleeve with ‘O’ ring Seal cage/ Lantern ring (Sets) Water thrower/ Deflector Bearing lock nut with washer Bearing cover gasket Casing split flange gasket Bearing (DE & NDE) Mechanical seal (optional)

PART No. 03, 24 15 07, 18 16 17 13 09 -

QUANTITY 02 02 02 02 02 01 02 01 02 02

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MAINTENANCE OF THE PUMP 7.3 MAJOR MAINTANENCE OF PUMP 7.3.1 PACKING BOX ASSEMBLY / MECHANICAL SEAL Put a warning board on starting device with words. MACHINE UNDER REPAIR : DO NOT START/CONNECT

The major cause of the packing box troubles are due to excessively or unevenly tightened packing / correct fitment of mechanical seal especially during the first hour of operation. WE WOULD CALL THE ATTENTON OF THE USER ON THE FOLLOWING RECOMMENDATIONS. Over tightening would immediately damage the packing. To replace a damaged / worn out packing, following steps should be taken: •

Remove split packing gland, old packing ring & finally lantern and end packing.

•

If pump is fitted with mechanical seal, then remove gland plate and mechanical seal, (refer fig. 5.4.5a).

•

Prepare bevel-cut packing ring, carefully made according to the dimension of recesses. This packing ring should be same grade as original packing.

•

Insert the packing ring by staggering the bevel-cut and fit it in original position. Reinstall the split packing gland and tighten it gradually.

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MAINTENANCE OF THE PUMP 7.3.2 BEARINGS GREASE LUBRICATED BEARINGS: •

Only Bearing grade grease should be used .Never use pink greases. Use Lithium based Grease suitable for use up to 100 degree Celsius.

•

Pack grease moderately to avoid overheating of Bearings.(preferably every 500 hrs).

•

All pumps with grease lubricated bearings are greased at the factory. As a secondary precaution, check and re-grease the bearing before starting the unit so as to ensure proper lubrication. This is recommended if the pump has been stored for three months or more.

•

One third to half of the volume in the housing should be filled with grease for normal applications. This will give the most ideal operating conditions. Greasing has to be done by a grease gun through the grease plug provided in the bearing housing. Complete Overhauls This depends on hours of operations of the pump/ the severity of the condition of service. Do not open the pump for inspection unless there is an indication of trouble inside the pump or in the bearings.

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MAINTENANCE OF THE PUMP 7.3.3 PUMP ASSEMBLY (U) REMOVAL Refer to the sectional drawing before dismantling of the pump (Fig. 7.3.3).

Typical View of U Pump Assembly

Fig. 7.3.3

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MAINTENANCE OF THE PUMP Cross Sectional Assembly

Fig: 7.3.3 Go Back to Menu

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MAINTENANCE OF THE PUMP 7.3.3.1 COMPLETE ROTATING ASSEMBLY REMOVAL Care must be exercised in dismantling operation to prevent damage to parts of the pump. Following points must be kept in mind during dismantling of the pump. The pump is separated from the drive after the pump has been electrically isolated & pump casing is drained down.

For convenience at re-assembly, layout all parts in the order in which they are removed. Protect all machined faces against metal to metal contact and corrosion.

•

Following Table 7.3.3.1 should be used for applying the fasteners torque.

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MAINTENANCE OF THE PUMP

Screw/bolt size M8 (5/16 in.) M10 (3/8 in.) M12 (1/2 in.) M16 (5/8 in.) M20 (3/4 in.) M24 (7/8 in.)

Torque Nm (lbf-ft) Pump feet fasteners 63 (46) 170 (125) 340 (250) 590 (435)

All other fasteners 10 (7) 20 (15) 34 (25) 84 (62) 165 (120) 285 (210)

Table 7.3.3.1 •

Withdraw the coupling guard and remove the coupling nut, bolts, distance pieces, washers applicable to flexible pin bush type coupling. For any other type of coupling, refer the manufacturer brochure.

•

Remove the sealing pipe (item 20) connected to the pump top half casing (item 02).

•

Withdraw dowel pins fitted in bearing housing (item 10) and loosen studs and nuts.

•

Remove bearing housing studs and nuts.

•

Remove hexagonal screws for bearing end covers (item 11,12) and slide the end covers from location to reset on the shaft.

•

Disconnect the glands (item 14) from casing by unscrewing nuts from gland’s studs.

•

With a suitable punch, drive out the two straight roll pins which are used at the horizontal split to align the upper (item 02) and lower casing halves (item 01).

•

Remove the bolts which hold the upper and lower half of the casing together.

•

By use of jacking screws located on the casing ease off the top half through equal jacking up and sling the top half casing (item 02) through the eye bolts provided at the top of the casing. Lift and place on the wooden supports. Go Back to Menu

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MAINTENANCE OF THE PUMP •

Remove split flange gasket carefully and store.

•

Sling the rotor assembly and carefully lift out from the bottom half casing in a perfectly horizontal plane as the coupling weight will tend to move the rotor towards the prime-mover during hoisting operation. Casing neck rings will be dislodged with the rotor. Hence care to be taken during hoisting to prevent falling off.

7.3.3.2 DISMANTALING OF ROTOR SHAFT The rotor assembly is removed as described in 7.3.3.1.Under mentioned procedure should be followed for dismantling: •

Lift out the rotor assembly. Use care in slinging, handling and supporting of the rotor for subsequent dismantling.

•

Remove the impeller wearing ring (item 06) by removing the locking grub screw (item 22).

•

Withdraw the pump half coupling from the shaft (item 04) by means of puller and withdraw the coupling key.

•

Withdraw the DE bearing housing (item 10). Note that the bearing is in interference fit with the bearing housing (item 10) hence withdraw should be square with the bore/shaft.

•

Withdraw the DE bearing (item 09) from bearing housing by suitable puller.

•

Remove DE & NDE bearing housing end covers (item 11,12) and slide bearing housing off the bearings.

•

Remove water thrower (item 18) from the shaft.

•

Remove gland packing (item 15) and lantern ring/seal cage (item 16).

•

Withdraw the sleeve nut (item 08).

•

Remove both the sleeves (item 07) from the shaft. Go Back to Menu

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MAINTENANCE OF THE PUMP •

Remove impeller (item 05) and impeller key (item 24).

•

Withdraw the NDE bearing housing (item 10).

•

Release the bearing lock washer at the NDE and remove bearing nut (item 13).

•

Remove the NDE bearing (item 09) and distance piece.

•

Remove water thrower (item 18), gland packing (item 15) & lantern ring/seal cage (item 16).

•

The rotor is fully dismantled for inspection and repair. All individual parts, all important joints and all wearing surfaces should be carefully examined and parts appreciably worn should be renewed.

7.3.3.3 METHOD OF REMOVING DOWEL BUSHING : As shown in sectional drawing (fig. 7.3.3) accurate alignment between the casing and bearing brackets is obtained with the use of straight hollow dowel bushings. The dowel bushings have internal threads which are used for milling the dowels see fig. 7.3.3.3a which shows the dowel bushing puller installed in position as shown, tighten the hexagon head bolt to remove dowels.

Fig. 7.3.3.3a Go Back to Menu

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MAINTENANCE OF THE PUMP 7.3.3.4 RE-ASSEMBLY OF THE ROTOR ASSEMBLY: To assemble the pump reverse the dismantling procedure as described in 7.3.3.2 & 7.3.3.1 respectively, except the following instructions. •

All bearings, wearing rings, gland packing ,sleeves should be checked and changed unless found in good. The gland packing details should be referred as per 5.4.4.

•

Impellers should be checked, before assembly, for dynamic balancing to grade 6.3 of ISO 1940.

•

Shaft to be checked for its trueness on V roller support on an inspection table. Pump shaft run out should be checked within 0.05 mm.

•

At bearing, impeller and coupling locations, the maximum permissible run out is 0.05 to 0.07 mm total indicated reading.

•

The clearance between impeller and casing neck ring should be maintained to the recommended values. Renewal is recommended when the worn value is twice the clearance. The diameter clearance value normally lies between 0.4 to 0.6 depending on the model size and may be obtained from the pump manufacturers for the given pump model.

•

When reassembling the impeller on the shaft, it is important to mount the impeller so that the vane tips point away from the apparent flow direction. The rotor always rotates towards increasing sections of the volute as shown in fig. 7.3.3.4

•

Install the rotor in the casing and check to see that the rotor rotates freely by hand, wearing surfaces at the impeller should not touch. Align the pump carefully and install the packing and seal cage.

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MAINTENANCE OF THE PUMP

FIG. 7.3.3.4 7.3.4 RE-ASSEMBLY OF THE PUMP UNIT: The rotating element is now fully assembled as described in rotor assembly 7.3.3.4. The further steps for pump assembly shall be followed as under. •

Clean the casing and remove any protrusions on split flange of casing.

•

Ensure threads, gaskets and ‘o’ ring (item 19) mating faces are cleaned. Apply thread sealant to non face sealing pipe thread fittings.

•

Fit casing gasket to the bottom half horizontal flange using a small amount of contact adhesive to prevent movement when the top half is fitted. Do not apply adhesive to the top surface of the gasket.

•

Hoist the rotor assembly (as described in 7.3.3.4) and gradually lower in to the bottom half casing (item 01). Care to be taken to see that neck rings and bearing housing get positively located at spigot area.

•

Unlock the rotor assembly from the sling after locating in bottom half casing.

•

Fit the NDE bearing housing. Note that bearing is interference with the bearing housing. Hence fitment should always be square to the bore/shaft.

•

Fit the DE bearing housing. Note that bearing is interference with the bearing housing. Hence fitment should always be square to the bore/shaft. Go Back to Menu

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MAINTENANCE OF THE PUMP •

Apply grease of the recommended type to the bearings.

•

Locate dowel pins in bearing housing and insert studs through bearing housing and tighten nuts both on DE & NDE sides.

•

Fix hexagonal screws to bearing housing end covers and tighten in position.

•

Now rotate shaft and ensure free rotation.

•

Apply a light layer of grease on split flange bottom half and locate gasket in position, ensuring that bolt holes are all clear from any obstruction.

•

Fix dowel pins to casing top half.

•

Hoist the top half casing (02) and slowly lower on to the bottom half. Ensure perfect match of the bolt holes. The dowel pins to be tapped in position.

•

Torque up the fixing screws. Firmly secure casing with nuts and bolts as per sequence as shown in fig. 7.3.4

•

Torque up the fixing screws.

•

Rotate the shaft and ensure the free rotation.

•

Connect water seal pipes and other accessories.

•

Fit the coupling and align the pump and motor unit.

•

If mechanical seals are fitted, a small amount of silicon rubber sealant along the horizontal joint line on the stuffing box face and fit the seal cover complete with gasket or ‘o’ ring.

•

Care must be taken to ensure the seal seat bore is concentric to the shaft sleeve and it can be achieved using filler gages between the stationary seal seat bore and the shaft sleeve.

•

Torque up the seal cover screws and check shaft/sleeve does not rub on seal cover or stationary seal seat bore.

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MAINTENANCE OF THE PUMP 7.3.5 DISMENTALING AND RE-ASSEMBLY OF U PUMPS RECOMMENDATION For Grease/Oil Lubrication, Refer Table 7.3.6.1 & 7.3.6.2 In U pump models, the horizontal pump unit is installed vertically along with pump and motor stools directly coupled with motor (fig. 7.3.5.a). In some cases intermediate shafts and bearings are used between the pump and motor. Since the horizontal pump unit is installed vertically hence the dismantling and re-assembly procedure will remain same except the following steps. •

Isolate the electrical connections of the motor.

•

Remove the motor half coupling bolts and free the coupling.

•

Hoist the motor from the motor stool after removing the motor stool bolts on motor side.

•

Remove the motor stool from the pump after removing the motor stool bolts from pump side.

•

Remove the upper half casing after disconnecting the sealing lines and other accessories.

•

While lowering the casing upper half over the lower half, take care to ensure that the wearing rings are correctly located in the upper half bores.

•

The remaining steps shall be followed as per 7.3.3.1, 7.3.3.2, 7.3.3.3, 7.3.3.4

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MAINTENANCE OF THE PUMP

Fig. 7.3.5.a

Fig. 7.3.5.a Go Back to Menu

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MAINTENANCE OF THE PUMP 7.3.6 LUBRICATION CHART 7.3.6.1 Recommended Grease Lubricants

Manufacturer ESSCO Petroleum Co. Ltd. Mobile Companies Throughout the world Shell Companies throughout the world Caltex Castrol Indian Oil

Grease Ball & Roller Bearings Beacon 2 or Beacon 3 Mobilux Grease No. 3 or Mobilplex 48 Shell Alvania Grease 3 Caltex Multifak 2 Castrol Spheerol AP 3 Servogem 3

Table 7.3.6 It is unsafe to mix greases of two or more grades for use in ball bearings. 7.3.6.2 Recommended Oil Lubricants

Table 7.3.6.1 Go Back to Menu

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MAINTENANCE OF THE PUMP 7.4 REFRENCE DRAWING, MATERIAL OF CONSTRUCTION & TECHNICAL DETAILS Reference drawing, material of construction & other technical details refer the following drawing for respective jobs General arrangement drawing. Cross-sectional drawing. For any correspondence/ordering spares, please quote the following.

CUSTOMER : PROJECT : WPIL REF. : PUMP MODEL : PUMP SERIAL No. :

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Contact Details Contact WPIL For any complaints and suggestion regarding Pumps Email us: [email protected] Phone: +91-120-3015784 Fax: +91-120-3015740 Factory Address: WPIL LIMITED A-5, Sector XXII, Meerut Road, Ghaziabad - 201002, (U.P.), India

Corporate Office Address: WPIL Limited Trinity Plaza, 3rd Floor, 84/1 A, Topsia Road (South) Kolkata 700 046, India P: +91.33.3021.6800 F: +91.33.3021.6835

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