MSS MULTI-STAGE SEAWATER HIGH PRESSURE PUMPS

Transcription

1 INSTALLATION & OPERATION MANUAL English Version MSS MULTI-STAGE SEAWATER HIGH PRESSURE PUMPS Models: MSS-15 MSS-20 MSS-30 MSS-40 MSS-50 MSS-55 MSS-55 MSS-70 MSS-75 MSS-90 MSS-120 MSS-160 MSS-200 MSS ONE COPY OF THIS MANUAL MUST REMAIN WITH THE EQUIPMENT AT ALL TIMES MSS Installation Operation Manual, XXXXXX-0

2 MSS TM Series ISO 9001 and ISO 14001: FEDCO Certifications FEDCO has adopted the ISO 9001 standard to define and develop our Quality Management System (QMS.) The QMS allows FEDCO to better serve our customers needs through continuous improvement of the quality, delivery, and efficiency of our products. 3 FEDCO achieved ISO 9001 registration in September FEDCO has adopted the ISO standard to define and develop our Environmental Management System (EMS) to better protect our environment. 3 FEDCO achieved ISO registration in September ISO ISO 14001: :2015 REGISTERED REGISTERED CE Stamp: CE marking confirms that specific products are in compliance with European Union requirements. This allows FEDCO s product lines to be sold throughout the European Economic Area. Most FEDCO products can be provided with the CE mark. Compliant Test Systems: Performance acceptance testing of FEDCO pumps and energy recovery devices are measured using procedures and instrumentation tested by a third party NSF auditing company to be in accordance to the Hydraulic Institute s H.I standards for centrifugal pump testing and data recording

3 MSSTM Series Commitment to Quality & Success Fluid Equipment Development Company (FEDCO) was founded in 1997 to develop new fluid machinery to reduce the cost of reverse osmosis desalination. The results included patented concepts, highly integrated design, superior production software, and sophisticated manufacturing processes. Our efforts culminated in multiple lines of energy recovery turbines and pumps uniquely suited for seawater and brackish RO desalination. We are the developers of the HP-HEMI ERD and control system for mega-scale SWRO systems, as well as the world s first low-cost integrated pump-erd for brackish water RO. Additionally, our Monroe facility operates the largest pump and ERD test system dedicated to SWRO systems in the world. Our teams of talented and energetic engineers, manufacturing specialists and systems experts have created a fully integrated enterprise with one aim to provide our customers with customized fluid machines with exceptional efficiency and low capital cost coupled with customer service that exceeds their expectations. The results include new designs, technology, manufacturing processes, and standards. Our pumps and ERDs use bearings that are lubricated by feed or brine to eliminate the numerous maintenance and logistics issues associated with oil or grease lubricated bearing systems. We offer three materials of construction: Duplex SS, Super Duplex SS and 316 SS. FEDCO pumps only cover flows and pressures found in BWRO and seawater SWRO applications. They are designed for clean fluids and are optimized for typical suction pressures in RO systems. Our ERDs include variable area nozzles that meet typical brine pressure variations. Our products eliminate external tubing carrying high pressure feed or brine that can fail creating hazards to personnel and equipment. Our units are designed for operation and maintenance by unskilled personnel in the harshest of desert or marine environments. With the longest warranty and the highest efficiencies, our product lines are unmatched in quality and performance by any manufacturer in the RO equipment market. FEDCO is a widely recognized supplier with thousands of units installed around the world. We design fluid machines to take full advantage of the technical characteristics of the membrane process. FEDCO USA FEDCO 800 Ternes Drive Monroe, MI 48162, USA Telephone: +1 (734) Fax: sales@fedco-usa.com FEDCO UAE Office 1910 Concord Tower P.O. Box Media City Dubai, United Arab Emirates Telephone: +971 (0) Fax: +971 (0) sales@fedco-usa.com Eli Oklejas - FEDCO CEO FEDCO SINGAPORE (No Office Address) Telephone: +(65) sales@fedco-usa.com For patent coverage visit patent.fedco-usa.com -3-

4 Table Of Contents MSS TM Series Unpacking/ Inspection/ and Storage...5 MSS External Components... 5 Inspection of Unit Upon Receipt... 5 Pump Storage Requirements... 6 Motor Storage Requirements... 6 Pre-Installation... 6 Theory and Operation...7 Technical Description... 7 MSS Pump Internal Components... 8 Installation Procedures...9 Warnings and Safety Precautions... 9 User Health and Safety In the Work Area Electrical Connections and Regulations Variable Frequency Drive (VFD) Requirements Motor and Pump Installation Requirements.11 Lifting and Handling Pump Assembly Lifting Motor and Pump Assembly Lifting Optional Baseplate Installation Foundation Specifications Pump Assembly...16 Motor Installation Initial Pump Alignment Final Pump Alignment Pump Piping Connections Optional High Pressure Seal Carrier Optional Shaft Position Sensor Recommended Instrumentation and Operation Upstream Filtration...35 Preparation For Pump Start Up...35 Start Up Precautions Start Up Check List Pump Start Up...35 Basic Troubleshooting...36 Visual Inspection Basic Troubleshooting Chart...37 Specifications...38 Recommended Spare Parts List Service Parts Kits Fastener Torque Specifications Pump Alignment Specifications Balance Disc Specifications Lubricants and Compounds Maintenance Schedule Service Policy...45 Return Material Authorization (RMA) Procedure Start-Up Record Overhaul Record Warranty Registration Form...48 MSS Unit Operating Conditions...49 Notes

5 MSS TM Series Unpacking/ Inspection/ and Storage MSS External Components Inspection of Unit Upon Receipt Review the contents of the packing list to make sure all components have been included. Inspect all components for signs of damage which may have occurred during shipping. If damage is present or if the contents are incomplete, please contact your shipping company or a FEDCO representative before proceeding Figure 1 - Pump Assembly External Components Item Description Item Description 1 Precision leveling foot 14 Series shell (if equipped) 2 Shell support bracket 15 Series shell O-ring (if equipped) 3 Inlet housing bolts 16 Shell flange bolts 4 Inlet housing O-ring 17 End shell 5 Inlet housing 18 Discharge housing O-ring 6 High pressure seal carrier O-ring (if equipped) 19 Discharge housing 7 High pressure seal carrier (if equipped) 20 Discharge housing retaining ring 8 Shipping plug 21 Retaining clips 9 Coupling guard screws (part of coupling guard) 22 Retaining clip cap screws 10 Coupling guard 23 Lock washer 11 Motor adapter 24 Throttle nipple 12 Motor adapter bolts 25 Throttle nipple O-ring 13 Flexible coupling 26 Bearing drain line - 5 -

6 Unpacking/ Inspection/ and Storage Continued MSS TM Series Pump Storage Requirements The MSS unit must be protected from moisture, sand, grit, and other foreign matter. Do not remove the protective covers from the pipe connections until ready to install. For long-term storage, keep pump and all other components in its original crate away from moisture, sand or dust. Long-Term Storage (>6 Months) Checklist 1. Check caps to ensure they have not been damaged or allowed debris inside the unit. Check for debris (wood, slag, sand or any dirt) and clean up with a clean, wet rag if minor. 2. Shaft Check: Turn manually and check for ease of turning or rubbing. Check for axial movement. 3. Seal Check: Prime MSS with clean water and allow the O-rings to soak for 1 hr before start-up. Check for leaks. Motor Storage Requirements Specific conditions are required for proper motor care and storage. Refer to the motor manufacturers instructions for specific steps and instructions. Pre-Installation All necessary installation accessories will be included with the pump. 4 to 6 Motor mounting bolts with washers and nuts (if motor and baseplate is provided by FEDCO) 4 to 8 Motor adapter bolts with washers Feeler Guages 2 Alignment Pins (Supplied unless motor is metric) Flexible coupling 2 Flexible coupling set screws ANTI-SEIZE Pump shaft key Anit-seize compound Motor shaft key (if motor is provided by FEDCO) Figure 2 - Installation Accessories - 6 -

7 MSS TM Series Theory and Operation Technical Description Multi-stage seawater (MSS) pumps are centrifugal feed pumps specifically designed for seawater reverse osmosis (SWRO) service. MSS pumps develop pressure by using a series of impellers mounted on a rotating shaft. Rotating this fluid through centrifugal force develops a pressure higher than the input pressure. Pressure can be increased through the addition of impeller stages or by increasing shaft rpm. Motors are selected according to equipment operating requirements. A flexible coupling allows the pump shaft to float within the coupling eliminating thrust against the motor. The inlet and discharge housing is designed to connect to grooved rigid piping with couplings. The inlet housing itself can be attached to the pump in four different positions 90 apart. A precision leveling foot supports the end shell housing and is fully adjustable to allow accurate pump to motor shaft alignment Item Description Item Description 1 Motor 7 Throttle nipple 2 Motor adapter 8 Discharge housing 3 Flexible coupling (inside of motor adapter) 9 Top cradle 4 Support bracket 10 End shell housing 5 Bearing drain line 11 Series Shell housing (if equipped) 6 Precision leveling foot 12 Inlet housing Figure 3 - MSS Pump External Components - 7 -

8 Theory and Operation Continued MSS TM Series MSS Pump Internal Components The internal components of an MSS pump can vary depending on pump configuration and number of stages. The basic components contained in a single stage consist of an impeller and a diffuser with a spacer and bushing which prevent friction and wear. Behind the discharge housing at the end of the pump is the WATER BEARING assembly. The balance disc rides in the bearing carrier and serves as a thrust bearing for the pump. This unique design uses patented WATER BEARING technology which allows feed water to cool and lubricate the balance disc. As the motor rotates the pump, pressure differences acting on the rotating impellers generate an axial thrust acting toward the motor. The water bearing employs the balance disc to create a counter-pressure which exactly cancels the impeller thrust load. The bearing drain line and throttle nipple are used help produce the counter-pressure on the balance disc. This thrust and counter-thrust allows the disc to self-balance based on operating conditions. WATER BEARING ASSEMBLY SINGLE STAGE INLET PRESSURE DISCHARGE PRESSURE Figure 4 - MSS Pump Internal Flow - 8 -

9 MSS TM Series Installation Procedures Warnings and Safety Precautions Safety practices and precautions for the operation and maintenance of all FEDCO pump products MUST BE FOLLOWED. This information supplements oral or written instructions that may be received. Safety MUST be practiced as part of the standard operating procedures for this equipment during any installation and operation. To ensure that safe operating and maintenance procedures are followed, operators should develop and keep up a program of safety checks and current instructions. This manual contains certain operating and maintenance procedures that involve exposure to potentially hazardous situations. The levels of hazardous situations are as follows: DANGER Hazards which are IMMEDIATELY ACCESSIBLE, and capable of causing SEVERE PERSONAL INJURY OR DEATH. WARNING Hazards which are NOT IMMEDIATELY ACCESSIBLE, but are capable of causing SEVERE PERSONAL INJURY OR DEATH. CAUTION Hazards which are NOT IMMEDIATELY ACCESSIBLE, and can cause PERSONAL INJURY. ELECTRICAL HAZARD Hazards which are related to Electrical Components and can RESULT IN ELECTRICAL RISKS, SHOCK, ELECTROCUTION OR DEATH if instructions are not followed properly. PUNCTURE HAZARD Hazards which are NOT IMMEDIATELY ACCESSIBLE and can RESULT IN SEVERE PERSONAL INJURY OR DEATH if instructions are not followed properly

10 Installation Procedures Continued WARNING All pump and safety precautions must be followed to prevent physical injury to the operator. It is illegal to operate the equipment in an EU member state if the manual(s) is not written in that states language. Contact FEDCO if a translated copy is needed. CAUTION A pump is a pressure-generating device with rotating parts that can be hazardous. Any device containing generated pressure can rupture, explode or discharge its contents if it is over-pressurized and may possibly result in personal injury, property damage, environmental damage and death. All necessary precautions must be exercised to insure over-pressurization does not occur. FEDCO will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual. WARNING Installation, operation or maintenance of the pump unit in any manner which is not covered in this manual could cause damage to the equipment, serious injury or death. This includes any modification to the equipment or the use of parts not provided by FEDCO. If there is a question regarding the intended use of the equipment, please contact a FEDCO representative before proceeding. CAUTION This manual clearly identifies accepted methods for safe disassembly and assembly. These methods must be strictly adhered to. WARNING Do not use the pump equipment for a different application than originally specified without the approval of a FEDCO representative. WARNING NEVER operate the pump equipment: below the minimum flow rate. when dry. without priming. without proper guards and safety devices installed. with the discharge valve closed. with the suction valve closed. WARNING MSS TM Series FEDCO pumps are intended to pump saltwater and brine to membranes for the reverse osmosis desalination process. FEDCO pumps are not intended to pump flammable or hazardous liquids. Solutions intended for human consumption need proper purification per product. FEDCO approval will be needed to control slurry and particle size for this specific product ELECTRICAL HAZARD Always follow the Lock-out / Tag-out procedure developed by your company before starting any maintenance or repair. Figure 5 - Typical Lock-Out Tag-Out Tag User Health and Safety Safety equipment and PPE (Personal Protection Equipment) should be used in accordance with company regulations. In the Work Area Always keep the work area clean and dry. Avoid all electrical dangers. Be aware of risks from electric shock or arc flash hazards. Utilize adequate lifting equipment and methods. Electrical Connections and Regulations Refer to the motor nameplate for specific electrical operating information. Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations and codes. Insure the product is isolated from the power supply and cannot be accidentally energized. Make sure all thermal contacts are connected to a protection circuit according to product specifications. All electrical equipment must be properly grounded. During installation, service and repair, the companies Lock out / Tag out Procedure must be followed

11 MSS TM Series Installation Procedures Continued CAT. NO. SPEC. HP VOLTS AMPS R.P.M. FRAME SER. F. GIANT INDUSTRIAL MOTOR VM A13T / / C HZ 60 PH CODE K DES B CLASS F Variable Frequency Drive (VFD) Requirements A VFD must be used to optimize the system to the best efficiency point (BEP) of the RO system. The VFD must be configured to match the motor nameplate information. The VFD does not come pre-programed. Please contact the equipment supplier if the VFD programming manual is not available. IN CE compliant countries the VFD must have a line filter which must be installed in the same metallic enclosure as the drive. NEMA NOM. EFF % P.F. 89 % RATING CC 40C AMB-CONT USABLE AT 208V 8.1 A BEARINGS DE 6205 ODE 6203 ENCL. TEFC SN FO MFG. BY BALFOR ELECTRIC CO. U.S.A NP1256L Figure 6 - Typical Motor Nameplate Motor Requirements AC SINE WAVE POWER VFD VARIABLE FREQUENCY POWER ELECTRICAL HAZARD Wiring of the motor shall be completed in conformance with all local electrical codes. All EU countries must follow EN If a variable frequency drive (VFD) is provided with the motor, it is recommended that shielded cables are used between the VFD and the motor. The shield must be connected at both ends. 3-PHASE MOTOR PIGTAILS GROUNDING LUG OPERATOR CONTROLS Figure 8 - Basic VFD Configuration Motor and Pump Installation Requirements A rigid mounting surface is required for pumpmotor assemblies in order to prolong the life of critical components. Mounting surfaces constructed of wood or other non-rigid materials are NOT acceptable as they may deflect during pump operation and cause shaft misalignment. All anchoring fasteners used should meet or exceed manufacturers specifications. All assemblies must be mounted on one of three types of substrates: concrete foundation. optional baseplate. container with a suitable steel substructure. Figure 7 - Typical Motor Electrical Connections

12 Installation Procedures Continued MSS TM Series Lifting and Handling CAUTION Observe all lifting precautions. Failure to follow all lifting and handling precautions may result in serious injury! Unit weight is listed on the unit nameplate. Determine the weight of the unit to select an appropriate lifting method. If the weight of the pump exceeds manual lifting limits, mechanical lifting equipment must be used. MSS pumps can be lifted by the shell using approved lifting straps together with suitable lifting equipment. The straps must be installed around the shell without disturbing the drain line. If straps are placed around the drain line, damage can occur. Pump Assembly Lifting NO Figure 9 - Improper Lifting Strap Positioning YES Figure 10 - Proper Lifting Strap Positioning

13 MSS TM Series Installation Procedures Continued CAUTION Whenever possible, all components should be lifted and moved separately for safety. Do not lift the pump up by the shaft. If the unit is lifted by the shaft, damage may occur. Lifting and handling of the motor must be performed according manufacturers instructions. Do not lift the pump and motor by the motor eyebolt. The eyebolt is used for lifting the motor only. Motor and Pump Assembly Lifting NO NO Figure 11 - Improper Motor and Pump Lifting Points Figure 12 - Proper Motor and Pump Lifting YES

14 Installation Procedures Continued MSS TM Series Optional Baseplate Installation Some units include an optional FEDCO baseplate which provides good mounting surfaces for the motor and pump. It also increases accuracy during the alignment process. Although the baseplate is precisely manufactured, it requires a solid foundation such as a concrete pad or rigid steel substructure. If the optional baseplate is used, it must be installed first to avoid distortion which may occur due to uneven floors or substructure. If the pump is installed within a container, it must be mounted on a rigid steel substructure that will not distort under the weight of the equipment or from torque reaction forces during pump operation Item Description Item Description 1 Motor mounting (4 to 6 depending on motor) 3 Precision leveling foot mounting 2 Support bracket mounting 4 Baseplate mounting feet Figure 13 - Optional Baseplate

15 MSS TM Series Installation Procedures Continued Foundation Specifications A concrete foundation is recommended for all MSS pump installations. Concrete provides good support and good vibration absorption. The foundation should have a mass that is 50% more than the total weight of the equipment and its perimeter should extend at least 6 inches (15 cm) on each side from the pump and motor. Make sure the concrete is completely dry and level before installing any machinery. Make sure anchor bolts and shims are properly sized and installed in cases of uneven surfaces. Figure 14 - Proper Shimming Uneven

16 Pump Assembly Motor Installation 1. Clean motor flange face with a clean cloth to remove any foreign matter, rust or protective coating and place motor in its mounting position. MSS TM Series Figure 15 - Placing Motor In Mounting Position Bolts 2. Install motor mounting bolts and shims as necessary. Tighten to motor manufacturers specifications. NOTES: Make sure to install shims where necessary to prevent motor frame distortion resulting from soft-foot. Soft-foot is a condition were one of the motor frame feet are not in flat contact with the mounting base. If not properly shimmed when the bolt is tightened, the motor frame will distort. SOFT-FOOT NO PROPERLY SHIMMED YES Figure 16 - Installing Motor Mounting Shims and Bolts

17 MSS TM Series Pump Assembly Continued Motor Rotational Direction Check 3. Prior to pump installation energize motor to determine direction of rotation. The correct rotation is indicated by arrows on pump motor adapter. If rotation is incorrect, reverse polarity of motor wiring to change direction of rotation. NOTES: Reversing polarity of VFD power input wires will not change motor rotational direction. Figure 17 - Directional Arrows On Motor Adapter 4. If motor rotational direction is correct, disconnect power to motor according to lockout/tag-out procedures and complete all electrical connections according to local codes and regulations. 5. Loosen screws and remove coupling guards. This allows better access to view the coupling alignment. Figure 18 - Removing Coupling Guards Flexible Coupling Check 6. Slide flexible coupling over motor shaft with motor shaft key. NOTES: If motor shaft key does not fit properly in the coupling keyway, lightly file motor shaft key until a proper fit is obtained. Figure 19 - Installing Flexible Coupling On Motor Shaft

18 Pump Assembly Continued 7. Inspect flexible coupling radial and axial fit. It should be tight with no visible radial movement and slide smoothly on and off the motor shaft. NO MOVEMENT NO MOVEMENT MSS TM Series NO MOVEMENT NO MOVEMENT SMOOTH MOVEMENT Figure 20 - Checking Flexible Coupling Fit On Motor Shaft 8. Slide flexible coupling over the pump shaft with pump shaft key. NOTES: The rounded end of the key must be placed in the rounded end of the keyway. Figure 21 - Installing Flexible Coupling On Pump Shaft

19 MSS TM Series LITTLE OR NO MOVEMENT LITTLE OR NO MOVEMENT LITTLE OR NO MOVEMENT Pump Assembly Continued 9. Inspect flexible coupling radial and axial fit. It should have little or no movement and slightly looser than the motor shaft fit. It should also slide smoothly on and off the pump shaft. LITTLE OR NO MOVEMENT SMOOTH MOVEMENT 10. Once proper flexible coupling fit on both shafts has been obtained, remove the flexible coupling and proceed with Initial Pump Alignment. NOTES: Flexible coupling will not be needed until Final Pump Alignment procedure. Figure 22 - Checking Flexible Coupling Fit On Pump Shaft

20 Pump Assembly Continued MSS TM Series Item Description 1 Top cradle 2 Bottom cradle 3 Threaded rod 4 Jam nut 5 Top nut 6 Threaded rod nut 7 Adjustment nut 8 Jam nut 9 Leveling foot frame Initial Pump Alignment 1. Remove nuts and top cradle from precision leveling foot. Figure 23 - Precision Leveling Foot Components Figure 24 - Removing Top Cradle 2. Install alignment pins 180 apart into motor face. NOTES: These are supplied unless motor is metric. 180 APART Figure 25 - Alignment Pin Installation

21 MSS TM Series Pump Assembly Continued 3. Carefully slide pump onto alignment pins and as close to the motor face as possible. NOTES: Depending on the motor manufacturer, a small gap may or may not be visible between the motor face and the pump adapter. Figure 26 - Positioning Pump Onto Alignment Pins FEELER GUAGE 4. If a gap exists between the motor adapter and motor, use feeler gauges (provided) to measure the gap at 4 different points 90 apart. NOTES: In some instances, there may be no gap between the motor and motor adapter. MOTOR ADAPTER MOTOR FLANGE FACE Figure 27 - Motor Adapter Gap Measurement Points

22 Pump Assembly Continued 5. Align pump by adjusting the precision leveling foot: A. ADJUST TOP AND BOTTOM GAP - by rotating the adjustment nuts. A MSS TM Series A B. ADJUST RIGHT SIDE AND LEFT SIDE GAP - by loosening the precision leveling foot mounting bolts and moving precision leveling foot side to side. B B Figure 28 - Precision Leveling Foot Adjustment 6. Measure the motor adapter top and bottom gaps (A&B) and continue adjustment procedures until the gap (if any) between the motor adapter and the motor is equal. NOTES: This step is critical in properly aligning the pump with the motor. All measurements must be the equal to ensure proper pump-tomotor shaft alignment. NO A B A NOTES: Acceptable motor adapter gap tolerance specified in the Pump Alignment Specifications section of this manual. NOTES: Record the A & B measured alignment gap if existent in the Start Up Record section of this manual. B A YES A=B B Figure 29 - Proper Top and Bottom Gap

23 MSS TM Series C NO C D D Pump Assembly Continued 7. Measure motor adapter gap and continue adjustment until the gap between the motor adapter and the motor is the same on both sides (C&D). NOTES: Acceptable motor adapter gap tolerance specified in the Pump Alignment Specifications section of this manual. NOTES: Record the C & D measured alignment gap if existent in the Start Up Record section of this manual. C D YES C=D Figure 30 - Proper Side-to-Side Gap 8. Secure the precision leveling foot to foundation with bolts, washers and tighten to values specified in the Fastener Torque Specifications section of this manual. NOTES: Do not secure the support brackets at this time. Figure 31 - Securing Precision Leveling Foot

24 Pump Assembly Continued 9. Carefully slide pump away from the motor and proceed to the Final Pump Alignment procedure. NOTES: Make sure pump is well supported and slide pump far enough to provide sufficient room to install flexible coupling. MSS TM Series 30.5 cm (12 inches) Figure 32 - Separating Pump From Motor Final Pump Alignment 1. Apply system compliant anti-seize compound on motor shaft and install motor shaft key in shaft keyway. APPLY SYSTEM COMPLIANT ANTI-SEIZE COMPOUND Figure 33 - Installing Motor Shaft Key 2. Position pump motor adapter against motor and verify gap between pump shaft and motor shaft. Gap should be 1/8 of an inch. 3. Separate pump from motor and proceed with next step. 1/8 Figure 34 - Verify Gap

25 MSS TM Series Pump Assembly Continued 4. Slide the flexible coupling onto the motor shaft until the end of the motor shaft is flush with the end of the motor half of the flexible coupling. NOTES: The motor shaft and its key should NOT be touching the plates of the flexible coupling disc pack. Ensure that the motor shaft key does not slide out of place or project past the end of the motor shaft. Figure 35 - Positioning Flexible Coupling On Motor Shaft 5. Install set screws and tighten to torque spec specified in the Fastener Torque Specifications section of this manual. NOTES: Set screws are only on the motor side of the flexible coupling. No set screws should be installed on the pump shaft side of the coupling. Figure 36 - Flexible Coupling Set Screw Locations APPLY SYSTEM COMPLIANT ANTI-SEIZE COMPOUND 6. Apply system compliant anti-seize compound on pump shaft and install pump shaft key. NOTES: The rounded end of the key must be placed in the rounded end of the keyway. Figure 37 - Pump Shaft Key Installation

26 Pump Assembly Continued 7. Rotate both shafts until the pump shaft key and the flexible coupling keyway are on top and aligned. MSS TM Series Figure 38 - Aligning Pump Shaft Keyway 8. Carefully slide pump against motor making sure the pump shaft key slides smoothly into the flexible coupling. Push pump by hand until motor adapter and motor are in contact. NOTES: Make sure pump shaft key does not jam or fall out during installation. Figure 39 - Position Pump For Final Alignment 9. Using feeler gauges, re-measure any gap between the motor adapter and motor at 4 different points 90 apart around the motor adapter. FEELER GUAGE NOTES: In some instances, there may be no gap between the motor and motor adapter. NOTES: These values should be identical with the A, B, C, & D values found in the Start Up Record section of this manual. Figure 40 - Motor Adapter Gap Measurement Points

27 MSS TM Series A B B A Pump Assembly Continued 10. If uneven gaps exist, adjust the precision leveling foot as necessary until any gaps between motor and motor adapter are all the same. The gap variation should not exceed the limits specified in the Pump Alignment Specifications section of this manual. Figure 41 - Precision Leveling Foot Adjustment Install motor adapter bolts and washers. Tighten to torque spec specified in the Fastener Torque Specifications section of this manual. NOTES: Tighten the motor adapter bolts in the sequence shown to minimize stress. NOTES: Pump removed for clarity Figure 42 - Motor Adapter Torque Sequence 12. Install top cradle back to precision leveling foot. Tighten to torque spec specified in the Fastener Torque Specifications section of this manual. Figure 43 - Installing Top Cradle

28 Pump Assembly Continued 13. Install support bracket anchor bolts and washers. Tighten to torque spec specified in the Fastener Torque Specifications section of this manual (to specification for the size bolts used). MSS TM Series Figure 44 - Pump Support Bracket Anchor Bolts 14. Adjust support bracket height and tighten adjustment bolts to torque spec specified in the Fastener Torque Specifications section of this manual. Figure 45 - Pump Support Bracket Adjustment Bolts 15. Install coupling guards and tighten screws. Figure 46 - Coupling Guard Installation

29 MSS TM Series Pump Assembly Continued Pump Piping Connections Minimizing Excessive Loads/ Pipe Stress Do not use the pump as an anchorage point for the piping. Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains. Piping Alignment Accurate alignment and support of all piping connected to the pump is critical. Any movement occurring at the inlet or discharge connections may cause misalignment and stress over time. Do not force any misaligned pipes to connect to the pump discharge or inlet. Pipe Coupling Connections Follow all manufacturer installation and torque specifications. Align all piping carefully before installing couplings. Make sure all seals seat correctly inside the coupling. If piping or seals are not aligned correctly, leaking may occur under pressure. Provide for expansion or contraction of piping. Always consider best setting for pipe end gaps for handling angular deflection and combinations of expansion and contraction. Separation and deflection recommendations are specified on the following page. FULLY APART Expansion Only FULLY BUTTED Contraction Only YES NO Figure 47 - Proper Piping Alignment PARTIALLY GAPPED Expansion and Contraction Figure 49 - Pipe End Separation GROOVED COUPLING COUPLING SEAL Θ Θ Figure 48 - Typical Grooved Coupling Figure 50 - Angular Deflections

30 Pump Assembly Continued Standard Flexible Pipe Couplings MSS TM Series Nominal inches ¾ 1 1½ Size Actual OD inches [mm] [26.7] [33.4] [48.3] [60.3] [88.9] [114.3] [168.3] [219.1] [273.0] [323.9] Pipe End Separation Allowable inches [mm] [0 0.8] [0 0.8] [0 0.8] [0 0.8] [0 0.8] [0 2.5] [0 2.5] [0 2.5] [0 2.5] [0 2.5] Per Cplg. degrees 3º 24 2º 43 1º 56 1º 31 1º 2 1º 36 1º 5 0º 50 0º 40 0º 34 Deflection Pipe in/ ft mm/ m 0.36 [30] 0.29 [24] 0.20 [17] 0.16 [13] 0.11 [9] 0.26 [21] 0.17 [14] 0.14 [11] 0.11 [9] 0.09 [7] Figure 51 - Flexible Pipe Coupling Dimensional Chart NOTES: Allowable pipe end separation and deflection figures show the maximum nominal range of movement available at each joint for standard roll grooved pipe. Figures for standard cut grooved pipe may be doubled. These figures are for design and installation purposes. All pump connections are standard cut grove - style 77. Figures and graphics are based on FEDCO s recommendations only. Follow all manufacturer installation recommendations and instructions

31 MSS TM Series Pump Assembly Continued Flanged Connections Flange faces should be parallel 1/16 inch per foot diameter. Flange bolt holes should be aligned with a maximum offset of 1/8 Flange faces must be no more than a maximum of.5 degrees from each other. Take appropriate measures to compensate thermal expansion of the piping. Measure and record the flange gaps in the Start-Up Records section of this manual. Flanges Pipe Size (in.) Allowable Gap (in.) ½ ¾ ½ Figure 52 - Pipe Flange Fitting Allowable Gap YES NO NO Figure 53 - Proper Piping Alignment

32 Pump Assembly Continued MSS TM Series Inlet Piping Keep the inlet pipe free of high points which could trap air and could disrupt pump priming. Vacuum and/or pressure gages are recommended to allow measurement of pump inlet pressure. NEVER throttle the pump on the inlet side. Outlet Piping The pump discharge piping should have a removable section of pipe such as a spool piece or elbow to allow the pump to slide forward for service. Servicing the shaft seal, water bearing or flexible coupling requires a space of approximately 30.5 cm (12 inches) minimum. The pump assembly must be free to move away from the motor in order to gain access to these components. OUTLET PIPING DISCHARGE HOUSING REMOVABLE SECTION FOR PUMP SERVICE OR 30.5 cm (12 in) MINIMUM Figure 54 - Removable Section For Pump Service

33 MSS TM Series Pump Assembly Continued Optional High Pressure Seal Carrier If equipped with an optional high pressure seal carrier, a vent line from the HPSC should be vented to the atmosphere and positioned to drain normally or connected to a low pressure manifold behind the first high pressure pump in the train. WARNING Under no circumstances should the vent line be plugged. A plugged vent line will result in insufficient water lubrication of the seal and balance disc causing internal damage to the unit. HIGH PRESSURE SEAL CARRIER VENT LINE TO ATMOSPHERE OR MAXIMUM PRESSURE OF 100 psig BEARING DRAIN LINE Figure 55 - High Pressure Seal Carrier Venting Optional Shaft Position Sensor The purpose of the shaft position sensor is to identify potential pump wear or failure before serious damage can occur. The shaft position sensor is positioned directly above the position collar. If for any reason the shaft moves toward the motor, the collar moves out of range of the sensor shutting down the pump. SHAFT POSITION SENSOR ADJUSTMENT LOCKNUT SPACER Figure 56 - Shaft Position Sensor

34 Pump Assembly Continued MSS TM Series Recommended Instrumentation and Operation For safe pump operation, a pressure switch or relief valve is recommended for the high pressure side (before the membranes). Pressure gauges should be installed at the inlet and outlet of the MSS pump. If a throttle valve is used, an additional gauge is needed on the output side of the valve. It is recommended that a pressure switch should be installed at the pump inlet to prevent pump operation if the feed pressure to the pump is below specifications. MSS pumps are not equipped with a check valve to prevent back flow. Refer to the pump yellow tag and pump nameplate for equipment specifications. PUMP INLET PG 2 PG 3 PS 2 PG 1 PS 1 MSS PUMP P THROTTLE VALVE (IF USED) MEMBRANE Figure 57 - Recommended Instrumentation MSS-XXXX S/N XXXX Version 1.0 Duty Point Feed Flow XXX gpm Inlet Pres XXX psi Disc. Pres XXX psi Feed SG (calc) XXXX RPM XXXX NPSHR XXXX (copy tag information here) YELLOW TAG FRONT YELLOW TAG REAR PUMP NAMEPLATE Figure 58 - Pump Operating Specifications

35 MSS TM Series Upstream Filtration The pump must be protected from debris in the feed water such as sand, gravel, or other particulate matter. A 20 micron filter must be installed upstream of the pump inlet to protect against foreign matter entering the system. Temporary strainers should be installed before initial start up or after repairs to protect the pump from possible debris. Preparation For Pump Start Up Start Up Precautions WARNING NEVER operate the pump equipment: below the minimum flow rate. when dry. without priming. without proper guards and safety devices installed. with the discharge valve closed. with the suction valve closed. ELECTRICAL HAZARD Refer to the motor name plate, electrical junction box cover, or wiring tag for proper wiring. All electrical connections should be made by a licensed electrician according to all local codes and regulations. Be sure to follow all manufacturer s instructions on motor lubrication. Ensure motor rotational direction is correct according to the arrow located on the motor adapter (Refer to Motor Rotational Direction Check). CAUTION Electric motors may develop continual noise over long periods. Proper ear protection should be worn during pump operation. Most noise will emanate from the electric motor. The noise level of the MSS pump is nominal and depends on its size and operating conditions. The typical level can range from 75dB to 85dB, measured at a distance of 1 meter (39 inches) around the pump. Sound may vary due to hydraulic resonance, valves and building walls. For applications were a minimum noise level is required, the system should be operated with the flow adjusted as close to optimum efficiency as possible. Vibration may also occur and varies based on pump size and operating conditions. As a reference, typical vibration levels can reach.177 (4.5mm) per second RMS. See vibration test records or specifications sheet for more information. Start Up Check List An additional start up check list is available in the rear of this manual. Also use the Start Up Record at the rear of this manual to record initial operating conditions at pump start up. Flexible coupling set screws tightened. Motor adapter guards installed. All anchor bolts tightened to specifications. All pipe couplings tightened to specifications. Motor rotational direction correct. Motor lubricated to manufacturers specifications. Final Pump Alignment performed. Inlet pressure indicator installed. Inlet pressure switch (if applicable) installed. Outlet pressure indicator installed. System pipes are clean and upstream filtration in place. System leak checked and all air vented from system. ALL safety devices in place. Pump Start Up NOTES: Use the Start Up Record located in the rear of this manual to record initial operating conditions at pump start up. 1. Start pump and vent air from the system. 2. Verify that there are no leaks in the system. 3. Activate the MSS pump. 4. Inspect the system for leaks. NOTES: Some mechanical seal leakage may occur for about 60 seconds after pump start-up. If the leakage continues longer than 60 seconds then proceed with the Mechanical Seal Replacement procedure located in the MSS Overhaul Manual. 5. Observe any unusual system noise or vibration. 6. If a vibration meter is available, record a baseline vibration reading at this time. Note this vibration level in the Start-Up Records section of this manual. 7. Adjust system valves and controls as needed to obtain the desired operating condition

36 Basic Troubleshooting MSS TM Series If the MSS pump does not operate properly, refer to the following troubleshooting charts as a guide to determining the concern and identifying the potential cause. If after consulting the troubleshooting charts the cause is still undefined, contact FEDCO technical support and choose the Service and Support tab, telephone or fax. FEDCO will give you easy, step by step instructions on how to proceed. Visual Inspection Make sure all items are accounted for on the start up check list. Inspect all piping and electrical connections to the motor and pump. Inspect the pump and motor mountings for signs of any movement or vibration. Inspect pressure gauges, switches and all other instrumentation for proper operation. Record any unusual readings. Motor Speed and Direction Correct? Air Vented From System? Motor Hooked Up Correctly According to Manufactures Specs. Inlet Piping Leaks? Pump Leaking? Inlet Restrictions? Discharge Restictions? Figure 59 - Basic Visual Inspection

37 MSS TM Series Basic Troubleshooting Chart Symptom Possible Cause Action Low flow or low pressure Restriction in inlet or discharge pipes - Check pump inlet pressure - Check position of all control valves - Check throttle valve is fully open Incorrect pump speed or direction Gauges not operating properly Air leaks (vacuum on pump inlet) Pump cavitation Air in casing - Check VFD for proper speed setting (if equipped). - Check power supply frequency (50 or 60 Hz) - Check rotational direction of motor - Inspect gauges for proper operation. - Inspect inlet piping joints for leaks - Inspect pump mechanical shaft seal for leaks - Check inlet pressure during operation - Check for excessive flow rate - Purge air from all piping Internal damage - Damaged balance disc Design parameters - Pump not designed for operating conditions Pump vibration or noise Operating conditions - Pump cavitation - Excessive flow rate - Insufficient flow rate Pump misalignment - Inspect alignment (Refer to Final Pump Alignment) Balance disc - Inspect balance disc for damage or wear Pump leaks Pipe joints - Inspect pipe joints for insufficient sealing Motor runs hot, is noisy or shuts off Pump shell Pump shaft Excessive motor load - Inspect pump shell for damaged O-rings - Inspect mechanical seal for leakage - Inspect pump shaft for misalignment - Check voltage supply for consistency - Check ambient air temperature - Check wiring and fuses for phase loss - Check flow rate and VFD settings (if equipped). - Check wiring length between motor and VFD (if equipped). - Check motor bearings NOTES: Contact motor manufacturer for proper repair procedures

38 Specifications Recommended Spare Parts List MSS TM Series 1-3 years of service Refer to Maintenance Schedule and Service Parts Kits chart on following 4 pages of this manual. 4-5 years of service A complete disassembly, cleaning and inspection of all pump components is recommended. An overhaul kit and stage kit should be made available before beginning this procedure. Refer to Maintenance Schedule and Service Parts Kits chart on following 4 pages of this manual. Service Parts Kits Refer to Maintenance Schedule and Service Parts Kits chart on following 4 pages of this manual. NOTES: Please provide pump serial number when ordering field service kits. Ordering Parts To order a component or service kit, simply contact a FEDCO representative at: ATTN: Field Service Department Additional Contact Information: FEDCO Tel Ternes Drive Fax Monroe, MI sales@fedco-usa.com USA techsupport@fedco-usa.com Web site: Choose the Service and Support tab

39 MSS-A Service Parts Kits Components Item Part Description BDK Balance Disc Kit MSK Mechanical Seal Kit MSK HP Mechanical Seal Kit HPSC OHK Overhaul Kit TNK Throttle Nipple Kit TNK HP Throttle Nipple Kit HP STG Stage Kit SHT Shaft Kit ORK O-Ring Kit ORK HP O-Ring Kit HP RRK Retaining Ring Kit RRK HP Retaining Ring Kit HP FCK Flex Coupling Kit ALK Alignment Kit DLK Drain Linke Kit 1 Shipping plug * 2 Stationary seal retaining ring X X X 3 Inlet washer X X X 4 Mechanical seal X X X 5 Mechanical seal shaft washer X X X 6 Rotating seal retaining ring X X X X 7 Inlet O-ring X X X X 8 Split collar retaining ring (MSS-15/20/30/50/70 only) X X X X 9 Split collar (MSS-15/20/30/50/70 only) X 10 Collar sleeve (MSS-15/20/30/50/70 only) X 11 Inlet ring * 12 Diffuser bearing X X 13 Stage spacer (MSS-15/20/30/50/70 only) X X 14 Diffuser bowl (+ First stage housing for MSS-15/20/30 only) X X 15 Impeller X X 16 Series spacer (MSS-15/20/30/50/70 two shell pumps only) X X 17 Series flange O-ring X X X X 18 Discharge ring * 19 Stage spacer (custom end spacer) X 20 Shaft washer/ balance disc washer X X 21 Bearing holder * 22 Balance disc key X X 23 Balance disc X X 24 Cavity cover O-ring X X X X 25 Discharge housing O-ring X X X X 26 Balance disc flatwasher X X 27 Balance disc lockwasher X X 28 Balance disc nut X X 29 Discharge housing retaining ring X X X 30 Pump shaft X 31 HP shaft bushing anti-roll pin X 32 HP shaft bushing X 33 HP shaft bushing O-ring X X 34 HPSC O-ring X X 35 HPSC retaining ring X X 36 Assembled flex coupling X X 37 Shaft key X X 38 Alignment pins X 39 SS shim set X 40 Throttle nipple elbow X X 41 Throttle nipple X X 42 Throttle nipple O-ring X X X X X X 43 Split cone (MSS-45/55/75 only) X X 44 Split cone nut (MSS-45/55/75 only) X X 45 Clamping neck ring (MSS-45/55/75 only) X X 46 Floating neck ring (MSS-45/55/75 only) X X 47 Drain line elbow X 48 Bearing drain line X 49 Drain line connector X * Not Included in any kit. Can be purchased separately

40 MSS-A Service Parts Kits Components MSS-40/55/ MSS-50/ Figure 60 - MSS-A Service Parts Kits Components

41 MSS-B/C Service Parts Kits Components Item Part Description BDK Balance Disc Kit MSK Mechanical Seal Kit MSK HP Mechanical Seal Kit HPSC OHK Overhaul Kit TNK Throttle Nipple Kit TNK HP Throttle Nipple Kit HP STG Stage Kit SHT Shaft Kit ORK O-Ring Kit ORK HP O-Ring Kit HP RRK Retaining Ring Kit RRK HP Retaining Ring Kit HP FCK Flex Coupling Kit ALK Alignment Kit DLK Drain Line Kit 1 Shipping plug * 2 Stationary seal retaining ring X X X 3 Inlet washer X X X 4 Mechanical seal X X X 5 Mechanical seal shaft washer X X X 6 Rotating seal retaining ring X X X X 7 Inlet O-ring X X X 8 Clamping neck ring (MSS-90/120 size only) X X 9 Floating neck ring/ diffuser wear ring X X 10 Diffuser bearing X X 11 Diffuser X X 12 Split cone X X 13 Impeller X X 14 Split cone nut X X 15 Series flange O-ring X X X X 16 Bearing holder * 17 Shaft washer/ flatwasher X X 18 Balance disc key X X 19 Balance disc X X 20 Cavity cover O-ring X X X X 21 Discharge housing O-ring X X X X 22 Cavity cover retaining ring X X X 23 Shaft washer/ flatwasher X X 24 Balance disc lockwasher X X 25 Balance disc nut X X 26 Discharge housing retaining ring X X X 27 Pump shaft X 28 HP shaft bushing anti-roll pin X 29 HP shaft bushing X 30 HP shaft bushing O-ring X X 31 HPSC O-ring X X 32 HPSC retaining ring X 33 Assembled flex coupling X X 34 Shaft key X X 35 Alignment pins X 36 SS shim set X 37 Throttle nipple elbow X X X 38 Throttle nipple X X X X 39 Throttle nipple O-ring X X X X X X X 40 Drain line elbow X 41 Bearing drain line 42 Drain line connector * Not Included in any kit. Can be purchased separately

42 MSS-B/C Service Parts Kits Components MSS-160/200/ Figure 61 - MSS-B/C Service Parts Kits Components

43 MSS TM Series Specifications Continued Fastener Torque Specifications Item Metric Standard Precision leveling foot top cradle nuts 34 N-m 25 Lb-ft Motor adapter bolts - 3/8" 34 N-m 25 Lb-ft Motor adapter bolts - 1/2" 61 N-m 45 Lb-ft Motor adapter bolts - 5/8" 108 N-m 80 Lb-ft Support bracket adjustment bolts 81 N-m 60 Lb-ft Inlet housing bolts MSS-15 through MSS N-m 24 Lb-ft Inlet housing bolts MSS-90 through MSS N-m 60 Lb-ft Inlet housing bolts (HPSC) MSS-15 through MSS N-m 24 Lb-ft Inlet housing bolts (HPSC) MSS-90 through MSS N-m 60 Lb-ft End/ Series shell flange bolts MSS-15 through MSS N-m 60 Lb-ft End/ Series shell flange bolts MSS-160 through MSS N-m 81 Lb-ft Discharge housing retaining clip cap screws 10 N-m 7 Lb-ft Pump shaft nut (balance disc nut) MSS-15 through MSS N-m 50 Lb-ft Pump shaft nut (balance disc nut) MSS-90 through MSS N-m 70 Lb-ft Pump shaft nut (balance disc nut) MSS-160 through MSS N-m 91 Lb-ft Pump support bracket anchor bolt 108 N-m 80 Lb-ft Stage split cone nut MSS-40 through MSS N-m 40 Lb-ft Stage split cone nut MSS-90 through MSS N-m 75 Lb-ft Stage split cone nut MSS-160 through MSS N-m 120 Lb-ft Stage split cone nut MSS N-m 150 Lb-ft Coupling set screws (M6/ M10) 9 N-m/ 41 N-m 7 Lb-ft/ 30 Lb-ft Pump Alignment Specifications Motor Adapter Gap Tolerances for Non-Uniform Gaps Good mm 0.015" Balance Disc Specifications Pump Model Original Thickness When New Wear Limit mm 0.020") MSS-15 through MSS mm (0.531") 13.0 mm (0.511") MSS-90 & MSS mm (0.630 ) 15.5 mm (0.610 ) MSS-160 through MSS mm (0.618 ) 15.2 mm (0.598 ) Lubricants and Compounds Lubricant Standard Glycerine or fresh water with soap ASTM D1257 Anti-seize compound Compliant with specific system

44 Specifications Continued Maintenance Schedule MSS TM Series By following the schedule of preventive maintenance presented below, the MSS pump will deliver years of trouble-free performance. One (1) day after commissioning 1. Recheck pump alignment (refer to Final Pump Alignment). 2. Visually inspect flexible coupling and tighten the coupling bolts to the specified torque as necessary. 3. Fill out and submit all warranty documentation to FEDCO. Six (6) months after commissioning 1. Inspect pump alignment (refer to Final Pump Alignment). 2. Inspect flexible coupling: check for wear, irregularities, torsional backlash, running behavior and tightening torque (refer to Flexible Coupling Check). 3. Inspect for leaks, damaged gaskets and condition of all pipe couplings. 4. Wipe pump, motor and baseplate with a clean, damp cloth. Twelve (12) months after commissioning 1. Inspect pump alignment (refer to Final Pump Alignment). 2. Inspect flexible coupling: check for wear, irregularities, torsional backlash, running behavior and tightening torque (refer to Flexible Coupling Check). 3. Inspect mechanical seal for early signs of leakage or failure. 4. Inspect balance disc (refer to Balance Disc Inspection in the MSS Overhaul Manual). NOTES: If balance disc requires replacement, mechanical seal should also be replaced. 5. Inspect for leaks, damaged gaskets and condition of all pipe couplings. 6. Wipe pump, motor and baseplate with a clean, damp cloth. Annually 1. Inspect pump alignment (refer to Final Pump Alignment). 2. Inspect flexible coupling: check for wear, irregularities, torsional backlash, running behavior and tightening torque (refer to Flexible Coupling Check). 3. Inspect for leaks, damaged gaskets and condition of all pipe couplings. 4. Inspect balance disc (refer to Balance Disc Inspection in the MSS Overhaul Manual). NOTES: If balance disc requires replacement, mechanical seal should also be replaced. 5. Wipe pump, motor and baseplate with a clean, damp rag. Five (5) Years 1. Annual maintenance per above. 2. Disassemble fluid end for detailed inspection (refer to MSS Overhaul Manual). NOTES: Follow manufacturer s recommendations for motor and VFD maintenance