INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

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Frank Reed
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INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Contents Section 1. General Observations... 2 2. Operation... 4 3. Control During Operation... 5 4. Trouble Shooting... 6 5. Maintenance.

1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Contents Section 1. General Observations Operation Control During Operation Trouble Shooting Maintenance... 7 Please read these Operating instructions before installation and operation of the pump. Should the pump or pumping set suffer damages because these instructions have not been followed the guarantee will become void. 1

2 1. GENERAL OBSERVATIONS 1.1 Location of Unit The installation location should provide enough room for inspection and maintenance work. The room should be well aired. If the temperature of the pumped liquid is high (80 C to max. 120 C) the room temperature should not exceed 40 C (otherwise use special motors). The pump-motor unit should be firmly fastened to its base in such a way that loosening through vibration is avoided during operation. Depending on the type of installation, horizontal and vertical installations are possible. The appropriate type of electric motor has to be selected. If vertically installed the position of the motor underneath the pump should be avoided since leakage through the mechanical seal may penetrate into the motor bearings. The pipework should be connected and supported in such a way that no stress is introduced into the pump casing. After unfastening the flange bolts, both flanges should spring apart by the thickness of the gasket and neither separate under an angle nor stay together under force. The preconditions are that: (a) (b) (c) suction and discharge pipes connect easily; suction and discharge pipes are independently supported near the pump; flexible connections are used if the temperature of the pumping liquid is high. Flange gaskets should not protrude into the bore, which should be clean of weld splatter, burrs, rust and other impurities. 1.2 Suction Piping The suction line should: (a) be as short and straight as possible and made one or two sizes larger than the pump suction, so that the flow velocity does not exceed m/sec; (b) (c) be equipped with eccentric reducers where the excess diameter is located on the lower side to avoid formation of an air pocket (Fig.1) be absolutely airtight and rise towards the pump or at least run horizontally;

3 (d) be equipped with a gate or foot valve. These valves must not be used to control the pump flow and must always remain fully open when the pump is running. 1.3 Discharge Piping The discharge line should: (a) (b) (c) have a diameter sufficiently large to limit the flow velocity to m/sec; be fitted with a non-return valve between pump and discharge valve to prevent reverse flow while the pump is stopped. This is particularly important when pumps are operated in parallel. If reverse flow is allowed to occur, the pump will 'turbine' backwards and may be damaged when started under these conditions; be equipped with a discharge valve for start-up and flow regulation Piping in General All bends should have large radii and their number should be limited to a minimum. If a strainer is used in the suction line to prevent foreign matter from being drawn into the pump the screen should have sufficient openings to keep the flow velocity through it below 0.6 m/sec. 1.5 Shaft Sealing This pump is equipped with either a mechanical seal or a packed gland. Check if the pump shaft can be rotated easily by hand. Do not start or rotate the pump without liquid nor rotate in the wrong direction since this will seriously damage the mechanical seal. 1.6 Attention: Empty pump and piping if there is danger of frost!

4 2. OPERATION 2.1 Control before Start-up The pump is ready for start-up when: the motor-pump unit is firmly mounted; the direction of rotation of the motor is correct; the motor protection has been adjusted to maximum load as indicated on the motor identification plate; the pump and suction line are primed; If the pump operates under positive suction pressure, priming may be achieved by venting the pump through the vent plug (057 in cross section). If the pump operates in a suction mode with a foot valve, the pump may be primed by filling pump and suction line through the vent plug. If no foot valve is installed, the pump can be primed with a vacuum pump. the pump shaft rotates freely. the alignment of the pump and motor must be checked and re-aligned. Initial factory alignment can alter when the base plate is secured on site. 2.2 Start-up Start the unit with closed discharge valve until pressure has built up in the discharge line, then open discharge valve slowly. Do not operate unit for prolonged periods with closed discharge valve to avoid over-heating of liquid and pump. The pump set should be shut down at once and the trouble corrected if: little or no liquid is delivered; the pump does not build up enough pressure; the pump set vibrates or makes excessive noise (watch for cavitation 'crackle').

5 3. CONTROL DURING OPERATION The following items should be checked on a routine basis: shaft sealing A new mechanical seal can leak after start-up. After approx. 60 min. of run-in, leakage should not exceed 1-2 drops per minute. Packed glands must drip. leakage of entire installation the cleanliness of the suction strainer (a clogged strainer may cause cavitation!) the relative pressure in suction and discharge lines the power absorbed by the electric motor the speed of rotation noise and vibration level of the pump-motor unit the temperature of the motor bearings (max. 70 C)

6 4. TROUBLE SHOOTING DEFECTS No liquid delivered CAUSES 1 Pump not primed X Not enough liquid delivered 2 Speed too low X X X Not enough pressure Loss of liquid after starting 3 Speed too high X X 4 Air leak on suction X X X X X 5 Air leak in seal X X 6 Air or gas in liquid X X X X 7 Discharge head too high (above rating) X X X X 8 Suction head too high X 9 Not enough suction head for hot liquid X 10 Inlet pipe not submerged enough X X X X X 11 Viscosity of liquid greater than rating X X X 12 Liquid heavier that rating X 13 Insufficient nett inlet head X X X X X 14 Impeller plugged up X X X 15 Wrong direction of rotation X X X 16 Excessive wear ring clearance X X 17 Damaged impeller X X X 18 Rotor binding X 19 Defects in motor X 20 Voltage and/or frequency lower than rating X 21 Foundation not rigid X 22 Misalignment of pump and driver X X 23 Bearing worn X 24 Rotor out of balance X 25 Pump shaft bent or improperly aligned with motor shaft 26 Impeller too small X X Vibration X Motor runs hot X Cavitation (Noise)

7 5. MAINTENANCE This pump does not need any special maintenance. However, it should be examined at regular intervals for vibration-free running, power absorption and leakages. Do not 'service' a well-operating mechanical seal since the seal faces have run in together in a given position. If the seal is disassembled and reassembled the faces will not touch in exactly the same position and as a consequence, the seal may leak. 5.1 Change of mechanical seal If the seal leaks more than 1-2 drops per minute and if this amount of leakage cannot be tolerated in the respective installation, the seal will have to be replaced by a new one since an adjustment is not possible. The pump casing can stay in the piping. Remove the nuts from the casing studs, and remove the bearing housing support foot. Withdraw the complete rotating element. Remove impeller nut, impeller and impeller key. Remove shaft sleeve, if fitted, and mechanical seal. Disengage casing cover. Before and after disassembly determine the cause of the seal failure. Frequently the cause does not lie in the mechanical seal itself but in the condition of the pump or its surrounding (i.e. dirt, temperature, excessive axial play, etc.). Examine the shaft sleeve and shaft (seat of sleeve gasket) for damage and replace if necessary. Check proper running of shaft with dial gauge. Check if the axial and radial play of the motor bearings are within the specified limits. Permissible axial play of the standard IEC motors depends on the location of the fixed bearing - shaft side or ventilator side. Most of the manufacturers locate the fixed bearing on the ventilator side and as a consequence the axial play on the shaft side can vary between mm when the motor is cold. If motors of this design are used care has to be taken that the movable ring will slide easily on the sleeve (moisten shaft sleeve with vegetable oil or liquid soap). Complete units which are assembled at the factory are preferentially equipped

8 with motors whose fixed bearing is located on the shaft side, thereby reducing the axial play when cold to mm Carefully clean seal chamber, sleeve and shaft before reassembly. Do not damage contact surfaces of seal faces. If PTFE O-rings are used, heat these rings in water bath to 80 o before assembling. Lubricate shaft sleeve slightly with vegetable oil or liquid soap. Mount seal cover, which supports the stationary ring of standardised seals, perpendicular to shaft. It is recommended that casing gasket (005)) be exchanged together with the mechanical seal Attention: When in doubt about the replacement seal or the elimination of the cause of the defect, consult with a specialist. 5.2 Change of Gland Packing The pump casing can stay in the piping. Remove gland (Ref. No. 20) from the rear of the casing cover. Remove all rings of old packing without damaging shaft or stuffing box bore. New Packing can now be installed in the stuffing box. Insert the first ring and tap it to the bottom of the stuffing box. Each following ring should be installed in the same manner and positioned in the stuffing box so that the split is advanced When the correct number of packing rings have been inserted, the last ring should not protrude past the stuffing box face, so that the Gland may be properly started in the stuffing box bore. Install Gland and tighten finger tight only. When the pump has been running for 10 minutes at full pressure, adjust nuts so that there is only a small leakage. A small leakage is essential to ensure that the packing is lubricated. Excessive Gland pressure will cause damage by cutting off lubrication to the packing and will burn and damage the shaft. 5.3 Leakage Test After assembly, fill pump with water and connect to pressure network (max. 10 bar) to check for leakage.

9 5.4 Pedestal bearings Sealed for life bearings require no lubrication and no provision is provided for this purpose. Greasable bearings will require regular greasing via the two ball-type grease nipples. Lubrication data for the following R.P.M.: 1500 R.P.M. : Approximately every 5,000 operating hours R.P.M. : Approximately every 2,500 operating hours. After approximately 10,000 operating hours, but not later than two years, the ball bearings need to be dismantled, washed, re-greased and can then be refitted. Under unfavourable operating conditions ( dusty, wet or high ambient temperatures) The period for re-greasing must be must be far shorter. The amount of grease required for each bearing depends entirely on the size of the ball bearing. SHAFT UNIT AMOUNT OF GREASE (gr.) , 35/1 8 35H 14 45, 45/1 12 If the bearings are over greased ( too much grease in the bearings) there is a danger of hot running. We recommend the following grease: (or their equivalent) ESSO SHELL B.P. BEACON EP3. SHELL ALNANIA R.2. B.P. ENERGREASE L.S.3. OIL LUBRICATED bearings have normal clearances. The quantity of oil used depends on bearing pedestal Shaft Unit size. SHAFT UNIT PUMP END BEARING COUPLING END BEARING APPROX. HOUSING OIL CONTENT Approx. 0.2 litre. 35, 35/ Approx Litre. 35H Approx Litre. 45, 45/ Approx. 0.9 Litre.

10 5.4 Pedestal bearings, continued. Lubricating oil must meet the following requirements: Extreme cleanliness, resistance to ageing, good viscosity and temperature behaviour, good water separating properties and corrosion protection. We recommend, depending on the operating temperature of the bearings and the speed Of the pump, to use lubricating oils according to DIN Operating Temperatures up to 80 0 Up to 1500 RPM More than 1500 RPM Bearing operating Temperatures Ambient Temperature < above 80 0 C 0 0 C Type of lubricating oil to DIN C49 C36 C68 C25 Kinematics viscosity at 50 0 C 10-6 m 2 /s 49~5 36~4 68~6 25~4 Suitable motor oil SAE 20 AND 20W SAE 30 SAE 10W

11 Regent Dinflow 14.3 PARTS LIST No. 2. PARTS LIST SECTION 14 PAGE 36 MARCH 1998 ITEM NUMBER DESCRIPTION QTY. PER UNIT ITEM NUMBER DESCRIPTION QTY. PER UNIT 001 CASING IMPELLER LOCK WASHER IMPELLER IMPELLER KEY CASING COVER COUPLING KEY GASKET, CASING CASING WEAR RING SLINGER DRAIN PLUG BEARING HOUSING GASKET, DRAIN PLUG SHAFT GAUGE PLUG SUPPORT FOOT GASKET, GAUGE PLUG GLAND STUD, CASING 8/ LANTERN RING STUD, CASING COVER 6/8 038 GLAND PACKING STUD, GLAND BEARING CAP SET SCREW, SUPPORT FOOT GASKET, BEARING CAP SET SCREW, BEARING CAP BEARING HEXAGON NUT, CASING 8/ FELT SEAL HEXAGON NUT, CASING COVER 6/8 046 SHAFT SLEEVE HEXAGON NUT, GLAND GASKET, SHAFT SLEEVE FLAT WASHER, GLAND IMPELLER NUT FLAT WASHER, SUPPORT FOOT 1

12 REGENT 'A' STYLE MECHANICAL SEAL ARRANGEMENT MECHANICAL SEAL ITEM DESCRIPTION 35 MECHANICAL SEAL 36 SHAFT SLEEVE 37 SEAL PLATE 41 O-RING

Installation Vertical Pump: Installation 'CM' and 'CDM' Style: Operation:

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