MULTI-STAGE SEAWATER (MSS TM ) HIGH PRESSURE PUMPS Overhaul Manual For Desalination Reverse Osmosis Service Models: MSS-90 MSS-120 MSS-160 MSS-200 MSS-240 Main Office Tel: 734-241-3935 Fax: 734-241-5173 techsupport@fedco-usa.com FEDCO 800 Ternes Drive Monroe, MI 48162, USA Dubai Office Tel: 971-04-880-7344 Fax: 971-04-880-7354 techsupport-dubai@fedco.com Technopark, Plot TP10501 Jebel Ali South, PO Box 37603, Dubai, UAE www.fedco-usa.com Singapore Office Tel: 65-6779-0123 Fax: 65-6779-6900 techsupport-singapore@fedco.com Singapore Branch 82 Toh Guan Road East #C2-14-4 WaterHub Singapore, 608576 For patent coverage visit patent.fedco-usa.com MSS 90-240 Overhaul Manual, 02-090-XXXXXX-1
Table Of Contents MSS TM Series Warnings and Safety Precautions...5 Inspection of Service Kits Upon Receipt... 5 User Health and Safety... 6 In the Work Area... 6 Electrical Connections and Regulations... 6 Pump Overhaul...7 MSS Pump External Components... 7 MSS Pump Internal Components... 8 Mechanical Seal Removal... 9 Mechanical Seal Installation... 12 HPSC Meahanical Seal Removal... 15 HPSC Mechanical Seal Installation... 18 Shaft Position Sensor Removal... 21 Shaft Position Sensor Installation... 22 Balance Disc Removal... 25 Balance Disc Inspection... 30 Balance Disc Wear Chart... 30 Balance Disc Installation... 31 Stage Removal... 37 Stage Assembly... 39 Specifications...42 Cleaning... 42 Inspection... 42 Fastener Torque Specifications... 43 Pump Alignment Specifications... 43 Balance Disc Specifications... 43 Lubricants and Compounds... 43 Notes...44-2 -
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 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 O-ring X X X X 20 Balance disc X X 21 Cavity cover O-ring X X X X 22 Discharge housing O-ring X X X X 23 Cavity cover retaining ring X X X 24 Shaft washer/ flatwasher X X 25 Balance disc lockwasher X X 26 Balance disc nut X X 27 Discharge housing retaining ring X X X 28 Pump shaft X 29 HP shaft bushing anti-roll pin X 30 HP shaft bushing X 31 HP shaft bushing O-ring X X 32 HPSC O-ring X X 33 HP shaft bushing retaining ring X 34 Assembled flex coupling X X 35 Shaft key X X 36 Alignment pins X 37 SS shim set X 38 Throttle nipple elbow X X X 39 Throttle nipple X X X 40 Throttle nipple O-ring X X X X X X * Not Included in any kit. Can be purchased separately. - 3 -
27 26 25 24 23 22 40 39 21 37 20 19 36 38 18 17 35 16 28 5 4 34 MSS-160/200/240 9 10 1 15 14 13 12 11 10 9 8 7 6 33 32 31 29 30 Figure 1 - Service Parts Kits Components 11 3 14 1 2 13 1 12 1-4 -
Warnings and Safety Precautions Inspection of Service Kits 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. 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. - 5 -
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, which requires CE compliance, if the manual is not written in that state s language. If a translation is needed, please contact a FEDCO representative. 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. MSS TM Series ELECTRICAL HAZARD Always follow the Lock-out / Tag-out procedure developed by your company before starting any maintenance or repair. Figure 2 - 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. - 6 -
Pump Overhaul MSS Pump External Components 10 12 13 6 8 1 2 3 4 5 7 9 11 14 18 21 20 19 16 27 15 23 24 22 25 26 17 Figure 3 - Pump Assembly External Components Item Description Item Description 1 Precision leveling foot 15 Series shell (if equipped) 2 Shell support bracket 16 Series shell O-ring (if equipped) 3 Inlet housing bolts 17 Shell flange bolts 4 Inlet housing O-ring 18 End shell 5 Inlet housing 19 Discharge housing O-ring 6 High pressure seal carrier O-ring (if equipped) 20 Discharge housing 7 High pressure seal carrier bolts (if equipped) 21 Discharge housing retaining ring 8 High pressure seal carrier (if equipped) 22 Retaining clips 9 Leakage bushing 23 Retaining clip cap screws 10 Coupling guard screws 24 Lock washers 11 Coupling guards 25 Throttle nipple 12 Motor adapter 26 Throttle nipple O-ring 13 Motor adapter bolts 27 Bearing drain line 14 Flexible coupling - 7 -
Pump Overhaul Continued MSS TM Series MSS Pump Internal Components 28 27 26 25 24 23 22 21 20 19 33 18 32 17 31 16 30 15 29 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Figure 4 - MSS Pump Internal Components Item Description Item Description 1 Shipping plug (optional) 18 Balance disc key 2 Stationary seal retaining ring 19 Balance disc O-ring 3 Inlet washer 20 Balance disc 4 Mechanical seal 21 Cavity cover O-ring 5 Mechanical seal shaft washer 22 Discharge housing O-ring 6 Rotating seal retaining ring 23 Cavity cover retaining ring 7 Inlet O-ring 24 Balance disc flatwasher 8 Clamping neck ring (MSS-90/120 only) 25 Balance disc lockwasher 9 Floating neck ring 26 Balance disc nut 10 Diffuser bearing 27 Discharge housing retaining ring 11 Diffuser 28 Pump shaft 12 Split cone 29 HP shaft bushing anti-roll pin 13 Impeller 30 HP shaft bushing 14 Split cone nut 31 HP shaft bushing O-ring 15 Series flange O-ring (two shell pumps only) 32 HPSC O-ring 16 Bearing holder 33 HPSC retaining ring 17 Shaft washer - 8 -
Pump Overhaul Continued 1 2 3 4 5 6 Item Description 1 Shaft retaining ring 2 Shaft washer 3 Mechanical seal 4 Stationary seal (with O-ring) 5 Inlet washer 6 Inlet retaining ring Figure 5 - Mechanical Seal Components Mechanical Seal Replacement - Standard ELECTRICAL HAZARD Make sure to disconnect the power supply to the motor before carrying out component replacement procedures. Follow all Lock out/tag out procedures developed by your company before starting any maintenance or repair. Figure 6 - Coupling Guard Removal Mechanical Seal Removal 1. Drain the piping and pump. 2. Disconnect the inlet and outlet piping. 3. Loosen screws and remove the coupling guards. 4. Remove the anchor bolts and washers from the shell support bracket(s) from the base plate. Figure 7 - Anchor Bolt Removal - 9 -
Pump Overhaul Continued 5. Remove the motor adapter bolts and washers. MSS TM Series Figure 8 - Motor Adapter Bolt Removal 6. Remove nuts and the top cradle from the precision leveling foot. Figure 9 - Top Cradle Removal 7. Install the alignment pins to prevent damage to the mechanical seal and carefully slide the pump at least 30.5 cm (12 inches) away from the motor. NOTES: Make sure to support the inlet end of the pump on the support bracket(s). 30.5 mm (12 ) Figure 10 - Separating Pump from Motor - 10 -
Pump Overhaul Continued 8. Remove inlet housing bolts and washers from the inlet Housing. Figure 11 - Inlet Housing Bolts Removal 9. Remove the motor adapter and shipping plug from the inlet housing. Figure 12 - Motor Adapter Removal 10. Remove the stationary seal retaining ring from the inlet housing. Figure 13 - Stationary Seal Retaining Ring Removal - 11 -
Pump Overhaul Continued 11. Apply soap and water to the shaft and using a suitable tool through the inlet housing fluid opening, gently push the shaft washer, mechanical seal, stationary seal and inlet washer toward the shaft end and remove. NOTES: Make sure to push the washer only. Do not push on the shaft retaining ring or damage may occur. NO YES MSS TM Series NOTES: The rotating seal (shaft) retaining ring does not need to be removed unless it is distorted or corroded and needs replacement. Figure 14 - Mechanical Seal Removal 12. Inspect the pump shaft, rotating seal retaining ring, inlet seal bore and pump shaft for any damage. Remove any oil or dirt with a clean cloth. Figure 15 - Inspecting Retaining Ring, Pump Shaft and Bore Mechanical Seal Installation 1. Install the new shaft washer onto pump shaft and slide the washer against the rotating seal (shaft) retaining ring. NOTES: Apply additional soap and water to shaft to allow mechanical seal to slide easier onto the shaft. Figure 16 - Shaft Washer Installation - 12 -
Pump Overhaul Continued 2. Slide on the new mechanical shaft seal followed by the stationary seal and inlet washer onto the shaft. Figure 17 - Mechanical Seal Installation 3. Press in on the inlet washer and install the stationary seal retaining ring into the groove on the inlet housing. NOTES: Make sure the inlet retaining ring is completely seated in the inlet housing groove. Figure 18 - Stationary Seal Retaining Ring Installation 4. Install the shipping plug into the motor adapter seat. Figure 19 - Shipping Plug Installation - 13 -
Pump Overhaul Continued 5. Secure the inlet housing to the motor adapter with inlet housing bolts with lock washers. Tighten bolts to values specified in the Fastener Torque Specifications section of this manual. MSS TM Series Figure 20 - Inlet Housing Bolts Installation 6. Apply system compliant anti-seize compound into the pump shaft keyway and install pump shaft key. APPLY SYSTEM COMPLIANT ANTI-SEIZE COMPOUND NOTES: The key should fit securely with the rounded end facing toward the pump. Figure 21 - Pump Shaft Key Installation 7. Carefully slide the pump against the motor making sure the pump shaft key slides smoothly into the flexible coupling. Push the pump by hand until the motor adapter and motor are in contact. NOTES: Make sure the pump shaft key does not jam or fall out during installation. 8. Refer to Final Pump Alignment from the Installation/ Operation Manual for pump alignment process. Figure 22 - Attaching Pump to Motor - 14 -
Pump Overhaul Continued 6 1 2 3 4 5 7 8 9 10 11 Item Description Item Description 1 HP shaft bushing retaining ring 7 Shaft washer 2 HP shaft bushing O-ring 8 Mechanical seal 3 HP shaft bushing 9 Stationary seal 4 Rotating seal retaining ring 10 Inlet washer 5 High pressure seal carrier O-ring 11 Stationary seal retaining ring 6 High pressure seal carrier Figure 23 - High Pressure Seal Carrier Components Mechanical Seal Optional High Inlet Pressure Design ELECTRICAL HAZARD Make sure to disconnect the power supply to the motor before carrying out component replacement procedures. Follow all Lock out/tag out procedures developed by your company before starting any maintenance or repair. HPSC Meahanical Seal Removal Figure 24 - Drain Line Disconnection 1. Perform Steps 1 through 7 in the Mechanical Seal Replacement - Standard removal procedure. 2. Disconnect the drain line(s) from the high pressure seal carrier. - 15 -
Pump Overhaul Continued 3. Remove the bolts and lock washers from the inlet housing. MSS TM Series Figure 25 - Inlet Housing Bolt Removal 4. Remove the motor adapter with the high pressure seal carrier from the inlet housing. Figure 26 - Motor Adapter With High Pressure Seal Carrier Removal 5. Remove the high pressure seal carrier bolts, the high pressure seal carrier and shipping plug from the motor adapter. Figure 27 - High Pressure Seal Carrier Removal - 16 -
Pump Overhaul Continued 6. Remove the stationary seal retaining ring, inlet washer, stationary seal, mechanical seal and shaft washer from the high pressure seal carrier. Figure 28 - Mechanical Seal Components Removal 7. Remove the high pressure seal carrier O- ring. NOTES: Do not remove or replace the HP shaft bushing anti-roll pin unless damaged. Figure 29 - High Pressure Seal Carrier O-Ring Removal 8. Remove the rotating seal retaining ring, HP shaft bushing and HP shaft bushing O-ring NOTES: If the HP shaft bushing O-ring and HP shaft bushing retaining ring appear weak or distorted, replace them. Figure 30 - HP Shaft Bushing Components Removal - 17 -
Pump Overhaul Continued 9. Inspect the high pressure seal carrier and inlet housing seal bores and shaft area for damage. Remove any oil or dirt with a clean cloth. MSS TM Series Figure 31 - Inspecting Seal Carrier and Pump Shaft HPSC Mechanical Seal Installation 1. Lubricate and install a new O-ring into the inlet housing. Install the HP shaft bushing and rotating seal retaining ring. NOTES: Make sure the slot in the HP shaft bushing is on the top of the shaft facing the end of the shaft. NOTES: Make sure the rotating seal retaining ring is completely seated in the shaft groove. Figure 32 - HP Shaft Bushing Components Installation 2. Lubricate and install a new high pressure seal carrier O-ring. Figure 33 - New High Pressure Seal Carrier O- ring Installation - 18 -
Pump Overhaul Continued 3. Install the new shaft washer, mechanical seal, stationary seal and inlet washer into the high pressure seal carrier and secure with the stationary seal retaining ring. NOTES: Make sure the stationary seal retaining ring is completely seated in the high pressure seal carrier groove. Figure 34 - Mechanical Seal Components Installation 4. Install the shipping plug and high pressure seal carrier onto the motor adapter and secure using the high pressure seal carrier bolts. Tighten bolts to values specified in the Fastener Torque Specifications section of this manual. Figure 35 - Assembling High Pressure Seal Carrier and Motor Adapter 5. Position the motor adapter and high pressure seal carrier onto the pump shaft. NOTES: Make sure the slot in the HP shaft bushing lines up with the anti-rotation pin on high pressure seal carrier. Figure 36 - High Pressure Seal Carrier and Motor Adapter Installation - 19 -
Pump Overhaul Continued 6. Position the high pressure seal carrier against the inlet housing aligning the antirotation pin with the slot in the HP shaft bushing. MSS TM Series Figure 37 - Aligning HP Shaft Bushing 7. Secure the high pressure seal carrier to the inlet housing with the bolts and lock washers and Tighten bolts to values specified in the Fastener Torque Specifications section of this manual. Figure 38 - High Pressure Seal Carrier Bolts Installation 8. Connect the drain line(s) to the high pressure seal carrier. NOTES: Make sure the vent line is clean and unplugged. The line 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. 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. 9. Perform Steps 6, 7 and 8 in the Mechanical Seal Installation procedure in the previous section. Figure 39 - Drain Line Installation - 20 -
Pump Overhaul Continued 1 2 3 5 4 Item Description 1 Light emitting diode 2 Adjustment shaft locknut 3 Shaft position sensor 4 Shaft collar 5 Spacer plate Figure 40 - Optional Shaft Position Sensor Components Optional Shaft Position Sensor ELECTRICAL HAZARD Make sure to disconnect the power supply to the motor before carrying out component replacement procedures. Follow all Lock out/tag out procedures developed by your company before starting any maintenance or repair. Shaft Position Sensor Removal Figure 41 - Loosen Adjustment Locknut 1. Disconnect the shaft position sensor from its power source. 2. Loosen the adjustment locknut at the top of the spacer plate. - 21 -
Pump Overhaul Continued 3. Unscrew and remove the shaft position sensor from the spacer plate. MSS TM Series Figure 42 - Shaft Position Sensor Removal 4. Inspect the shaft collar to ensure it has not moved from its position on the pump shaft. NOTES: If the shaft collar has moved on the pump shaft, inspect the set screw keyway on the pump shaft for excessive wear. SHAFT COLLAR SET SCREW SET SCREW KEYWAY Figure 43 - Shaft Collar Inspection Shaft Position Sensor Installation CAUTION DO NOT supply the shaft position sensor with current and voltage higher than the sensor is rated to operate at. Higher than rated electrical current or voltage may damage the sensor. 1. Connect a temporary power supply to the shaft position sensor which will allow the sensor to be adjusted. 2. Loosely thread the shaft position sensor into the spacer plate. Figure 44 - Shaft Position Sensor Installation - 22 -
ROTATE 1/4 TURN AFTER SENSOR ILLUMINATES Pump Overhaul Continued 3. Slowly rotate the sensor clockwise until the sensor becomes illuminated with a green and red light. Once the sensor is illuminated, rotate the sensor a further one quarter (1/4) turn. Figure 45 - Shaft Position Sensor Adjustment 4. Tighten the adjustment locknut to prevent sensor movement. TIGHTEN ADJUSTMENT LOCKNUT NOTES: If a false shut down occurs after the adjustment procedure, loosen the adjustment locknut and rotate the sensor a further onequarter (1/4) turn to ensure no misadjustment has occured. 5. Once the sensor is properly adjusted, disconnect the sensor from the temporary power supply and permanently connect the sensor to the VFD. Figure 46 - Tightening Adjustment Locknut - 23 -
Pump Overhaul Continued MSS TM Series 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Figure 47 - Balance Disc Components Item Description Item Description 1 Cap screws 10 Lock washer 2 Lock washers 11 Washer 3 Retaining clips 12 Balance disc 4 Discharge housing retaining ring 13 Balance disc O-ring 5 Discharge housing O-ring 14 Balance disc key 6 Discharge housing 15 Balance disc washer 7 Cavity cover O-ring 16 Bearing carrier 8 Cavity cover 17 Throttle nipple O-ring 9 Pump shaft nut 18 Throttle nipple - 24 -
Pump Overhaul Continued Balance Disc ELECTRICAL HAZARD Make sure to disconnect the power supply to the motor before carrying out component replacement procedures. Follow all Lock out/tag out procedures developed by your company before starting any maintenance or repair. Figure 48 - Disconnecting Drain Line Balance Disc Removal 1. Drain the piping and pump. 2. Disconnect the outlet piping. 3. Disconnect the bearing drain line from the throttle nipple. 4. Remove the throttle nipple from the discharge housing. Figure 49 - Throttle Nipple Removal 5. Remove the throttle nipple O-ring from the discharge housing. Figure 50 - Throttle Nipple O-Ring Removal - 25 -
Pump Overhaul Continued 6. Remove the support bracket anchor bolts and washers. NOTES: For one shell pumps, remove inlet support bracket anchor bolts (center support bracket will be nonexistent). MSS TM Series NOTES: For two shell pumps, removal only necessary for center support bracket anchor bolts. Figure 51 - Support Bracket Anchor Bolt Removal 7. Loosen both jam nuts and top cradle nuts. Figure 52 - Loosening Jam Nuts and Top Nuts 8. Loosen the shell flange bolts. NOTES: For two shell pumps, separate the series shell flange from endshell flange. NOTES: For one shell pumps separate the endshell flange from the inlet flange. Figure 53 - Loosening Flange Bolts - 26 -
0.64cm (0.25 ) Pump Overhaul Continued 9. Using a suitable tool, pry the shell flanges apart until a gap of approximately 0.64cm (0.25 ) is obtained. Figure 54 - Separating Shells 10. Remove the cap screws, lock washers and retention clips from the discharge housing. Figure 55 - Discharge Housing Cap Screws Removal 11. Remove the discharge housing retaining ring and discharge housing with O-ring. Figure 56 - Discharge Housing Removal - 27 -
Pump Overhaul Continued 12. Remove the cavity cover retaining ring and cavity cover with O-ring. MSS TM Series Figure 57 - Cavity Cover Removal 13. Loosen screws and remove the coupling guards. Figure 58 - Coupling Guard Removal 14. Lock the flexible coupling with a suitable strap or chain wrench to prevent pump shaft rotation. SUITABLE STRAP OR CHAIN WRENCH Figure 59 - Securing Pump Shaft - 28 -
Pump Overhaul Continued 15. Remove the pump shaft nut, lock washer and washer. Figure 60 - Shaft Nut and Washers Removal 16. Remove the balance disc and bearing carrier. Figure 61 - Bearing Carrier and Balance Disc Removal 17. Remove the balance disc key, washer and O-ring. Figure 62 - Balance Disc Washer and Key Removal - 29 -
Pump Overhaul Continued Balance Disc Inspection 1. Inspect the surfaces of the balance disc for unusual wear. The surfaces may have some wear but should be smooth. FRONT SIDE MSS TM Series REAR REAR FRONT Figure 63 - Balance Disc Inspection 2. Measure the balance disc outer hub thickness. Refer to the Balance Disc Wear Chart for wear limit specifications. The maximum acceptable balance disc wear is 0.508 mm (0.020 ). If the balance disc wear exceeds its wear limit, it must be replaced. Balance Disc Wear Chart IF DISC IS WORN MORE THAN 0.508 mm (0.020 ) FROM ORIGINAL THICKNESS, REPLACE BALANCE DISC Balance Disc Model Original Thickness When New Wear Limit - 0.508 mm (0.020) MSS-90 and MSS-120 16.0 mm (0.625+/-.002 ) 15.5 mm (0.603 ) Figure 64 - Measuring Balance Disc 3. Inspect the bearing carrier for unusual wear or scoring and replace if necessary. Figure 65 - Inspecting Bearing Carrier - 30 -
Pump Overhaul Continued Balance Disc Installation 1. Carefully install the bearing carrier into the end shell. Figure 66 - Bearing Carrier Installation APPLY SYSTEM COMPLIANT ANTI-SEIZE COMPOUND 2. Apply system compliant anti-seize compound into the balance disc keyway, lubricate a new balance disc O-ring and install the balance disc key, washer and O-ring. NOTES: Make sure the balance disc keyway is on top and the key is installed with the rounded end facing outward toward the discharge housing. Figure 67 - Balance Disc Key, Washer and O- Ring Installation 3. Install the balance disc into the bearing carrier. NOTES: Make sure the balance disc is firmly seated in the bearing carrier. Figure 68 - Balance Disc Installation - 31 -
Pump Overhaul Continued 4. Apply system compliant anti-seize compound onto the pump shaft threads and install the balance disc washer, lock washer and pump shaft nut. With the suitable strap or chain wrench still attached (preventing pump shaft rotation), tighten bolts to values specified in the Fastener Torque Specifications section of this manual. NOTES: The pump shaft nut preload is critical to proper balance disc operation. A properly calibrated torque wrench must be used for this step. APPLY SYSTEM COMPLIANT ANTI-SEIZE COMPOUND MSS TM Series Figure 69 - Balance Disc Washers and Nut Installation 5. Lubricate the cavity cover O-ring, install cavity cover and secure with the cavity cover retaining ring. NOTES: Make sure to align the throttle nipple opening with the bottom of the pump. Figure 70 - Cavity Cover Installation 6. Lubricate the discharge housing O-ring and install the discharge housing and retaining ring. NOTES: Make sure to align the throttle nipple opening on the discharge housing with the throttle nipple opening in the cavity cover. Figure 71 - Discharge Housing Installation - 32 -
Pump Overhaul Continued 7. Temporarily install the throttle nipple to ensure the cavity cover and discharge housing are properly aligned. 8. Remove the throttle nipple. Figure 72 - Inspecting Discharge Housing Alignment 9. Install the retention clips, lock washers and cap screws into the discharge housing and Tighten bolts to values specified in the Fastener Torque Specifications section of this manual. Figure 73 - Discharge Housing Retention Clips Installation 10. Gradually and evenly tighten the shell flange bolts until both flanges are in contact. Tighten bolts to values specified in the Fastener Torque Specifications section of this manual. NOTES: If the pump has only one shell, tighten the flange bolts securing the end shell and inlet housing in the same manner. Figure 74 - Tightening Flange Bolts - 33 -
Pump Overhaul Continued 11. Tighten the top cradle nuts to values specified in the Fastener Torque Specifications section of this manual. MSS TM Series Figure 75 - Tightening Jam Nuts and Top Nuts 12. Reinstall the support bracket anchor bolts and washers. Figure 76 - Support Bracket Anchor Bolts Installation 13. Lubricate and install a new throttle nipple O-ring into the discharge housing. Figure 77 - Throttle Nipple O-Ring Installation - 34 -
LUBRICATE Pump Overhaul Continued 14. Apply thread sealing tape to the throttle nipple threads and lubricate the shank of the throttle nipple. THREAD SEALING TAPE Figure 78 - Taping Throttle Nipple Threads 15. Carefully twist the throttle nipple through the O-ring and into the cavity cover. NOTES: Be careful not to dislodge the O-ring out of its O-ring groove. Figure 79 - Throttle Nipple Installation 16. Reconnect the bearing drain line to the throttle nipple. Figure 80 - Connecting Drain Line - 35 -
Pump Overhaul Continued 17. Remove the strap or chain wrench, install the coupling guards and tighten the screws. 18. Refer to Final Pump Alignment from the Installation/ Operation manual. MSS TM Series Figure 81 - Coupling Guards Installation - 36 -
Pump Overhaul Continued Stage Replacement MSS-90/120 4 5 6 7 MSS-160/200/240 3 4 5 6 2 3 1 1 2 Item Description Item Description 1 Floating Neck Ring 5 Split Cone Nut 2 Clamping Neck Ring 6 Impeller 3 Diffuser Bearing 7 Split Cone 4 Diffuser Item Description Item Description 1 Diffuser Wear Ring 4 Split Cone Nut 2 Diffuser Bearing 5 Impeller 3 Diffuser 6 Split Cone Figure 82 - MSS Stage Components Stage Removal NOTES: Place pump on flat surface in the vertical position. 1. Install gauge block to keep shaft from slipping (not provided). Figure 83 - Install and Set Gauge Block 2. Preform the Balance Disc Removal procedure as described earlier in this manual. 3. Remove pump shell (series + endshell or just endshell) bolts from inlet/ flanges. 4. Remove pump endshell. Figure 84 - Pump Shell Removal - 37 -
Pump Overhaul Continued 5. Remove diffuser MSS TM Series Figure 85 - Diffuser Removal 6. Remove split cone, split cone nut, and impeller. Figure 86 - Impeller Removal 7. For: MSS-90/120 units, remove clamping neck ring and floating neck ring. MSS-160/200/240 uints, remove diffuser wear ring. MSS-90/120 MSS-160/200/240 Figure 87 - Stage Component Removal - 38 -
Pump Overhaul Continued NOTES: For two shell pumps: - The final stage in the series shell does not include a clamping or floating neck ring. a) Repeat stage removal process until all endshell stages are removed. b) Remove series shell. 8. Repeat stage removal process until all stages are removed. Figure 88 - Series Shell Removal 9. Shaft will no longer be supported by stages, and will fall over if not supported by the mechanical seal and shipping plug (if installed). NOTES: The shaft must be supported to avoid damage to the bushing and seal. Figure 89 - Shaft Support Stage Assembly 1. With the pump inlet bolted on to the motor mount. Slide the shaft through the shipping plug and support it on the gauge block. NOTES: Contact FEDCO field service for gauge block height. The pump serial number must be provided. Figure 90 - Shaft Assembly - 39 -
Pump Overhaul Continued 2. For: MSS-90/120 units, Install floating neck ring and clamping neck ring. MSS-160/200/240 uints, Install diffuser wear ring. MSS-90/120 MSS-160/200/240 MSS TM Series Figure 91 - Stage Components Assembly 3. Install impeller and snug Impeller to shaft and fully tighten split cone nut to specified torque value specified in the Fastener Torque Specifications section of this manual. NOTES: Check gauge block to assure no shaft movement occurred. Figure 92 - Impeller Assembly 4. Install diffuser with diffuser bearing onto pump shaft. Figure 93 - Diffuser Assembly - 40 -
Figure 94 - Stage Spacer Assembly Pump Overhaul Continued 5. Single Shell Pump: a) Repeat the stage assembly process until required amount of stages are installed. b) Install pump endshell. Multi Shell Pump: a) Install all series shell stages and series shell (reference next step). Note that the final stage in the series shell does not include a clamping or floating neck ring. b) Repeat the stage assembly process until required amount of endshell stages are installed. c) Install pump endshell. NOTES: A.095 gap must be present between diffusers and shell flanges to set impeller height. Temporally install spacer washers until the split cone nut is fully tightened. ONE SHELL TWO SHELL 6. Single Shell Pump: Slide the endshell over the stage stack and fasten into inlet. Multi Shell Pump: Slide the series shell over the stage stack and fasten into inlet. Install shell O-ring and endshell and fasten to series shell flange. 7. Refer to Balance Disc Assembly Figure 95 - Shell Assembly - 41 -
Specifications MSS TM Series Cleaning WARNING NEVER use petroleum or alcohol based solvents when cleaning pump components. Solvents can degrade or damage vital seals and O-rings over time. Use fresh water with mild soap (Make sure cleaning chemical are compatible with membranes and other chemicals in the system) and rinse all components thoroughly with fresh water before assembly. Internal Components Clean all internal components with mild soap and fresh water. Rinse thoroughly before use. Internal components should dried with a clean, lint free cloth before assembly. Inspection Internal Components Inspect all internal components for signs of excessive wear or damage. Pay particular attention to bearing surfaces. Replace if necessary. Fasteners Inspect all fastener threads for signs of wear or distortion and replace if necessary. O-Rings Inspect all O-rings for cuts or damage and replace as necessary. WARNING Using compressed air can be hazardous. Observe safety precautions accordingly Nameplate Protect nameplate integrity. Use considerable caution when cleaning. Do not use products that may damage painted or engraved surfaces. FEDCO recommends soap and fresh water for cleaning nameplate surfaces. - 42 -
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" 81 N-m 60 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-75 33 N-m 24 Lb-ft Inlet housing bolts MSS-90 through MSS-240 81 N-m 60 Lb-ft Inlet housing bolts (HPSC) MSS-15 through MSS-75 33 N-m 24 Lb-ft Inlet housing bolts (HPSC) MSS-90 through MSS-240 81 N-m 60 Lb-ft End shell flange bolts MSS-15 through MSS-120 81 N-m 60 Lb-ft End shell flange bolts MSS-160 through MSS-240 109 N-m 81 Lb-ft Series shell flange bolts MSS-15 through MSS-120 81 N-m 60 Lb-ft Series shell flange bolts MSS-160 through MSS-240 109 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-75 68 N-m 50 Lb-ft Pump shaft nut (balance disc nut) MSS-90 through MSS-120 95 N-m 70 Lb-ft Pump shaft nut (balance disc nut) MSS-160 through MSS-240 123 N-m 91 Lb-ft Pump support bracket anchor bolt 108 N-m 80 Lb-ft Stage split cone nut MSS-40 through MSS-75 54 N-m 40 Lb-ft Stage split cone nut MSS-90 through MSS-120 101 N-m 75 Lb-ft Stage split cone nut MSS-160 through MSS-200 162 N-m 120 Lb-ft Stage split cone nut MSS-240 203 N-m 150 Lb-ft Pump Alignment Specifications Motor Adapter Gap Tolerances for non-uniform gaps Good 0.381 mm 0.015" Balance Disc Specifications Pump Model Original Thickness When New Wear Limit - 0.508 mm (0.020") MSS-15 through MSS-75 13.5 mm (0.531") 13.0 mm (0.511") MSS-90 & MSS-120 16.0 mm (0.630 ) 15.5 mm (0.610 ) MSS-160 through MSS-240 15.7 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 - 43 -
Notes - 44 -
Visit our website for the latest version of this document and more information. www.fedco-usa.com Main Office Tel: 734-241-3935 Fax: 734-241-5173 techsupport@fedco-usa.com FEDCO 800 Ternes Drive Monroe, MI 48162, USA Dubai Office Tel: 971-04-880-7344 Fax: 971-04-880-7354 techsupport-dubai@fedco.com Technopark, Plot TP10501 Jebel Ali South, PO Box 37603, Dubai, UAE Singapore Office Tel: 65-6779-0123 Fax: 65-6779-6900 techsupport-singapore@fedco.com Singapore Branch 82 Toh Guan Road East #C2-14-4 WaterHub Singapore, 608576 FEDCO Sales Office Service Center - 45 -