MANUAL : STD: IS-5120: SERIES: VCP

MANUAL FOR

Instructions on Installations, Operation and Maintenance of Type VCP Pump applicable for 2+1 Bearing with single driving head

Manufactured by :

Varat Pump & Machinery Pvt. Ltd. 20, NETAJI SUBHAS ROAD KOLKATA – 700 001 WEST BENGAL INDIA DOC. NO. : VP-MM-VCP-03/0

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Contents Point No.

Description

Page No.

1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 14.1 14.2 15.0 15.1 15.2

General Model Coverage Storage Long Storage Installation Location Foundation Handling Leveling

3 3 3 3 3 3 3 4 4 4 5 5 8 8 8 8 8 10 10 11 11 11 12 12 13 13 14 14 14 14 14 14 15 17 17 17 17 17 18

Flexible Coupling

Alignment Misalignment Grouting Piping Suction Pipe Delivery Pipe Vacuum Equalizing Line Foot Valve Stuffing Boxes and Packing Lubrication Ball Bearing Priming Preparation of Pump Starting Starting and Stopping of the Pump Bearing Lubricant Stuffing Box Gasket Coupling Guide Ring / Wearing Ring Shaft Sleeve Spare Parts Trouble Shooting Maintenance Daily Checks Periodical Maintenance Overhauling Dismantling of Pump Reassembling of Pump

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1.0

1.1

GENERAL

The Operation & Instruction Manual is required to read carefully who will work on this Pump sets. The working Instruction should be followed strictly so that damages to the equipment, specially for the Pump is avoided. This book let covers instructions for following Models of VARAT Centrifugal Back Pull Out Process Pump Model: 40VCP2, 40VCP3, 40VCP3N, 50VCP1, 50VCP2, 50VCP3, 65VCP3, 65VCP3M, 65VCP3N, 80VCP1, 80VCP1K, 80VCP2, 100VCP2,

1.2

When the pumps are received sometime before the use of the pump it should be located in dry place. The coupling should be rotated once in a month to prevent pilling of bearing surfaces.

1.3

When the pumps kept idle for a period after one use, it should be cleaned properly and overhauling should be made before long storage.

Unauthorized Modes of Operation To ensure operational reliability and safety of the pump / unit supplied, the machine shall be used exclusively in accordance with its designated use as described in the following sections. The limits stated in the data sheet must not be exceeded under any circumstances. Unauthorized Modification and Manufacture of Spare Parts Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer for consequential damage.

2.0 3.0

INSTALLATION

2.1

LOCATION The pump should be located as near the liquid source as possible. This will minimise the suction lift and pump will give better performance. Ample space should be provided on all the sides so that the pump can be inspected while in operation and can be serviced conveniently whenever required.

2.2

FOUNDATION The foundation should be sufficiently substantial to absorb any vibration and to form a permanent rigid support for the base plate. This is important in maintaining the alignment of a direct connected unit. A concrete foundation on a solid base is advisable. Foundation bolts of the proper size should be embedded in the concrete located by a drawing or template. A pipe sleeve about two and one-half diameter larger than the bolt should be used to allow movement for the final position of the foundation bolts.

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2.3

HANDLING The pump set should be properly handled and slung for transport. Do not thread the ropes through the eyebolt on the Motor or Pump during handling complete set. During handling do not remove the blank rubber gasket provided on the suction and discharge nozzles. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pump using suitable slings under the outboard end of the bearing frame and under the suction flange.

Warning : Pump and Components are heavy. Failure to properly lift and support equipment could result in serious physical injury or damage to pumps 2.4

LEVELLING When the unit is received with the pump and driver mounted on the base plate, it should be placed on the foundation and the coupling halves disconnected. The coupling should not be reconnected until all alignment operations have been completed. The base plate must be supported evenly and placed closed to the foundation bolt. In each case, the supports should directly under the part base plate carrying the greatest weight and spaced closely enough to give uniform support. A gap of about 25 to 50 mm should be allowed between the base plate and foundation of grouting. Supporting will be such that it will not be distorted or sprung by the uneven distribution of the weight. Adjust the wedges until the shafts of the pump and driver are in level. Check the coupling faces, suction and discharge flanges for the horizontal or vertical position by means of spirit level.

2.5

FLEXIBLE COUPLING A flexible coupling will not compensate for misalignment of the pump and driver shafts. The purpose of the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts without interference with each other while transmitting power from the driver to the pump.

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2.6

ALIGNMENT Pumps and drivers that are supplied by the manufacturers, mounted on a common base plate are accurately aligned before despatch. All base plates are flexible to some extent and alignments are likely to be disturbed during transit to some extent and therefore must not be relied upon to maintain the factory alignment. Re-alignment is necessary after the complete unit has been leveled on the foundation and again after the grout has set and foundation bolts have been tightened. The alignment must be checked after the unit is piped up and re-checked periodically.

2.7

MISALIGNMENT There are two types of misalignment between the Pump shaft and the driver shaft: (a) Angular misalignment: Shafts with axis concentric but not parallel. (b) Parallel misalignment: Shafts with axis Parallel but not concentric. The unit can then be grouted by soft concrete under the edges.

DIAL GAUGE ALIGNMENT An approved method for putting the coupling halves in final accurate alignment is by the use of a dial indicator. Check the alignment by straight edge and fillers as accurately as possible as described above. Fasten the indicator to the pump half of the coupling with the indicator button resting on the other half of the coupling periphery (FIG 3). Set the dial to the 0 and chalk mark the coupling half beside where the bottom rests. For any check, top or bottom or sides, rotate both shafts by the same amount i.e. all readings on the dial must be made with bottom beside the chalk mark. The dials reading will indicate whether the driver has to be raised or lowered or moved to either side. Accurate alignment of shaft center can be obtained with this method.

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ALIGNMENT OF SPACER TYPE COUPLING Where a spacer type coupling is used between the pump and driver, it is may not be possible to align the couplings to the pump and driver exactly as described above. To align unit with a floating coupling, remove the spacer between the pump and driver. Use a magnetic stand and place the dial indicator as given in FIG 4, make a chalk mark of the coupling half beside where the bottom rest and set the dial to Zero. To check for parallel alignment, rotate both shafts be the same amount i.e. all readings are made with the bottom beside the chalk mark. After parallel alignment has been obtained change the indicator so it bears against the face of the same coupling half and follow the same procedure to check angular alignment that were used for parallel alignment. The angular alignment may also to check by using inside micrometer as shown in FIG 4. After final alignment is obtained, insert the spacer and bolt the coupling halves. ALIGNMENT CRITERIA Good alignment is attained when readings as specified in this section have been achieved with pump and driver at operating temperatures (final alignment). Table 1 shows maximum allowable Total Indicator Reading (T.I.R.) for parallel and angular misalignment.

Maximum Allowable Parallel and Angular Misalignment Group

All

Maximum Allowable Misalignment Parallel Angular 0.03 degrees 0.05 mm [0.125 mm/cm (.0005 (.002 in.) in. /in.) of coupling face diameter]

NOTE A: For electrical motros, motor shaft initial (cold) parallel vertical alignment settings should be 0.05-0.10mm (.002-0..4 in) lower than pump shaft. NOTE B: For other drivers (turbines, engine etc.), follow driver manufacturers’ recommendation.

ALIGNMENT TROUBLESHOOTING Problem Cannot obtain horizontal (Side-toSide) alignment, angular or parallel

Probable Cause Driver feet bolt bound. Baseplate not leveled properly, probably twisted.

Cannot obtain vertical (Top-toBottom) alignment, angular or parallel

Base plate not leveled properly, probably bowed.

Remedy Loosen pump hold down bolts and slide pump and driver until horizontal lignment is achieved. Determine which corner(s) of the baseplate are high or low and adjust leveling screws at the appropriate corner(s) and realign. Determine if center of baseplate should be raised or lowered and correct by adjusting leveling screws equally at the center of the baseplate.

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2.8

GROUTING When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly. Working soft concrete under the edges can then grout the unit. Foundation bolts should not be fully tightened until the grout is hardened, usually 48 hours after pouring.

2.9

PIPING Both suction and delivery pipes and accessories should be independently supported near the pump so that when the flange bolts are tightened no strain will be transmitted to the pump casing. It is usually advisable to increase the size of both suction and delivery pipes at the pump nozzles in order to decrease the loss of head from friction and for the same reason piping should be arranged with as minimum bends as possible, as these should be made with a long radius wherever possible. The pipe lines should be free from scales, welding residuals etc., and have to be mounted in such way that they can be connected to suction and delivery flanges without any stress on the pump. Adequate supports should be given to pipe lines so that the weight of the pipelines does not fall on the pump. The use of minimum number of the bends and other fittings will minimise the friction losses.

2.10

SUCTION PIPE The suction pipe should be as short as possible. This can be achieved by placing the pump close to the liquid to be pumped. The suction pipe must be kept free from air leaks. This is particularly important when the suction lift is high. A horizontal suction line must have a gradual rise towards the pump. Any high point in the pipe will be filled with air and thus prevent proper operative of the pump. A concentric taper piece should not be used in a horizontal suction line as it forms an air pocket in the top of the reducer and the pipe. Use an eccentric per piece (FIG 5). The end of the suction pipe must be well submerged to avoid whirlpools and ingress of air but must be kept clear of any deposits of mud, silt grit etc. The pipe must be clear from any side of wall by at least 450mm. The end of the suction pipe should be provided with a strainer of sufficient open area.

2.11

DELIVERY PIPE A check (non-return) valve and a gate or sluice valve (regulating valve) should be installed in the discharge line. The check valve placed between the pump and the gate valve is to protect the pump from excessive pressure and to prevent water running back through the pump in case of failure of the driving machine i.e.-excessive backpressure. Discharge piping should be provided with a sluice valve to control the discharge, if required. The valve is used in primary, starting and when shutting down the pumps. If increaser is used on the discharge side to increase the size of discharge piping they should be placed between the check valve and pump.

2.12

VACCUM EQUALIZING LINE (AND LIQUID LINE) (SEE FIGURE 6) If the pump draws from system under vacuum a equalizing pipe min 25 NB must be carried from the highest point of the suction line, however, as close to the suction flange of the pump as, to the top of the feed tank to keep gas bubbles that might have been entrapped in the flow from entering the pump. The line should be fitted with an isolating valve, which should be closed only for maintenance work on the pump set. Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air and in the case of pumps with packed stuffing box It is convenient to tap the sealing liquid from the delivery line above the non-return valve.

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2.13

FOOT VALVE It is advisable to install a foot valve to facilitate priming of pump. Foot valve should have sufficient clear passage for water. Care must be taken to prevent foreign matter from being drawn into the pump or choking the foot valve and for this purpose an efficient strainer should be provided.

2.14

STUFFING BOXES AND PACKING Stuffing boxes should be carefully cleaned and the packing placed in them. Be sure that sufficient packing is placed at the back of the water seal cage. If the water to be pumped is dirty or gritty, sealing water should be piped to the stuffing boxes from clean outside source of supply in order to prevent damage to the packing and shaft. In placing the packing, each packing ring should be cut to the proper length & ends at 450 so that ends come into correct contact with one another but do not overlap. The following packing rings are then inserted into the packing compartment one by one making sure that the butt joint of each ring is offset by 900 approx. in relation to the butt joint of the preceding ring. The succeeding rings of packing should be placed in the Stuffing Box so that the joints of the several rings of packing are staggered and cutting the shaft. If the stuffing box is not properly packed, friction in stuffing box prevents turning the rotor by hand. On starting the pump, Stuffing Box Packing should be left slightly loose without causing an air leak, and if it seems to leak instead of putting too much pressure on the gland, put some heavy oil in the stuffing box until the pump works properly and then gradually tighten up the gland. The packing should be occasionally changed. Cutting of the packing rings to correct length & ends at 450 most important so that ends come into correct contact with one another.

MECHANICAL SEAL (MOSTLY APPLICABLE FOR SINGLE BALANCE SEAL) Since mechanical seals are made in a wide variety of designs, the instruction for the specific seal must be carefully studied and followed exactly. A Mechanical Seal is a precision device and must be treated accordingly. If any leakage is found, observe carefully whether it is found from:1) Between shaft & sleeve or 2) Between stuffing box flange and sleeve or 3) Between stuffing box and seal cover For clause no.1 PTFE gaskets & ‘O’ ring (Item no. 03 & 17) are to be replaced. For clause no.2 if adequate leakage from the sleeve surface is found then after inspection of the seal face damage, compression of the seal is to be increased. Unscrewing 4 nos.align screws for holding rotary part on the sleeve, you have to slide the seal rotary part towards the stationary part and tightening the 4 nos. align screw can do this. You have to keep the compression of the seal about 3 to 4 mm. If the leakage is little then it is normally through the `O’ Ring provided inside the rotary seal. The ring may be required to be replaced. For clause no.3 tighten the 4 nos. gland nut (No. 35), if any further leakage found then seal cover ‘O’ ring/gasket (No.13) is to be replaced. DOC NO.:VP-MM-VCP-03/0

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2.15

LUBRICATION Pump is usually provided with a special auto feed oil lubrication pot. Initially fill up oil at the driving head through the breather port. The oil pot provided at the side of driving head, is to be removed, during initial filling. When oil just comes out from the port then replace the oil pot and stop the oil filling through the breather part. Lift the oil pot as explained in the figure 7 and fill up oil at the pot. Release the pot and find that due to spring action pot will take its place. Oil level inside the pot will decrease automatically until the pre-determined required level is reached. The repetition of the process of oil pot filling is required if you find the pot empty. Never fill up oil through others part of oil pot, which may cause excess filling of lubricating oil. This will result in excess rise of temperature of the bearing. Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigrade above ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Explained with below figure. The Bearing Housing should be filled with oil of any one of the following types and specification : Indian Oil Hindustan Petroleum Bharat Petroleum

2.16

Servosystem 46 Enklo 46 Bharat Hydrol 68

BALL BEARING Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as guide to relubrication periods under normal conditions. Quarterly when on continuous duty. Half yearly when on eight-hour per day duty. The bearings and housings should be completely cleaned and recharged with fresh oil after 2500 hours or the nearest pump overhaul time.

2.17

PRIMING No pumping action occurs unless the pump casing is filled with liquid. Pump casing and suction pipe must therefore be completely filled with the liquid and thus all air removed before the pump is started. Several different priming methods can be used depending on the kind of installation and service involved. (1)

Liquid level above pump level. Pump is set below liquid level of source of supply so that liquid always flows to pump under positive head.

(2)

Priming with Foot Valve. (a) When pump is installed on suction lift with foot valve at the end of suction line, fill pump with water from some outside source till all air is expelled and water flows through air vent or filled up up to Delivery flange of Pump. (b) When there is liquid under some pressure in the discharge pipe, priming can be effected by bypassing the pressure liquid around the check and gate valve. Provide one stop cock at bypass line. Of course, the initial priming must be effected from some outside source. NOTE: In this case, the foot valve must be capable of withstanding pump pressure and possible surge.

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(3)

Priming by ejector: An ejector operated by steam, compressed air or water under pressure and connected to air vent on top of casing can be used to remove air from and prime the pump on suction lift installations.

(4)

Priming by dry vacuum pump: A hand or power pump sucks in all the air from the casing and the suction pipe, and thus primes the system

3.0

PREPARATION OF PUMP STARTING:

After the pump and the drive are mounted, the plant should be prepared for starting. rules should be observed before starting the pump:

The

following

The pins or pad should be inserted into the coupling or placement of spacer for spacer coupling not before making sure of the correct rotation of drive motor. In case of the drive rotating in the wrong direction, the connection of two cable conductors supplying the current to the motor should be interchange in case of DOL starting. Check presence of oil in bearings and correct location of water deflector on shafts that ensure flashing, quenching, and lubrication in case of mechanical seal as well as if required as per design. Gland packing should be tightly stuffed, but not over tightened. The sealing packing should be tightened to such an amount as to allow the pumping liquid to seek to the outside. Over tightening of sealing packing causes quick wear out of shaft sleeves, increases its friction and lowers the efficiency factor of the whole plant. Check the free rotation of pump rotor, turning it by hand to verify any major obstruction or friction with wearing parts. Check the proper order of suction and pressure pipelines, tightening of flanges, fittings of inlet valve and presence of drain plug. Check the correct direction of rotation of pump and drive. The pump rotor should rotate according to direction of rotation marked on pump. Getting reasonably sure of the proper order of the whole plan and its readiness for operation, the suction pipe should be primed with water / liquid. Arrangement for priming funnel and three ways connection of pressure gauge with air-cock after delivery flange but before delivery sluice valve is required. The pump is being filled up (Primed) until the air-cock produces water jet without air bubbles. Then the primary funnel, air-cock and sluice valve is required to be closed. After all these operation and checking, the pump is ready for starting. 4.0

STARTING AND STOPPING OF THE PUMP: The pump should be loaded gradually, when the drive is engaged. When the prime movers attain full speed, the regulating sluice valve should be smoothly opened. This will avoid overloading of the drive. On the other hand it should be kept in mind that a lengthy operation with completely close sliding valve is likewise to be avoided, since this causes unnecessary heating of the liquid in the pump.

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By controlling the sliding valve the required flow and head may be obtained. After setting of pressure gauge at required point, check ampere consumption. If found value exceeds required value, pump should be stopped 5.0

BEARING: Generally the pump is supplied with 2 nos. anti-friction ball bearings or angular contact ball bearing at DE and 1 no ball or self align roller bearing at NDE according to the load factor of pump. Bearings are of SKF/NBC/RHP/ equivalent make.

6.0

LUBRICANT: Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigrade above ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Level is maintain in bearing housing. Explained with below figure. The Bearing Housing should be filled with oil of any one of the following types and specification : Indian Oil Hindustan Petroleum Bharat Petroleum

Servosystem 46 Enklo 46 Bharat Hydrol 68

Procedure : Unscrew vent plug. Pour in oil through the vent plug aperture after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of the connection elbow of the constant level oiler (see figure below). Then fill the reservoir of the constant level oiler with oil and snap it back smartly into the operation position. Screw vent plug in again. After a short time has elapsed, check whether the oil level in the reservoir has sunk. The reservoir should always remain filled.

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7.0

STUFFING BOX: Stuffing Boxes are extra deep and suitable soft packing and/or for single balance mechanical seal. Mechanical seal must be over oiled before starting the pump after long time storage. Soft-packing stuffing boxes reduce the flow of leakage liquid at the clearance gap between casing and shaft protection sleeve when the pressure inside the pump is higher than atmospheric. Conversely, on pumps which operate on suction lift, the soft-packed stuffing box prevents the ingress of air into the pump.

8.0

GASKET Compressed asbestos packing gasket for joining of volute casing is used. However, packing gasket suitable to handle corrosive liquid and high temperature fluid is supplied against specific requirements.

9.0

COUPLING Normally star type spider coupling with spacer is used. Other type of coupling may be supplied against specific requirements.

10.0

GUIDE RING / WEARING RING Replaceable throat bush as guide ring and wearing ring for protection of both side of impeller provided at casing cover (optional) and Volute Casing of pumps.

11.0

SHAFT SLEEVES Replaceable sleeve for protecting the shaft and for Balance seal step sleeve is being provided. Sleeve is extended beyond seal cover or gland flange.

12.0

SPARE PARTS One set Anti-friction bearing, Wearing Ring, Shaft Sleeve, Gland Packing/ Mechanical seal, Sleeve gasket, Gasket for Impeller nut, Lantern ring, and Gasket & “O” ring set must always be kept with the actual users of the pump to ensure uninterrupted service from the pump.

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13.0

TROUBLE SHOOTING SL.NO. 1.

DEFECTS Pump does not deliver liquid.

CAUSES (1)Insufficient quantity of water/water not filled in pump casing (2) Incorrect direction of rotation. (3) Pump is clogged.

(4) Pump speed too low. (5) Suction Lift too high. (6) Leakage in Suction Pipe. (7) Incorrect layout of Suction Line. (8)Valve in Suction Line not open properly. (9) Shaft Sleeve & Gland packing worn and air leaks. (10) Delivery liquid too viscous.

2.

Flow not adequate.

(11) Incorrect selection of pump for operating condition. (1) Speed too low. (2) Leakage in Suction side fitting and piping (3) Discharge Head too high. Excessive high back pressure. (4) Pump Casing or Piping are not vented carefully. (5) Rubber Flap Valve clogged.

(6) Leakage through seal and air leaks. (7) More clearance between Impeller and Wearing Plate.

(8) Suction lift too high or suction pipe too long. (9) formation of air pocket (10) Supply line or Impeller passage obstruction

REMEDY (1) Fill up pump casing with clear water or liquid to be pumped. (2) Change the direction of rotation of prime mover. (3) Check up Impeller may clog. Clean Suction pipe and Strainer. (4) Check up speed of prime mover and adjust. (5) Reduce Suction Lift. (6) Prevent leakage in suction Pipe. (7) Correctly install the Suction Line. (8) Check up the opening of line valve. (9) Replace Shaft-Sleeve & Gland Packing. (10) Liquid viscosity to be checked & corrected. (11) Replace the pump with a suitable designed capacity. (1) Check up speed of prime mover and adjust. (2) Prevent leakage in suction pipe and fittings. (3) Check up vertical head obstruction of frictional losses. Adjust duty point. (4) Fill up the pump casing/ vented pressure pipe. (5) Check up rubber Flap assembly & leakage from pump casing. (6) Check Mechanical Seal unit and rectify/replace if required. (7) Measure the clearance between Impeller and Wearing Plate and adjust by using proper Packing. (8) Avoid High Suction lift and Suction piping. (9) After piping layout fit a vent valve (10) Remove deposit in piping and inside of Impeller DOC NO.:VP-MM-VCP-03/0

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SL. NO. 3.

DEFECTS

CAUSES

Pump takes more Power.

(1)Opening Voltage is too low. (2) Specific gravity of liquid is higher than specified. (3) Motor running on two phase (4) Speed too high. (5) Head/Back pressure less than rating. (6) Shaft Bent (7) Misalignment of the set. (1) Prime mover not running at rated speed. (2) Leakage through Gland Packing. (3) Too much clearance between Impeller and Wearing plate.

4.

Rated pressure not developed.

5.

Pump vibrates and makes more noise.

6.

Bearings have short life. Increase in Bearing Temperatu re

7.

Excessive pressure

(1) Pump casing not filled with Water/Liquid (it is only possible only during priming time). (2) Suction lift too high. (3) Mis- alignment (4) Foundation not rigid (5) Shaft bent (6) Bearing Worn out (7) Lack of Lubrication (8) Pump operating at very low capacity. (1) Misalignment (2) Shaft bend (3) Excessive Oil or lack of oil. (4) Dirty water getting into Bearings. (5) Pump is on vibration in the pipe line

(1)Speed is too high than rated RPM

REMEDY (1) Provide required voltage (2) Reduce speed if possible. (3) Rectify defective phase (4) Check and correct the speed. (5) Provide minimum head. Adjust duty point (6) Check and replace the Shaft. (7) Correct the alignment. (1) Check the speed of Prime mover and correct it. (2) Replace Gland Packing. (3) Measure the clearance between Impeller and Wearing plate and adjust by using proper packing. (1) Fill up the pump casing.

(2) Reduce the suction lift or install the Foot valve. (3) Correct the alignment. (4) Check up the foundation bolt. (5) Replace the shaft (6) Check & replace Bearing. (7) Lubricate the Bearings. (8) Reduce total head. (1) Correct the alignment. (2) Check the shaft condition. (3) Check up lubrication. (4) Protect bearing neatly. (5) Check pipe line & ensure proper fixing of pipe line. Reduce distance of piping support. Fix pipe line using anti vibration material. (1) Adjust speed to the rated RPM

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14.0

MAINTENANCE Preventative maintenance schedule are the periodical checks and precautions by which possibilities of failures and breakdowns are made very remote.

15.0

14.1

Daily Checks Pressure gauge reading Bearing temperature Leakage through stuffing box Noise and vibration Voltage and current Constant flow of cooling water.

14.2

Periodical Maintenance Replace the oil for bearing lubrication. Change of stuffing box packing. Check the alignment of the pump set. Calibrate the measuring instruments. Check the sealing and cooling connections etc.

OVERHAULING Normally the pump will be due for overhauling after about 3000 working hours. Pump dismantling and assembling should be done by skilled personal. Special attention should be given to continuous running pumps & advice is to keep stand by pump for emergency services.

15.1

DISMANTLING OF PUMP: (Refer cross section drawing with list of component.) 1. Remove Coupling Guard, Pressure Gauge, Oil Pot, Cooling Pipe, Flash Pipe and other fittings as applicable. Drain out pumping liquid by removing casing drain plug (Item.26) and drain out oil from Bearing Housing by removing plug (Item.42) 2. The Design advantage of this BPO pumps is, dismantling of pump can be done without disturbing the pipe line connected to suction or delivery flange. If spacer type coupling is provided than remove both side spacer bolt (Item.21) by unscrewing it and then remove the spacer of the coupling (Item. 24). Remove support foot (Item 45) by unscrewing the bolt (Item.46) and removing bolt & nut of base frame fixed with it the support leg. 3. Unscrew and remove the nut from the stud (Item 29) for casing and take out the Driving Head assemble with impeller and shaft along with bearing housing without disturbing the pump casing. Take assistance of forcing screw if provided for removal of Casing Cover from Casing(Item no.03). Special care may be taken during removal of casing cover to save the casing gasket. 4. To dismantle dynamic assembly, first unlock the lock washer (Item no.03) of impeller lock nut (if applicable) and remove impeller lock nut (Item 01) by unscrewing it. Remove lock washer (Optional). Now pull out the Impeller (Item 04) from shaft and take out the Impeller key (Item no.05). 5. In case of mechanical seal don’t disturb the gland nut (Item 35). After removal of impeller take out the guide ring/throat bush (Item no.08) unscrewing 4 numbers screw(Item 07). For gland packed pump remove gland flange (Item no.34) and then take out Stuffing Box Packing (Item 31) and Lantern Ring (Item 30) one by one after removal of Throat Bush for Mechanical Seal application, take out sleeve with mechanical seal rotating assembly from non-driving end. This is major advantage of our DOC NO.:VP-MM-VCP-03/0

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mechanical seal design that you can remove the rotating part of seal without disturbing the stuffing box. Remove key for sleeve (optional) before removal of the sleeve. 6. Remove Casing Cover (Item no.28) with stuffing Box (Item no.11) (along with gland flange for mechanical seal pump) from the driving head by removing the bolt (Item 33). In special case for few model casing cover and stuffing box are integrally casted. 7.

For mechanical seal pumps remove seal cover fitted with stationary parts of mechanical seal from stuffing box by unscrewing 4 Nos. gland nut (Item no.35). Take out the mating rings (stationary seal) from the seal cover along with seal secondary ‘O’ ring for inspection of stationary face & ‘O’ring condition.

8. Remove align screw (Item no.22) provided at coupling, take out pump coupling half & Key for coupling (Item no.23). 9. Remove both side baring cover (Item 39&53) by unscrewing bolt (Item no.38&49) provided for it. Remove both side oil seal (Item no.41&52) from bearing covers. 10. Carefully take out the pump shaft (Item no.20) together with bearings (item no.43) towards driving end. In few model NDE bearing provided self align cylindrical rotter type instead of ball bearing providing a cieclip inside NDE housing. Check the condition of NDE bearing housing circlip and replace it if required (Applicable for self align cylindrical bearing if provided at NDE.) Remove NDE roller case of cylindrical roller bearing from housing. 11. Unlock bearing lock washer (Item no.51) and remove bearing lock nut (Item no 50) by unscrewing it before removal of the bearing from the shaft. Pull out D.E. bearings (Item no 47) from the shaft and take out NDE bearing (Item no.43) or the inner race of the cylindrical roller bearing as applicable. 12. Check wearing ring provided at casing and casing cover (optional) (Item no. 02 & 06) and if required replaced it. Wearing ring may be provided with cod screw. Pull out the wearing rings after removing the cod screw if provided. 13. After removal of all above pump parts it is necessary to check up properly for any wear and tear and if any part is found to be worn out, the same should be replaced or rectified. Special care should be taken for check up of Wearing ring, Sleeve, Throat Bush, Mechanical Seal, Lantern Ring, Bearings Gasket & ‘O’ Ring. 15.2

Reassembling of Pump: 1. The pump should be reassembled in accordance with the rules of sound engineering practice. Before reassembling all parts are to be cleared and it is advised to paint all the parts which are without machined faces. Paints should be dry before reassembling. Bearings are to be cleaned with petrol. All machined faces should be rubbed with suitable Lubricant, Lubricant to be applied on screwed components also. 2. Reassembly proceeds in reverse sequence to dismantling. Fit driving end bearings (Item no.43) with the pump shaft (2 nos. Bearing to be fitted back to back if supplied with angular contact ball bearings as applicable) lock with lock washer clip after slipped on lock washer (Item no.50) and screwed on bearing lock nut (Item no.51) firmly fix up of lock washer. After tightening of bearing fold the lock washer peak to lock the nut . NDE ball bearing (Item no.43) or inner ring of self-align bearing for non-driving end is to be fitted with the shaft. For oil lubrication don’t apply any grease to the Bearings. If bearings are not replaced then provide few drops of oil at bearings. For NU series self align bearing only outer ring of N.D.E. roller bearing to be inserted at N.D.E. bearing housing after providing the circlip at inside bose of NDE housing.(Bearing & Inner ring may be preheated on oil DOC NO.:VP-MM-VCP-03/0

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bath

to

800C

before

fixing

at

shaft).

3. Insert the pump shaft with bearing assembly from driving end inside bearing housing keeping proper direction of shaft. Fixed up bearing at its position by a press fit. 4. Fix up bearing cover at driving end (Item no.53) and other bearing cover (Item no.39) at non-driving end. Don’t forget to replace Bearing Cover Gasket (Item no.40&48) and the Oil Seal inside Bearing Cover (Item no.41&52) before insert it. Put coupling key (Item no.23) at shaft, fit pump half coupling and tighten the coupling grub screw (Item no.21). 5. For balance mech. seal pump gland flange is to be fitted with stationary part (Item no.15) of the seal by hand press fit providing ‘O’ ring (Item no.14) for it. At first stuffing box(Item no.11) is to be fitted with Casing Cover (Item no.28). Then the gland flange (Item no.34) along with the stationary seal is to be fitted with stuffing box tightening the Gland Nut (Item no.35). Provide gasket /’O’ ring (Item no.13) before placement of seal cover. Also check for ‘O’ ring (item no.36) and if required replace it. 6. Now fixed up casing cover (Item no.28) with bearing housing (Item no.18) i.e. driving head-shaft assembly and tighten the stud-nut/bolt (Item no.33) as applicable. 7. Before mounting the seal on the sleeve measure the distance of seal face from setting face of throat bush and additional compression to be required at about 3 to 4mm. Sleeve may be provided with a separate key / lock screw (Item no.36) for locking it. Provide key if applicable after placement of the sleeve. Provide guide ring /Throat Bush (Item no.08) and tight 4nos screw (Item no.07) to fix up throat bush from NDE. 8. Put impeller key(Item no.05) to shaft and PTFE gasket(if applicable) between sleeve and impeller and fix up the impeller on the shaft. Tighten the impeller lock nut. Provide a lock washer (if applicable) between impeller and nut and lock the nut by lock it by folding the tooth of washer after full tight. 9. Now the assembly is ready to fit with volute casing providing one recommended ring gasket(Item no.27). Fit all oil pot, seal flash pipe, pressure gauge and other fittings applicable. This completes the reassembling. 10. While ordering the spares please inform us your pump sl. No. along with item no. and Cross Section drg. no. Recommended Stock of Spare Parts for two years of Operation Number of Pumps (including standby pumps) Item No. Designation 2 3 4 5 6 8 10 and more Quantity of spares parts 42 Pump Shaft 1 1 2 2 2 3 30% 01 Impeller 1 1 1 2 2 3 30% 37 Bearing (DE) 1 1 2 2 3 4 50% 34 Bearing (NDE) 1 1 2 2 3 4 50% 12 Guide Ring 1 1 2 2 2 3 30% 19 Stuffing Box Packing/Mechanical 2 2 3 3 3 4 40% Seal 06 Wearing Ring 2 2 3 3 3 4 50% 08 Wearing Ring 2 2 3 3 3 4 50% 14 Shaft Sleeve 2 2 3 3 3 4 50% 09 Casing Gasket 4 6 8 8 9 12 150% 11,13,16,26,29 Other secondary seal like ‘O’ Ring 4 6 8 8 9 12 150% DOC NO.:VP-MM-VCP-03/0

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DOC NO.:VP-MM-VCP-03/0

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DOC NO.:VP-MM-VCP-03/0