英文TMC IOM ManualVER1.0-2020 Jinguang

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Table Of Content
1 GENERAL REMARKS...................................................................................................................... 2
1.1 ABOUT THIS MANUAL................................................................................................................................ 2
1.2 GUARANTEE .......................................................................................................................................... 2
1.3 TYPE OF OPERATING MANUAL..................................................................................................................2
1.4 SERVICE DATA - SERVICE CONTRO ......................................................................................................... 3
2 SAFETY..................................................................................................................................................4
2.1 MARKING OF INSTRUCTIONS IN THE OPERATING MANUAL......................................................................... 4
2.2 QUALIFICATION AND TRAINING OF PERSONNEL ....................................................................................... 4
2.3 DANGER ON NON-OBSERVATION OF THE SAFETY REGULATIONS ............................................................. 4
2.4 SAFETY-GUIDED WORKING ..................................................................................................................12
2.5 SAFETY INSTRUCTIONS FOR USER / OPERATOR ...................................................................................12
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND ASSEMBLY JOBS .................................... 12
2.7 PROHIBITION OF UNAUTHORIZED REBUILDING MEASURES OR ALTERATIONS ........................................ 12
2.8 INADMISSIBLE OPERATING MODES .......................................................................................................12
3 TRANSPORT AND STORAGE...................................................................................................... 6
3.1 TRANSPORT / LIFTING ...........................................................................................................................6
3.2 PRESERVATION AND STORAGE ..............................................................................................................7
4 DESCRIPTION.....................................................................................................................................10
4.1 DESCRIPTION OF THE PUMP.................................................................................................................. 10
4.2 BEARING AND LUBRICATION.................................................................................................................. 10
4.3 ABSORPTION OF THE AXIAL THRUST - BALANCE DRUM............................................................................ 10
5 INSTALLATION OF THE PUMP................................................................................................... 12

5.1 MOUNTING............................................................................................................................................ 12
5.2 ALIGNMENT OF COUPLING...................................................................................................................... 14
5.3 SUCTION AND DISCHARGE PIPEWORK......................................................................................................16
5.4 NCILLARY EQUIPMENT ........................................................................................................................... 18
6 OPERATION........................................................................................................................................ 21
6.1 GENERA................................................................................................................................................. 21
6.2 COMMISSIONING..................................................................................................................................... 21
6.3 PUMP START-UP AND OPERATION COMMISSIONING ..................................................................................22
6.4 INADMISSIBLE OPERATING MODES ........................................................................................................... 22
6.5 SHUT DOWN ...........................................................................................................................................23
6.6 RESTART PROCEDURE ............................................................................................................................23
6.7 SERVICE CONTROL .................................................................................................................................23
6.8 OPERATING FAULTS ............................................................................................................................... 25
7 MAINTENANCE AND OVERHAUL..................................................................................... 27

7.1 MAINTENANCE-PUMP.............................................................................................................................. 27
7.2 MAINTENANCE-SHAFT SEAL .................................................................................................................... 28
7.3 MAINTENANCE-BEARING LUBRICATION .................................................................................................... 29
7.4 OVERHAUL-DISMANTLING OF THE PUMP ..................................................................................................32
7.5 OVERHAUL-INSPECTION OF WEARING PARTS ........................................................................................... 34
7.6 OVERHAU - ASSEMBLY OF THE PUMP ................................................................................................. 12
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INSTALLATION，OPERATION & MAINTENANCE MANUAL
1. SUBJECT: GENERAL REMARKS Page 2 of 41
1. GENERAL REMARKS
1.1 About this manual

The operating manual contains important information on how to operate the pump safely, properly
and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and
downtimes and to increase the reliability and life of the pump.
How to use this manual
The operating manual must always be available wherever the pump is in use. These instructions must
be read an applied by any person in charge of carrying out work with and on the pump, such as
transport, storage, installation, operation and maintenance.
This manual should be used together with all other machine documentation in order to have
accurate information of your pump. Do not start or operate this pump unless you have
complete understanding
of the pump system and all auxiliary systems (driver, cooling, seal flushing…).
1.2 Guarantee
Guarantee is assumed according to the contractual agreements.
The normal DNB warranty covers manufacturing or material defect, it does not cover the damage
caused by improper storage conditions, incorrect installation, operation and using against designated
use.
During the period of guarantee, repairs or modifications only can be made by our service personnel or
with our agreement.
1.3 Type of operating manual (Acc. to DIN 8418 )

Documents no.: see cover sheet
Service address: see cover sheet
Issue: 2002
We reserve all rights in this manual and in the information contained. Reproduction, use or disclosure to
third parties without our approval is strictly forbidden.
Remark
In the case of further questions, of spare part orders and other correspondence please mention always
the S Serial No. and pump type. Both can be gathered from the rating plate of the pump.
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SUBJECT: GENERALREMARKS Page 3 of 41
1.4 SERVICE DATA - SERVICE CONTROL

1.4.1 Data
S Serial-No.:
Item-No.:
Medium delivered
Capacity m3/h
Minimum capacity m3/h
Differential head m FS
NPSH - R m
Differential pressure bar
Suction pressure norm. /max bar
Discharge pressure norm. /max bar
Pumping temperature (PT) 0
C
Specif. grav. at PT kg/m3
Pump input kW
Speed 1/min.
1.4.2 Lubrication
Oil (according to DIN 51 524) ISO VG 46 see also 7.3
Oil temperature 0
C 40 - 70
Quantity of oil per bearing frame Liters
1.4.3 Cooling
Cooling water m3/h
Pressure normal/max bar
Temperature outlet max. 0
C
1.4.4 Heating
Heat exchanging medium
Pressure normal/max bar
Temperature entry max. 0
C
1.4.5 Flushing (shaft seal)
Flushing / Sealing medium
Quantity min m3/h
Pressure bar
Temperature of flushing medium 0
C
1.4.6 Flushing (wear ring)
Flushing / Sealing medium
Quantity min m3/h
Pressure bar
1.4.7 Quench
Quench medium
Quantity min m3/h
Pressure bar
1.4.8 Safety technical limit data
Max. allowable working pressure bar
Max. allowable working temperature 0C
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SUBJECT: SAFETY Page 4 of 41
2. SAFETY
This operating manual contains basic information, which has to be observed on the installation,
commissioning, operation and maintenance. Therefore this operating manual has to be read before
assembly and commissioning by the service engineer and service personnel in charge respectively user
and has to be available constantly at the site of the machine/installation.
Not only have the general safety instructions to be observed, which are given under this main point
"Safety", but also the special safety instructions given below in the operating manual.
2.1 Marking of instructions in the operating manual

- Non-observance of the safety regulations which might cause an endangering of people are marked
with the general sign for danger
Warnings of electrical voltage are marked specifically by
- Safety regulations the non-observation of which may cause danger for the machine and its
operatability are marked by
- Indications which are directly attached at the machine itself such as
- arrow for rotational sense
- marking for fluid connections etc.
have to be kept in good, legible condition, as they have always to be observed.
2.2 Qualification and training of personnel

The personnel for service, maintenance, inspection and assembly has to hold the necessary
qualifications for this kind of jobs. Range of responsibility, competence and the monitoring of the
personnel have to be fixed clearly by the user. In case the personnel should not have the required
knowledge, they have to be trained and instructed. This may be undertaken by the manufacturer of the
machine, if required, on user's request. Further the user has to ensure that the personnel has a
complete understanding of the contents of the manufacturer's instruction manual.
2.3 Danger on non-observation of the safety regulations

By non-observation of the safety regulations danger may arise for persons as well as for
environment and machinery and may lead to a complete loss of any claims for damages.
- Non-observance may lead for example to the following dangers:
- Failure of important functions of machine/plant
- Failure of required procedures of maintenance and repair
- Endangering of people by electrical, mechanical and chemical impacts
- Endangering of environment by leakage of dangerous materials

2.4 Safety-guided working
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SUBJECT: SAFETY Page 5 of 41
The safety regulations given in this operating manual which consist of national regulations on accident
prevention, as well as company- internal job, operating and safety regulations issued by the user, have
to be observed.
2.5 Safety instructions for user / operator

- In case hot or cold machine parts may lead to any danger, they have to be secured by user against
touching.
- Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.
- Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be
disposed of in such a way as to prevent any endangering of people and environment. Legal
regulations have to be observed.
- Endangering by electricity has to be excluded (details see for example in the regulations by the VDE
and local energy suppliers).
- The special safety instructions in the following paragraphs of this operating manual have to be
observed.
2.6 Safety instructions for maintenance, inspection and assembly jobs

- The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by
authorized and skilled personnel only, who have been adequately informed by studying the
operating manual carefully.
- Basically any works on the machine may be carried out only during shut-down of the machine. The
procedure described in the operating manual for the shut-down of the machine has to be strictly
adhered to. The machine has to be locked against unauthorized or involuntary start-up.
- Pumps or aggregates delivering media hazardous to health have to be decontaminated.
- Immediately following the end of the works, all safety and protective devices have to be
reassembled respectively have to be put to work again.
- On a repeated start-up all points given in the paragraph initial commissioning have to be observed
again.
2.7 Prohibition of unauthorized rebuilding measures or alterations

- Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer.
Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee
safety. The use of other parts may lead to a loss of the manufacturer's liability for the
consequences.
2.8 Inadmissible operating modes

- The operational safety of the delivered machine is only guaranteed by proper use acc. to the data
under item 1.4 of the operating manual.
- The limits given in the data sheet must not be exceeded in any case.
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SUBJECT: TRANSPORT AND STORAGE Page 6 of 41
3. TRANSPORT AND STORAGE

3.1 Transport / Lifting
General remarks
For all transport jobs the general rules of engineering and regulations on the prevention of accidents
have to be strictly observed.
These are especially
VBG 1 - General regulations
VBG 5 - Power-driven working devices
VBG 8 - Lifting devices
VBG 9 - Cranes
VBG 9a - Load suspension device with hoists and conveyors
The above regulations are applicable in the area of the Federal Republic of Germany, in other countries
the appropriate regulations have to be observed.
For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.
Transport
Transport devices (including vehicles) have to be checked for the admissible load weight. Total
weight of the delivered goods see dispatch documents. The load has to be secured during
transport against shifting.
Lifting
Check of the load suspension devices / ropes
It has to be assured that admissible, undamaged ropes and lifting
devices will be used. The loading capacity of the lifting devices and the
ropes has to be suitable to take up the weight of the goods to be lifted.
Load weight indications of the delivered units are given in the installation plan
respectively the dispatch documents.
Fastening of the sling ropes on crates

The points for the fastening of sling ropes on closed crates are marked.
As the center of gravity (mass) cannot be recognized in closed crates, the
sling rope fastening has always to be done at the marked spots. See
sketch 3.1-1.
Fastening of the sling ropes on bar shaft pumps
The pump without packing can be lifted and transported by ropes witch are laid
around casing parts (shaft seal housings). See sketch 3.1-2.
Fastening spots for units
In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these
spots by shackling the rope. See sketch 3.1-3.
Units up to a certain weight can also be lifted by ropes which are laid around certain parts of the pump
such as pump branches, bearing frames, motor housings etc. See sketch 3.1-4.
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Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the
complete assembled pump or even the whole unit. The eyebolts are only meant for the lifting of
the loosened parts during assembly and disassembly
3.2 Preservation and storage
Preservation for despatch
Standard
When the pumps are shipped, smooth outside faces are sprayed with Tectyl 506 and pump internals
with Mobilarma 524. Attention: this is not suitable as long-term preservation; 6 months are max.
allowed time for storing.
Seaworthy packing
If the pump is despatched with PE-foil welding with moisture absorber (sea-worthy packing) the pump
can be stored up to one year without any special maintenance if the packing is not damaged.
Special packings
On special request the pump can be packed in aluminium foil. In this case the preservation time
amounts to 2 years.
If the seaworthy or other special package is removed, only the standard preservation
is effective, i.e. if no further measures are taken, the max. storage period will be 6
months.
Intermediate storage
Centrifugal pumps which are not installed and commissioned immediately after delivery can be stored
for the period determined by the dispatch preservation.
To avoid the forming of condensate and consequently corrosion (especially in the
gap areas), bearing damage and contamination, a dry room, possibly with constant
temperature as well as a clean, shock- free storage space has to be selected.
In each case unfavourable climatic circumstances will have a negative influence on
period of proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed:
In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt
etc.) the connection flanges of the pumps have to be plugged airtight.
Longterm storage – preservation
In case a longterm storage is to be previsaged in the store of the client or on site or pumps affected by a
longer shutdown of the plant or standby pumps are to be preserved, the following instructions have to be
observed:
If pumps have been in service before, pump parts having been in contact with the
pumped liquid must be cleaned and after drying be moistened with a preservative.
For this purpose the disassembly of the hydraulic part of the pump becomes
necessary in most cases.
I. Protection of unencumbered, bright parts of the pump
e.g. - pump shaft
- raised faces of flanges
- coupling
- connections for small conduits etc.
We would urgently advise against using normal lubricating oil as a rust preventative. For the
preservation of bright pump parts, the mineral-oil industry has developed special rust preventatives
which at first are liquid and are applied manually, by means of brushes, spray nozzles or aerographs.
After the evaporation of the solvent, a wax-type cover will remain.
This protective film can be removed by means of solvents or alkaline cleansing agents.
We recommend rust preventatives

- Rust Ban 397 from ESSO
- Tectyl 506 from VALVOLINE
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Other rust preventatives of the same quality may however be used as well. The average time of
protection is 1-3 years. Rust preventatives are rust-preventing agents which however do not remove
rust. For this reason, it is a prerequisite for the application of rust preventatives that the parts to be
protected are clean and rustfree. The surface of the parts has to be cleaned carefully before the
respective rust preventative is applied.
II. Protection of the interior of the pump
e.g. - pump casings

- stuffing box chambers
- bearing frames etc.
For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 – 70
mm2/s should be used.
We recommend the rust preventatives
For gaskets in Perbunan (NBR), Viton (FPM), Teflon (PTFE):
- Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
For gaskets in ethylene-propylene (EPDM):
- Klüber Syntheso D 220
III. Proceeding in case of longterm preservation

1. Shaft seal
1.a Centrifugal pumps with soft packings
If the pump is supplied with a stuffing box packing installed, the packing has to be
removed and replaced by a special packing which is to remain in the stuffing box
chamber during the preservation time, only.
For packing material, we recommend:
- synth. fibres, with PTFE impregnation (e.g. Chetra 1711 GS or Hecker 1820)
The packing chamber is filled completely with the separate packing rings (stagger joints at 90 degree
intervals).
Note: Before commissioning, make sure that the preservation packing is removed and replaced by
packing rings of the quality provided for operation.
1.b Centrifugal pumps with mechanical seals

The complete mechanical seals remain within the stuffing box chamber. Pour rust preventative through
the circulation and quench connections (see II.) and turn pump shaft manually several times while filling
in the preventative.
2. Pump casing
At first the raised faces of the pump flanges have to be cleaned thoroughly and preserved with one of
the rust preventatives mentioned under I. On smooth flanges and those with annular tee-slots, flat
gaskets should be placed; in case of slotted flanges, 2 gaskets should be placed in the slot, and all the
sockets have to be closed tightly by means of metal covers. The connections for the cooling
water/circulation lines etc. should also be closed by means of normal steel plugs, using Molykote. Then
fill pump casing with rust preventative (see II.). While filling in this agent, turn pump shaft manually
several times (observe sense of rotation).Generally speaking in practical handling the casing interior of
bigger pumps usually is only sprayed, in this case the preservation has to be repeated every 6 months.
3. Bearing frame
Also fill with rust preventative (see II) until lower edge of the shaft.
IV. Maintenance of the stored centrifugal pumps

At the parts which are filled with rust preventative (pump casing/stuffing box housing/bearing frame) the
condensate should be drained every 6 months; rust preventative should be added, if required. To avoid
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corrosion damage at bearings, the pump rotor should manually be turned simultaneously, so that the
preservation oil will be distributed over the running surfaces of the bearings.
According to manufacturers indications, the rust preventative has to be discharged
and the spaces have to be refilled every 12 months*. If the rust preventative is not
renewed within this period the risk is to be taken by the storage keeper. In order to
have a guarantee for the proper execution of the maintenance instructions, we recommend to establish
maintenance sheets.
* If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than
after 6 months.
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SUBJECT: DESCRIPTION Page 10 of 41
4. DESCRIPTION
4.1 Description of the pump
General: Pumps of the DS series are horizontal, multi-stage, ring section centrifugal pumps designed
for boiler feed and other high pressure applications.
The pumps are suitable for pumping clean liquids. The permissible operating
pressures and permissible operating temperatures depend upon the material
specification. See 1.4.8 for safety limit data for the pump supplied.
The materials of construction have been selected for the liquid specified in your
order. Before the pump is operated with other liquids or at other temperatures it is
essential that the manufacturer be consulted.
Casing: The casing is radially split and consists of suction casing, stage casings as required and
discharge casing. The elements are sealed by O-rings and held together by external tie bolts.
Shaft: Accurate machining provides precision fits and clearances for assembly and operation. Machined
shoulders provide positive location of mounted parts.
Impellers: The impellers are key-driven, have closed channels and are sealed against the casing
elements by replaceable casing wear rings. The flow is guided from stage to stage by stationary
diffusers.
Shaft seal: The inner chamber of the pump which is filled with liquid is sealed at the shaft by packed
glands or mechanical seals. See 7.2 or description of the seal manufacturer for further information.
The stuffing box housings are fitted with a cooling chamber as required. In order to
prevent evaporation in the vicinity of the shaft seal, the cooling water quantity given
under 1.4.3 must be assured. Non-compliance can lead to total failure of the shaft
seal.
Coupling: Flexible couplings must be used to connect the pump to the driver: these couplings must be
able to absorb small axial, radial and angular shaft misalignments.
4.2 Bearing and lubrication
Bearing housings: The bearing housings flanged on both pump sides are equipped with splash oil
lubricated bearings. The lube oil quantity is given under 1.4.2 and 7.3 .
Antifriction bearings: Roller bearings are used as bearings for the massive pump shaft in the bearing
bracket on the drive side, whereas paired taper roller bearings take up the axial forces at the non-drive
side.
Fan: A fan assembly is provided to enhance air cooling of the bearing bracket non-drive side.
Constant Level Oiler: An oiler is installed on each bearing housing. The oiler automatically maintains
bearing housing oil level and provides a means of monitoring and refill. See also 7.3
4.3 Absorption of the Axial Thrust - Balance drum
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SUBJECT: DESCRIPTION Page 11 of 41
General
During operation of the pump an axial thrust is exerted on the rotor towards the suction side. This arises
because the area of the back shroud of the impeller is larger than that of the front shroud which is
interrupted by the impeller eye, both being subjected to the same liquid pressure. In multi-stage pumps
the forces per stage are cumulative and considerable axial loads result. These forces are absorbed by
the hydraulic balance device.
Working principle
The balance device consists of a balance drum
rotating with the shaft and a balance drum liner
housed in the discharge casing. The pressure
difference between the pressure within the
pump 'a' (discharge pressure) and the pressure
in the balance chamber 'b' (suction pressure +
frictional resistance in the balance pipe) creates
an axial force 'F' on the balance drum. This
axial force is opposite in direction to the pump
axial thrust. The magnitude of the force 'F'
depends on the area "A" of the balance drum
which is sized such that the axial thrust at the
operating point is almost completely
compensated.
The residual axial thrust is absorbed by a thrust
bearing. The pressure difference between 'a'
and 'b' also sets up a flow through the throttling
clearance 'c' into the balance chamber. A
perfect balance is only achieved if there is no
build up of pressure in the balance chamber as
a result of the balance flow being restricted.
Balance pipe
Severe damage to the pump will result, if the instructions for the laying of the
balance pipe are not strictly observed.
To prevent a pressure build-up in the balance chamber there must be a drain for the
admitted liquid. A tapping for this purpose is provided in the pump balance chamber
(the position is indicated on the dimension drawing).
- The routing of the balance pipe depends on the operating conditions. It is either:
returned to the suction tank
or returned to the suction casing.
The data on the installation drawing is decisive for the pump supplied.
Note! With flow returning into the suction tank the following must be observed:
The frictional resistence of the balance pipe must not exceed 0,8 bar (12 psi).
Choose corresponding nominal diameter.
A valve should be fitted in this pipe for maintenance purposes. Steps must be taken
to ensure that this can be locked in the open position to prevent unauthorized and/or
accidental closur
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SUBJECT: INSTALLATION OF THE PUMP Page 12 of 41
5 INSTALLATION OF THE PUMP
5.1 Mounting (see dimension drawing / installation plan)

General
Good planning and preparation result in fast, simple and correct installation. Safe running conditions
with maximum accessibility are assured. When preparing for installation of the machine, it is necessary
to take the following aspects into account:
The main dimensions, connections, position of fixing bolts etc., are shown on the dimension
drawing/installation plan.
Suitable lifting devices must be available for installation and repair work. Good lighting is important and
sockets for portable lights should be available. The pump should be readily accessible from all sides.
The pump foundations and type of installation should be designed so that vibration is kept to a minimum
both during operating and when the pump is at rest, otherwise the pump life will be reduced.
A drain must be provided so that gland leakage, cooling water (open system) and liquid drained from the
pump during overhaul can be led away.
The draining of the pump respectively the disposal of the leakage for pumps delivering toxic,
explosive, hot or in any other ways dangerous fluids, must not lead to any endangering of
operator(s) and environment.
Following manufacture the pump flanges and external tappings are protected by plastic plugs which
should not be removed before the pipework is ready to be attached to the pump. The pump should be
protected, if further site work is necessary nearby.
The foundation or any other necessary building work must be finished, set and dried. Roughen and
clean the foundation. All preliminary work for erection must be completed. With large units, suitable door
and wall openings are to be provided for transport to the installation site.
Grout selection
Select a nonshrinking grout that is compatible with the highest and lowest temperatures to which it may
be exposed. Use concrete from a concrete company with a final strength of 25 N/mm2 (B25) or better.
If the service of a concrete company is not available the figures given below may be taken as a guide.
- The concrete mixture suitable for grouting machine baseplates should contain 300 to 350 kg cement
per 1 m3 of concrete. The sand and gravel proportion for 1 m3 of finished concrete (1.2 m3 mixture) is
as follows:
For grouting of the foundation bolts: 65% Fine sand grain size 1 - 5mm
35% Coarse sand grain size 5 - 10mm
water as required
The use of so called „fast cement“ with short setting time is possible.
For grouting (filling) of the baseplate: 40% Fine sand grain size 1 - 5 mm
60% Coarse sand grain size 5 - 10 mm
100 - 140 liters of water
Only clean, washed sand may be used. The water-cement ratio has a decisive
influence on the final strength of the concrete.
A high concrete strength will be attained with high standard strength of the cement, low water-cement
ratio, and compacting by vibrating.
Installation of pump and driver
With separate baseplates for pump and driver first erect the pump, then align the
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driver.
- Roughen and clean the foundation. Walls of the grouting holes must have rough surfaces and must be
free from pollution. Remove any loose particles, dirt or oil-soaked concrete. All baseplate surfaces which
will be in contact with grout must be clean. Remove rust, paint or other extraneous material.
- Attach wire rope slings to the baseplate transport eyes (see 3.1 transport/lifting) and lift the baseplate
with pump and driver. Insert foundation bolts into the holes in the baseplate and tighten the nuts a few
turns.
- Lower the baseplate carefully into position on the foundation. The foundation bolts have to be lowered
into the foundation holes.
Levelling
- Place steel shims under the adjusting screws and align the pump unit horizontally with the aid of the
adjusting screws. Provide proper grouting clearance between foundation and baseplate (see installation
plan).
Check levelling in the direction of the pump axis and also at right angles along the
horizontal flange with a spirit (machinist’s) level. The flanges must be vertical on
horizontal branches. See sketch 5.1.1. Max. permissible variance 0.5 mm over 1m.
- Push steel shims into line to the right and left of the foundation bolts. The shims must be thick enough
so that there will be only minimal clearance between baseplate and shim. The space between baseplate
and shim must be filled with one or two thin parallel sheet metals which must be available in different
thicknesses. See sketch 5.1-2.
- Loosen adjusting screws and check levelling. If required correct levelling.
Grout in the foundation bolts

- Before grouting wet the foundation holes. Fill foundation holes with concrete.
- After setting tighten the foundation bolts (see table 5.1-1) and check horizontal alignment again. If the
position of the pump has changed, correct alignment.
Do not bend the baseplate since this will cause development of vibration and noise
during operation or the alignment of the coupling will not possible.
- Before grouting the baseplate align the coupling as described under 5.2 (alignment report).
Completion of grouting (when properly aligned)

Grouting of the machine into the foundation is a very important part of the
installation.
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Problems can arise, if materials are of poor quality, which may

show up early or after several months of operation.
- Build a dam around the foundation. Forms must be strong
enough to withstand the grout pressure. Attach a chamfer strip
on the form inside, at grout grade elevation, to provide
a neat beveled edge. See sketch 5.1-3.
- Finish grouting the baseplate in conformity with the
corresponding installation plan. Fill the baseplate with thin-
bodied concrete through grout holes. Take care that the
baseplate is completely filled with grout, vibrate as necessary.
The concrete must neither dry out nor
freeze during the first 48 hours. During this
time the temperature of the foundation
should not fall below 10oC. The optimum temperature for the
setting process is 20oC +/-10 oC.
- If necessary: Seal the grout openings by covering with a
quality paint or with grout hole covers.
When the concrete has set, re-tighten foundation bolts (see table 5.1-1) and check coupling
alignment, see 5.2 (alignment report).
Tightening torques for foundation bolts (Table 5.1-1)
5.2 ALIGNMENT OF COUPLING

General
Before aligning the coupling, and with the pump and driver uncoupled, check the
direction of rotation of the driver corresponding with the direction of rotation arrow on
the pump.
Flexible couplings need very careful alignment of the shafts which can be achieved by
placing thin shims under the machine feet. Negligence in alignment will destroy the
coupling and damage the pump and motor bearings, too.
Misalignment types
There are three basic types of misalignments between the pump and driver shafts:
Assembly
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The assembly of the coupling must be carried out in accordance with the coupling manufacturer's
instructions. For mounting the coupling halves onto shaft ends see also 7.6.
Check for “soft machine feets”
Before coupling alignment the driver and pump fixation must be checked regarding “soft feet“ issue
Loosen machine feet fasteners one after the other and check with feeler gauge if a gap between
machine feet and baseplate occur. If the gap is larger than 0.05 mm (0.002 in.), then the gap have to be
compensated by shimming.
If the base plate has not grouted jet, the “soft feet” may also be compensated by re-adjustment of the
baseplate.
If the pump or driver are not properly fixed to the base plate higher intermittent
vibrations or excessive misalignment due to nozzle loads can be expected .
Pump foot tightening torques
For the transport the tie bolts have to be tightened at the pump feet. To render possible a tension-free
thermal expansion of the pump during operation, the screws loosened again for the precision alignment
of the coupling must not be screwed so tight on the non-drive side as on the drive side. Essential values
for the tightening torque of tie bolts on drive side and non-drive side are shown in the table below.
Coupling alignment procedure

Every alignment check must be preceded by a
runout measurement at the coupling flanges. Record
the results always in a log. All readings for radial and
axial misalignment are determined in the gauge
positions: top, bottom, right and left, i.e. every 90o,
while both shafts are simultaneously turned.
Alignment should be carried out with clock gauges
in radial and axial direction (see sketch 5.2-6).
The maximum admissible axial misalignment is
0.05 mm (0.002 in.) on diameter, although ≤ 0.03
mm (0.001 in.) is preferable.
The maximum admissible radial misalignment is
0.1 mm (0.004 in.) on diameter, although ≤ 0.05
mm (0.002 in.) is preferable.
Optical Alignment
Instead of using a clock gauge assembly, optical
(laser) alignment equipment may be used.
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Laser optical alignment is the most exact shaft aligning method. The transmitter is a laser diode
mounted on one side of the coupling and the prism is mounted on the other side. The laser beam
emitted by the laser diode is reflected by the prism to the localizer. The offset can be detected by
rotating the shafts.
Coupling safety guard
The pump only have to operate with mounted coupling safety guard. After each alignment
check the coupling guard must be refitted immediately. Check for correct assembly, fastening
and distance to rotating coupling.
5.3 SUCTION AND DISCHARGE PIPEWORK

General
Pipe diameters will have already been determined at the planning stage and many factors unknown to
the pump manufacturer will have been taken into account. As a general rule the liquid velocity should
not exceed 2 m/sec (6.5 ft./sec) in the suction pipework and 3 m/sec (10 ft. sec) in the discharge
pipework.
It is also good engineering practice to increase the size of both suction and discharge pipes at the pump
nozzles in order to decrease the head loss from friction. For the same reason piping should be arranged
with as few bends as possible and even then should be made with a long radius wherever possible.
A few useful hints are given below which should be observed when the pipework is installed.
In case the possibility of dangerous recirculation may occur after shut-down of pump,
especially with "emergency trip out", back-flow preventors (check valve) have to built
in.
Assembly
The pipework must be supported in an adequate manner to ensure that no
inadmissible bending moments or stresses caused by the weight of the pipework or
thermal expansion are transmitted to the pump flanges (install an expansion piece).
All supports and expansion equipment must be installed before making connections to pump flanges.
Ensure that the correct gasket is used at all flanged joints and that the gasket is mounted concentric with
the bore of the pipe.
Stress free pipe connection
The stress free pipe connection is to be checked (cold condition, pump empty) in the following way:
The pipe has to be suspended over the pump flange and there must be space enough to easily build in
the sealing.
The supports have to be designed in such a way that the weights of the pipe and the fluid are
compensated and will not put inadmissible high pressure on the pump branch (observe nozzle loads in
the installation plan).
 If the pipe supports (especially fixed points) are not near to the pump with 1 or 2 elbow (45° or 90°
direction change ) the pipe can be considered as flexible. In such cases following tolerances can be
used for “stress free connections”
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Adjustments must be made to the piping, if these limits are exceeded or serious
damage to the pump may result.
Pipe fittings
A check valve and a shut-off valve should be installed in the discharge line. The check valve, placed
between the pump and the shut-off valve, is to protect the pump from reverse flow and excessive back
pressure. The shut-off valve is used in priming, starting and when shutting down the pump.
In the suction line a shut-off valve should be installed for extended shut downs, repairs and for pump
draining.
Fittings having the same nominal bore of the pipework should be used. If the pump
branches have a smaller nominal bore than the fittings suitable taper pieces should
be installed.
Suction pipe
On flooded suction applications, the horizontal sections of the pipework should descend towards the
pump and on suction lift applications they should steadily rise towards the pump to prevent air locking.
The pieces should be designed and constructed so as not to obstruct the free flow of the liquid. The
transition from small to large pipe diameters must be gradual. As a general guide the length of a
concentric taper piece must be 5-7 times the difference in pipe diameters.
Sudden reductions in pipe cross sectional area and sharp bends should be avoided especially in the
suction or inlet pipework, as these greatly increase the frictional resistance within the pipework. A high
frictional resistance within the suction or inlet pipework leads to reduced pressure available at the
suction branch. Too low pressure leads to cavitation at the impeller inlet.
To prevent turbulent flow into the pump, do not position the shut-off valve in the suction piping adjust to
the pump suction nozzle. The suction valve should be positioned with the handwheel horizontally or
vertically downwards to prevent air pockets forming.
Multi-pump installations should have separate suction pipes to each pump. Excepted are duty and
standby pumps which may have common suction pipework since only one pump operates at any time.
Cleaning the pipework
Before a pumpset is commissioned, all traces of foreign bodies and impurities must
be carefully flushed out of the supply tank and pipework. Where pipework has been
welded, all welding slag etc. must be removed.
Suction strainer
In order to prevent any of the above impurities entering the pump, it may be necessary to install a
suction strainer made of stainless steel in the inlet pipework. The strainer insert should consists of a
supporting strainer (plate with round holes 5 to 8 mm, 0.2 to 0.32 in.) to which a wire screen (wire cloth
0.315 x 0.2 mm, 0.0125 x 0.008 in.) is fixed by welding. The effective area of passage of this strainer
must be at least 1.5 to 2 times the pipe diameter.
Monitor the pressure drop across the strainer by a differential pressure gauge. If at any time, a reduction
in pump suction pressure is observed, the strainer should be removed and cleaned.
The differential pressure ≥0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5 bar (7 psi.) the
pump is SHUT OFF; higher differential pressures may lead to the damage of the strainer result in
serious damage to the pump.
The given values are limits for the load on the strainer. As NPSHavailable at the suction
branch is reduced by the max. admissible differential pressure at the strainer
whereas NPSHavailable has always to exeed NPSHrequired , lower regulation limits for
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ALARM / SHUT OFF may have to be set accordingly.

Pressure test
The pipework should be pressure tested in accordance with the statutory
regulations.
5.4 ANCILLARY EQUIPMENT

General
Ancillary equipment is used to monitor the pump (measuring equipment for pressure, temperature etc.)
and to maintain operation (cooling, flushing, sealing etc.). The extent depends on the application and
installation requirements. For type, position and dimensions of the ancillary connections please see
installation drawing.
In case the failure of any auxiliary devices (e.g. cooling, circulation) may lead to an inadmissible
pressure build-up in the pump suitable safety devices have to be installed by user (e.g. alarm,
emergency shut-down or similar).
Do not mix up connections. After laying the pipes (and also after repairs), check the
pipe runs.
The following instructions may be used as a guide insofar as they apply to the pump as
delivered.
Ancillary pipework
- Drainage of the pump casing can be effected by leading a pipe into the drip tray of the baseplate or
into a collection pipe. Isolating valves must be installed in the pipe and must have a pressure rating at
least equal to the rating of the casing.
The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead
to any endangering of operator(s) and environment.
- Gland leakage from the shaft seal can also be led into the drip tray or collection pipe.
The leakage of dangerous fluids has to be drained or quenched in such a way as to prevent any
dangers to persons and environment.
- Cooling through cooling liquid: Connections and scope see installation plan or separate drawing
respectively. Don't confuse inlet and outlet connection. (Inlet lowest, outlet highest point of cooling
chamber). For the adjustment of cooling water quantity regulating valves are installed in the supply
pipings. At open system lead the drain pipings over a funnel.
- Flushing and / or sealing of the shaft seal: Connections and scope see installation plan or separate
drawing respectively. For pipings which lead to a heat exchanger, pressure transmitter or supply
reservoir, a vent possibility is provided at the highest point. In case of thermosyphon revolution the
biggest pipework diameter possible will be used. Supply piping is layed evenly ascending and without
sharp bend.
- Quench: In case the necessity arises to quench any leakage from the mechanical seal see 1.4.7 for
information on quench media and quantity.
Pressure measuring equipment
- The start-up and monitoring of the operating point of the pump is made easier with pressure gauges.
See also 6.1 and 6.3. Pressure gauges should be mounted on a common gauge panel and connected to
the tappings in the pump branches or adjacent pipework using a hydraulic tube with an expansion loop.
Isolating and vent valves should be installed in the pipework for ease of maintenance.
Bearing monitoring (impact impulse measurement, only possible with antifriction bearings)
- Advancing bearing damage can be recognised and monitored by means of impact impulse
measurement. This requires a special measuring unit which is connected near the bearing through
screw fittings (e.g. SKF connecting nipple No. 1649013 and SKF measuring unit MEPA 21 A).
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Temperature measuring instruments

- If pump operates near the vaporization point of liquid, thermometers are recommended for control of
liquid temperature. See also point 5.4 "Minimum flow device". At installation of thermometers in the
pipework let submerse the temperature gauge at least 40 mm into the fluid. At pressures over 16 bar
use protection tube.
- If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid
vaporization in the sealing range (see 1.4.5).
- At heating the max. temperature of heat carrier has to be controlled (see 1.4.4).
- A measuring possibility of cooling water outlet temperature is favourable, as the adjustment of outlet
temperature smaller than 40 oC avoids deposits in the cooling water pipings.
- At pumps with high loaded bearings numeros controls of bearing- or oil temperature are required. If
necessary control by means of contact thermometer. Execution and measuring points see pipework
scheme or installation plan. Limit values see 7.3 and 1.4.2.
- It's useful to control temperature under sound insulation covers with tele-indication. Align such a way,
that oil- or bearing temperature respectively of pump and driver cannot exceed the permitted limit.
Flow indication or flowmeters

- According to technical requirements flow indicators are installed in the reflux of supply pipework. Don't
start-up pump before auxiliary pipings are open and the liquid stream can be determined on flow
indicator.
- If there is danger for mechanical seal in case of too low circulation, a flowmeter is installed in the
circulation piping, which causes alarm when circulation quantity decreases or which shuts the pump
down.
Electrical connections
Electrical connections for motors and controlling devices may only be implemented by skilled
personnel.
The instructions of the electrical equipment manufacturers have to be observed as well as the valid
national regulations on electrical installations and the legal regulations of the local power suppliers.
Note: In accordance local-safety standards these instructions must form part of every operating manual.
Safety instructions for pumps which operate in the partial load region. The following information may be
disregarded, if the pump supplied never runs in the partial load region.
Minimum flow device

General
In the partial load region (when operating the pump near zero flow) almost the total
pump power is imparted to the flow as thermal energy. If this flow is less than a
certain minimum (see 1.4.1), heating will occur and continue until the liquid boils, causing severe
damage to the balance device, impellers and casing wear rings leading to eventual breakdown of the
pump. To avoid this there must always be a certain flow of liquid through the pump. The following two
situations arise for multi-stage pumps with hydraulic balance of the axial thrust:
1. The balance quantity is sufficient
This means that in cases of relatively low driver power and favourable suction conditions the
balance flow is sufficient as the leak-off to be piped away. If this condition applies to the pump
supplied, it is noted expressly on the data sheet under 1.4.1 that the minimum flow is equal to the
balance flow. The balance pipe must not be connected to the suction casing, but must lead to the
suction tank.
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2. The balance quantity is insufficient

A device must be fitted in the discharge pipe immediately after the pump, which guarantees minimum
flow even with closed discharge valve. The following devices have proved successful in use:
a) Automatic leak-off non-return valves operate such that as the flow decreases the minimum flow
line automatically opens and an integral throttle element controls the minimum flow. The contrary
happens on increasing the capacity. The minimum flow line is directly flanged to the automatic leakoff
non-return valve.
b) Constant by-pass. A by-pass line is fitted between the pump and the discharge valve, which also
leads back to the suction tank. A throttle is built into the pipe which determines the flow rate. With this
type it should be remembered that the by-pass quantity also flows with the discharge valve open, which
reduces the efficiency of the pump. It must be considered carefully whether it is worth buying an
automatic leak-off non-return valve.
Minimum flow line or by-pass

The minimum flow line is not supplied by the pump manufacturer. It must be provided
by the operator. The pipe must always lead from the pump to the suction tank. For
shutdown and disconnection for maintenance, a shut-off valve must be fitted in the minimum flow line,
but must be locked open before commissioning. If several pumps are installed to operate in parallel and
the minimum flow pipework connects into a common header, it is necessary to install a non-return valve
in each feed piping.
Separate pipes must be laid for minimum flow pipe and balance pipe if both are required to be led back
to the suction tank.
Never operate below pump minimum flow (see 1.4.1). Operation at minimum flow
should be maintained for no longer than 2 hours in any 24 hours of operation.
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6. SUBJECT: OPERATION Page 21 of 41
6. OPERATION
6.1 General
The following recommended start-up and operating procedures apply to the pump only. For information on any
equipment (driver, shaft coupling, shaft sealing system ...) refer to manufacturer’s instructions.
Safety information
Do not start or operate the pump,
- unless the installation has been verified to be correct and all safety and control functions have been
checked.
- unless you have a complete understanding of the location and function of all components of the
pump aggregate including valves and any upstream and downstream equipment that my effect
the flow of medium to or from the pump.
- unless you have a complete understanding of the all auxiliary mechanical, electrical, and
hydraulic systems as well as the function of all monitoring gages and warning devices.
When starting the pump, be prepared to execute an emergency shutdown in case of failure of the
pump or auxiliary system.
6.2 Commissioning
The items described individually have to be carried out, as far as applicable, step by step
during commissioning.
With electric drive it has to be assured by qualified personnel that the necessary protection measures
work. Earthing, reset, residual current failure operated device etc. have to be ready for service acc. to
approval by skilled personnel.
Before commissioning
a. Connections Check bolted connections and plugs. Inspect ancillary pipework for correct installation.
b. Lube Rinse bearing housing with light oil and allow to drain. Fill with lubricating oil, see also 1.4.2 / 7.3 and
lubricant table T3.
c. Shaft seal Check shaft seal (see 7.2). In case of double acting mechanical seal fill and vent sealing
system (refer to manufacturer’s instruction).
d. Filling the pump - feeding operation Filling the Pump - suction lift
 Fully open shut-off valve in inlet line  Fully open shut-off valve in suction pipe
 If existing (see installation plan) Open  If existing (see installation plan): Open
vent (not valid for self-venting casing) vent (not valid for self-venting casing)
 In case of mechanical seal: Shaft sealing  In case of mechanical seal: Shaft sealing
chamber has to be vented (see also 5.4 chamber has to be vented (see also 5.4
Flushing and Sealing) Flushing and Sealing)
 As far as existing: Close vent when  Fill pump (suction pipe must have foot
pumped medium flows without bubbles valve)
 Mount coupling guard  As far as existing: Close vent when
pumped medium flows without bubbles
 Mount coupling guard
Before starting the pump, the suction piping, pump case and shaft seal chamber must be
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SUBJECT: OPERATION Page 22 of 41
completely filled with liquid.

If there is danger of frost, protect the pump casing, bearing housing and cooling chambers against freezing.
e. Minimum flow line (if fitted) Open and lock the valve in the minimum flow line (see also 5.4 - para. Minimum
flow device).
f. Balance line If the balance line is returned to the suction tank, also open and lock the valve in this line. (see
Installation Plan or P & I Diagram)
6.3 Pump start-up and Operation

a. Ancillary equipment If available, put ancillary equipment into operation (e.g.sealant pressure), open the
valves in the ancillary pipework (cooling, heating...), vent pressure gauge (see also 5.4).
b. Start-up with non-pressurized system Start-up with pressurized system
Start-up with pressurized system (precondition is non-return valve in discharge pipe)
 Close shut-off valve in the discharge pipe  Start driver with open discharge valve and
(minimum flow must be guaranteed). bring the pump rotor immediately to
 Start driver and bring the pump rotor operating speed
immediately to operating speed.
 Open discharge valve slowly, until the
differential pressure drops to the value
given on the data sheet.
Warning: The differential pressure must not fall below the design point even with plants with fluctuating system
pressure. Note: The pressure gauge on the discharge side shows the differential pressure plus the suction
pressure.
c. Observe ammeter reading The full load amps given on the rating plate of the motor must not be exceeded.
d. Adjustments The pump capacity can be adjusted by the discharge valve.
Do not operate pump below minimum flow (see 1.4 and 5.4 Minimum flow). During pump
operation the valve in the suction line must be fully open.
6.4 Inadmissible operating modes

Overloads have to be avoided by all means as they may lead to a failure of parts due to too stringent
mechanical requirements. Overloads occur, if the pump is run beyond its original application range, i.e.
 exceeding of the max. admissible speed

 remaining of the min. speed
 exceeding or remaining of the medium viscosity
 exceeding of the max. admissible inlet pressure
 exceeding of the max. admissible temperature
 exceeding or remaining under the operating range of the pump
 running of the pump without proper venting of pump interior
 running of the pump without required safety devices ( safety valves, electrical overload protection
etc.)
 operation of the pump with closed or strongly throttled shut-off device in the discharge line without
having a minimum flow device (exception: during start-up).
 operation of the pump with closed or throttled shut-off device in the inlet line (dry running)
 operation of the pump for the delivery of fluids, for which the materials of the pump are not suitable
(chemical, solids ...)
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 operation of the pump with wrong sense of rotation

 operation of the pump with inadmissible bearing lubrication or with wrong lubricant
Operating modes like that and other inadmissible operating modes may lead to heavy damage on the
pumps and other parts of the plant. Danger may arise by the bursting of pressure-holding parts and
people within the range of danger may be hit by pieces or fluid, which may be hot, aggressive or toxic, as
the case may be. There may be mortal danger.
6.5 Shut-down (observe sequence)
a. If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shut-down is for a
short time only. For lengthy shut-downs, for repairs and where there is no non-return valve, the discharge valve
must be closed.
b. Stop the driver, when doing this pay attention to whether the rotor runs down smoothly.
Standby service
Ancillary systems as cooling, sealing and quench systems are operational. Standby pumps should be started at
regular intervals to ensure their readiness for immediate service. We recommend to start-up the pump unit once
every month and run for 30 minutes.
Extended shut down
c. If the pump works on a suction lift and is not to be left ready for start-up, the suction valve should also be
closed.
d. If existing, close quench piping.
e. If fitted, close the valves in the ancillary pipes with the exception of the cooling water, which should only be
switched off when the pump has cooled down.
Freeze damage, preservation
g. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including external
heat exchangers and pipings.
6.6 Restart procedure

If the pump is switched off by emergency shut down or trip, do not restart before the causes of the
emergency has been found and removed.
a. Before restarting, check that the pump shaft is at a standstill. If the non-return valve in the discharge pipe is
leaky, the pump shaft may rotate in reverse direction due to the backflow of the medium delivered.
The pump must not be switched on when the pump shaft is rotating in reverse direction, as
this may damage the pump shaft.
b. Proceed restart as given in section 6.3 Start-up and operation.
6.7 Service Control

General
A pump must be looked after and carefully supervised to ensure trouble free running.
During the first period of operation (24 hours) supervision should be intensive. Read and check the operating
parameters every hour. During the next period of operation (first week) supervision should be done every 24
hours. During normal use checking should be done together with the regular inspections at least ones a week.
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If any vibrations, unusual noises or faults are observed stop the pump unit at
once.
Refer to section “Operating faults”.
Number of starts
The pumps are designed for continuous operation. Too many and too frequent starts can accelerate
ageing and result in abnormally high wear and short life time. In case of many starts we recommend an
intensive supervision and maintenance intervals should be shortened. The recommended number of
start-ups are as following:
- Commissioning phase: up to 200 start / stops (max. 6 starts / day)
- Commercial operation: up to 3 starts / day
Cumulated number of starts max. 600 starts / year
Remark: In case of many start / stop cycles we recommend to perform a general overhaul of the pump
after 6 years running time.
Checking the duty point (design point) of the pump

Particularly important at the initial start-up:
 Check the speed.
 Read the discharge pressure and subtract the suction pressure.
Convert this pressure (generated pressure) to a head and compare it with the generated head shown on
the pump duty plate at the corresponding speed.
generated pressure (bar) x 10 200
generated head (m) =
density of liquid (kg/m3)
Metric units
generated head (m) x density of liquid (kg/m3)
generated pressure (bar) =
10 200
generated pressure in psi x 2.31

generated head in feet =
specific gravity
U.S. units
generated head in feet x specific gravity
generated pressure in psi =
2.31
The generated pressure must not fall below the value given in the pump data sheet,
otherwise the maximum allowable capacity could be exceeded, the driver could be
overloaded or the suction pressure could fall below the minimum
required by the pump.
Checking the capacity
The capacity is determined from the pump performance curve
and the generated head (m) as calculated above.
- Find the calculated value of the generated head on the
vertical axis of the performance curve.* Draw a horizontal line
through this point until it intersects the curve. The corresponding
capacity is read on the horizontal axis vertically below the point of
intersection.
* If the characteristic curve sheet only includes the pressure of

one stage divide head by number of stages of the pump supplied.
6.8 Operating faults

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Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable
operating faults in the plant.
There is usually a certain connection between the different types of faults. It is, therefore, expedient to
list and compare the symptoms as well as the possible causes. Assistance can be found for individual
operating faults in virtually all cases.
Symptoms / Possible causes of faults / Remedies

Symptoms Possible causes of faults Remedies
1 Pump does not Driver out of service, speed too low Check - refer to manufacturer‘s manual
work. Rotor blocked Check and correct
No discharge Wrong direction of rotation Check-refer to pump rotation arrow
pressure. Pump not primed Vent pump
(Failure at start- Suction valve/line blocked Inspect and correct
up) Foot valve blocked or damaged Inspect foot valve
Impeller passages blocked Inspect pump internals
2 Loss of discharge Suction pipe not completely full Fill the system
pressure after Too much air or gas in the pumped liquid Check operating data (1.4)
start-up Leakage of air into pump suction Check and correct (seal)
3 Pump flow too Suction or Discharge valve not fully open Check valve position and correct as
small. required
Differential Suction strainer blocked Disassemble and clean strainer
pressure too low. Minimum flow line open, minimum flow valve Check minimum flow line, minimum
Efficiency loss damaged or bypass orifice worn flow valve, bypass orifice (5.4)
Furring of the pump internals and/or Clean and flush pipework.

pipework Disassemble and clean pump internals.
Impeller passages blocked Disassemble and inspect pump internals
Pump internals worn (gap clearances) Disassemble and inspect pump
clearances (7.5)
4 Pump vibrates or Coupling alignment faults Check coupling alignment (5.2)
causes too much Worn shaft coupling Check coupling condition and replace
noise Suction valve not fully open Check and correct (open fully)
Suction strainer blocked Disassemble and clean strainer
Pump runs with cavitation Check operation data (1.4). Create
more pressure at the pump suction.
Piping strain, excessive high nozzle forces Piping should be properly supported
and moments to prevent strains from being
imposed on the pump
Foundation too weak, base not or not Inspect foundation bolt tightening and
correctly grouted baseplate grouting (5.1)
Impeller damaged or blocked Inspect pump internals
Bearings damaged Disassemble and replace bearings
(7.4 to 7.6)
Unbalanced rotor – causes vibration Check balance of coupling, driver
and pump rotating parts
Shaft bent Disassemble and check shaft runout
(7.4 to 7.6)
Symptoms Possible causes of faults Remedies
5 High shaft seal. Seal flush insufficient (flow rate) or missing Check flow requirements
temperature. Wrong orifice size or worn orifice Check size, flow requirements
High leakage of Solids block seal rings/springs Disassemble and remove solids,
mechanical seal. review application
Short shaft seal Vaporisation in the seal ring area Check circulation flow or cooling
life requirements (1.4, 7.2)
Seal fluid not suitable (abrasive) Review application, install filter or separator
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Seal rings, auxiliary gaskets (O-rings) or Disassemble and replace damaged

springs damaged seal parts (7.4 to 7.6)
Dry operation of seal. Seal system not Fill and vent shaft seal
correctly filled or vented chamber/system
Seal face material inadequate Review application with seal manufacturer
Pump shaft bent Check shaft runout at seal area
6 High bearing Pump not running at operating point Review operating parameters (1.4)
temperature. Coupling alignment faults Check coupling alignment (5.2)
Short bearing life. Too much grease or oil in the bearing Check and correct (7.3)
Oil level too low or high Check and correct oil level (7.3)
Wrong lube oil quality Verify that recommended lubricant is
used (7.3, T 3). Change lube oil.
Bearings loaded during assembly Examine assembly and condition of
bearing and associated parts (7.4-7.6)
Insufficient bearing cooling (air / water) Check air intake (environmental
temperatures under noise hoods).
Check cooling water requirement (1.4)
Bearings damaged Disassemble and replace bearings
(7.4 to 7.6)
Excessive pump thrust Check hydraulic balance device, balance
pipe. Disassemble and inspect pump
internal clearances (7.4 to 7.6)
Shaft bent Disassemble pump and check shaft runout
(7.5)
7 Lube oil leakage Oil level too high Check and correct oil level (7.3)
Labyrinth seal or shaft seal ring Examine assembly (labyrinth leakage
improperly installed bore downwards)
Bearing cover gasket or seal Disassemble and replace
damaged gaskets/seal (7.4, 7.6)
Vent blocked Check and clean vent connection
8 Excessive wear of Pump not running at operating point Review pump operating parameters
pump internals Insufficient suction pressure. with a DNB representative, make necessary
- Corrosion Operating fluid differs from specified correction to unit design.
- Erosion value (temperature, specif. gravity...) Refurbish pump with correct parts, clean
- Loss of material Materials of construction not system. Assemble filter or separator.
compatible with medium delivered
9 Pump Operating below minimum flow Review hints for minimum flow. (1.4,
overheating/seizur (pump dry running) 5.4) In case of seizure disassemble
e and repair unit.
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SUBJECT: MAINTENANCE AND OVERHAUL Page 27 of 41
7. MAINTENANCE AND OVERHAUL
7.1 Maintenance pump

General
The operating personnel shall inspect the machine frequently. The purpose of the inspection is to
thoroughly familiarize personnel with the equipment. This is imperative if abnormal occurrences are to
be detected and remedied in time. It is vital that the inspections cover the following points:
1. Leakage Check main connections on pump suction and discharge

Check leakage on shaft sealings, auxillary connections
Check for oil leakage on bearing housing
2. Gauges Check pressure gauges (pump suction, discharge, ...)
Check temperature (fluid, bearings, driver, ...)
Check ammeter (motor)
3. Bearings Check the bearing temperature
Feel the bearing vibrations (measure the SPM- values)
Check the oil level, refill constant level oiler
4. Vibration, Noise Feel the machine
Check for undue vibration
Check for unusual noises
For further information about these inspections see chapter 7.1 to 7.3
If any vibrations, unusual noises or faults are observed stop the pumpunit at
once.
Ascertain the cause and rectify (refer to Operating faults).
Monitor ancillary equipment during operation (if fitted)

Gauges: pressure, temperature, ammeter at regular intervals
Cooling: flow and temperature
Flushing/Sealing: pressure, temperature, (quantity)
Any deterioration in pump performance not caused by alteration or furring of the pipework is probably
due to wear of the pump internals. The pump should be taken out of service and overhauled. See
section 7.4 to 7.7 for details on overhauling the pump.
The pressure in the balance chamber should always remain constant. If the
balance pressure increases by 2-3 bar over the pressure when the equipment is
new, the balance device must be checked for damage. In most cases it will be necessary to change the
balance parts. The increase in balance pressure can, however, also be attributed to the increase in
resistance in the balance line due to furring.
Bearings
For information about lubrication see chapter 7.3.
Bearing housings has to be kept clean on the outside, since the radiation of heat is reduced by deposits
of dust or dirt.
Bearing monitoring: Check the bearing vibration during running.
In case of antifriction bearing, by means of shock impulse method. Carry out checks according to the
operating instructions of the measuring gauge in fixed intervals. During first start-up the initial values
must be recorded to find out deviations of later measurement. After measuring put coloured caps on
measuring nipples distinguishing,
green cap = everything o.k
yellow cap = increased attention
red cap = beginning bearing damage
Vibrations
These can be detected by hand or with electronic equipment (frequency or amplitude analyser).
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Horizontal pumps, which are fastened to the foundation with anchors should not exceed a vibration
speed of 4.5 mm/s. Vertical pumps, as well as horizontal pumps being mounted on buffer elements,
should not exceed a vibration speed of 7.1 mm/s.
When determining the measured values pump should operate at design point, see Chapter 1.4 (in case
pump is operating at partial load or overload the vibration behaviour, f.e. by cavitation, will be influenced
negatively). Measured values which are too high can also be caused by the plant (pipings/accessories)
or by other vibration sources (machines). In order to determine the reason for high vibration values
a vibration analysis is necessary.
Noise
Some abnormal noises can be heard immediately, such as those due to rolling element indentations
because of improper mounting; others are progressive. Noise is usually an indication of incipient failure
and varies in intensity and frequency with the extent of damage.
Alignment
During shut-down (according to operating requirements) check the alignment of the coupling (at
least once a year). Re-align if necessary (see 5.2).
Operating log
It is recommended to enter operating data and data on lubrication, repairs etc. in an operating log. An
ongoing operating record will assist troubleshooting and machine service decisions. Analyse machine
performance regularly.
Spare parts
It is recommended that spare parts listed below are always kept in stock. This modest investment can
often prevent minor faults from developing into serious trouble. The following parts should be stocked:
Antifriction bearings, in case of plain bearing (set bearing shells, pads)
Balance drum and liner (set balance discs)
Wear rings and setscrews
Gaskets and O-rings
Mechanical seals
For pumps used in extremely important service or if several identical machines are operating in the
same plant, it is recommended that a complete machine be stocked at job site.
Orders for spare parts should always include the following information:
Type of pump (rating plate or operating manual)
Order number (rating plate or operating manual)
Quantity and designation of parts / article-number (parts list)
Part number (parts list or sectional drawing)
7.2 MAINTENANCE - SHAFT SEAL
Single-acting mechanical seal (for make, type and size see sectional drawing)
General remarks
In the case of mechanical shaft seals the exit of the medium delivered is prevented by two plane parallel
lapped ring surfaces which are pressed together with the help of spring force and liquid pressure. Seal
rings (stationary and rotating) are sealed against adjacent pump parts with the help of adjoining sealings
(as for example O-rings) serving simultaneously as elastic bearing.
Conditions
In order to have trouble-free operation a liquid film has to form between the slide
faces and therefore the following conditions have to be fulfilled by the medium
delivered:
- sufficient lubricating properties
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- evaporation temperature higher than working temperature

- no impurities in the slide ring region
If auxiliary facilities like
- flushing
- blocking
- cooling
- heating
- cyclone separator/filter (in case of an impure medium delivered) are necessary for arriving at the
operating conditions required the details given in paragraph 1.4.3 / 1.4.4 /
1.4.5 / 5.4 and in the installation plan of the pump have to be observed.
Maintenance
The maintenance of the mechanical seal is limited to the control of the leakage, of the temperature and,
if fitted, to the auxiliary facilities.
A small leakage of the mechanical seal is normal. It is impossible, however, to make

special statements with regard to the leakage of the mechanical seal, as the quantity
of leakage depends on a lot of different factors (e.g. size, material, liquid pumped, temperature etc.). In
case of high leakage seal ring pairs may also leak. If so the damaged parts have to be replaced.
Secondary seals (e.g. O rings) have to be replaced during each assembly. Rotating and stationary seal
rings must be replaced together.
7.3 MAINTENANCE – LUBRICATION

Anti-friction bearing with splash oil lubrication or ring lubrication
General
Centrifugal pumps are often exposed to heavy stress caused by continuous
operation and heavy forces (radial, axial). Therefore a proper oil quality is a
prerequisite for a long bearing life and trouble free operation. The oil must not contain any foreign
substances, acids or resins. Minimum requirements of suitable lubrication oils see DIN 51 524 (or
alternatively DIN 51 517).
Oil viscosity
Since, with anti-friction bearings, the self-heating of the bearing due to fulling plays an important role,
and since, on the other hand an oil viscosity of at least 12 mm2/s (12 cSt) at operating temperature of
the bearing is required for a sufficient lubrication film, the oil viscosity has to be selected as follows:
Temperature °C kin.viscosity in ignit. point

ISO
50 °C (120 °F)
Sump External ring Viscosity class 40 °C (100 °F)
*
>40 – 65 °C >60 – 85 °C 45 mm²/s 25 mm²/s 185 °C
VG 46
(100 - 150 °F) (140 - 185 °F) (45 cSt) (45 cSt) (365 °F)
(* The figures for 50 °C (120 °F) correspond to the previous system of lubricants.)
When during operation under extreme conditions (high ambience temperature, high
bearing load etc.) a higher temperature is found at a certain measuring point, oil of
the viscosity class ISO VG 68 has to be used. The max. allowable values given in
the table will then rise by 10 °C (20 °F).
In case of bigger deviations contact the service. Besides we recommend to carry out the lubrication
renewal under extreme bearing temperatures as described above in change intervals of half a year.
Change intervals and oil quantity
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In case of first commissioning or of an overhaul, drain an change the oil after 10-15 hours of operation. If
further pollution by foreign substances and water is low, change intervals of 6 months can be adhered
to.
In the case of automatic constant–level-oilers pay attention to refill the reservoir (oiler tank).
Max. allowable temperatures
Measuring spot
Mode
externally at bearing at external bearing race in oil bath
housing near bearing
continuous operation < 80 °C (175 °F) < 90 °C (195 °F) < 70 °C (160 °F)
Alarm at > 90 °C (195 °F) > 100 °C (210 °F) > 80 °C (175 °F)
switch off aggregate > 100 °C (210 °F) > 110 °C (230 °F) > 90 °C (195 °F)
Check temperature at the measuring spots regularly.

Suitable lubricators of different brands see lubrication recommendation T 3 annex.
Recommended Lubricants T3
Proper lubrication is particularly important for the operational safety of centrifugal pumps.
If suitable lubricants are correctly applied, an optimum performance is obtained and trouble and
its consequences are avoided. Supplementing the operating instructions, the table gives the
lubricants which are recommended for the lubrication of centrifugal pumps which are suitable for
an ambient temperature between -10 up to +40 oC (15 up to 100 oF).
The lubricants have been listed in alphabetical order which does not say anything about their
quality
Supplier Hydraulic oil according DIN 51 524 (DIN 51 517)

ISO VG 46 ISO VG 68
ADDINOL ADDINOL HLP 46 ADDINOL HLP 68
AGIP AGIP OTE 46 AGIP OTE 68
ARAL ARAL VITAM GF 46 ARAL VITAM GF 68
BP ENERGOL HLP 46 ENERGOL HLP 68
CASTROL HYSPIN VG
CASTROL CASTROL HYSPIN VG 68
46
CHEVRON EP HYDRAULIC Oil 46 EP HYDRAULIC Oil 68
DEA ETERNA LTD EP 46 ETERNA LTD EP 68
ELF ELF OLNA 46 ELF OLNA 68
ESSO ESSO NUTO H 46 ESSO NUTO H 68
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MOBIL OIL MOBIL D.T.E. 25 MOBIL D.T.E. 26
SHELL SHELL TELLUS OEL 46 SHELL TELLUS OEL 68
TEXACO TEXACO RANDO 46 TEXACO RANDO 68
WINTERSHALL WIOLAN CA 46 WIOLAN CA 68
Filling-in of oil with constant level oiler (Type Adams)

Remove air release filter at the bearing bracket and tilt back oil reservoir of the constant level oiler. Fill
oil through the opening at the bearing bracket until the branch of the constant level oiler begins to fill up.
Then fill the reservoir with the same oil and put it back into its original position. Repeat this procedure
until a minimum of 2/3 of the reservoir remains filled up. Screw in air release filter. Check the supply in
the reservoir at times and refill, if necessary.
Function
When the oil level within the bearing bracket drops, the upper edge of the oblique cut of the drain pipe
gets free. Oil flows from the supply reservoir until the former oil level is reached and the oblique cut of
the drain pipe is immersed again.
Oil replacement
Warning: Lubrication can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the manufacturer.
For oil replacement proceed as follows:
1. Shut down pump.
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2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage
bores and size of the screw plugs see installation plan or dimension sheet.)
3. Remove screw plug, drain oil thoroughly. Tighten screw plugagain securely.
4. Fill bearing bracket with fresh oil as described above.
Dispose of used oil according to statutary regulations.Do not put into waste water by any
means.
7.4 OVERHAUL - DISMANTLING OF THE PUMP
When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts) well
beforehand to minimize the down time. When ordering spare parts it is essential to give an exact
description of the part, its part number, the pump type and serial number (see the duty plate).
References Refer to specific drawings (section drawing(s), parts lists, installation plan).
Note: A pump should only be disassembled by qualified specialists with suitable tools and by strictly
observing the instructions.
Preliminary work
- Close the suction and discharge valves and secure them against unauthorized opening.
- Let hot pumps cool down to ambient temperature before disassembly.
- Isolate the driver to prevent start-up.
With electrical driver: Remove residual current (take away safety fuses). Have electrical
connections disconnected by an electrician.
- Drain the pump (position of drain screw see installation plan)
The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead
to any endangering of operator(s) and environment. Observe legal provisions for disposal.
In case the pump delivered aggressive, toxic or otherwise dangerous media, it has to be flushed
carefully, to be cleaned on the outside and to be decontaminated in the case of radioactivity.
If the pump is sent to the manufacturer to be repaired, the cleaning / decontamination has to be
carried out before transport.
The service personnel will have to be careful however inspite of this, as even in the case of a thorough
flushing and cleaning, residues of the fluid may leak out.
- Remove the coupling guard and separate the coupling halves.
- Remove any instruments and ancillary pipes.
- Drain off oil from bearing brackets.
Dispose of used oil acc. to legal regulations. Never put it into the sewage system.
Remark: Maintenance, inspection and repair works on the bearing
shaft seal and balance device does not require hydraulic pump part
dismantling.
- Disassemble pump and take it to assembly site.
Pay attention to hazardous situations during
disassembly, i.e. take care to stand firm, secure
assembly parts against dropping, support or prop loose
parts etc.
- Remove coupling half on pump side (see sketch 7.4-1), take off
key .
To avoid damage to the bearings or to the shaft
centering thread use a suitable puller and protect
the shaft centering thread by a disc. The bearings must by no means
be subjected to any pressure or shock.
Dismantling of bearing - non-drive side
- Remove screws for the fastening of the fan cover and take off fan cover. Take circlip out of shaft
groove by means of spring ring pliers, push fan off the shaft and remove key.
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- Remove hexagon socket screws from bearing cover . Take off bearing cover, push shaft seal ring off
the shaft.
- Bend lockwasher tang out of bearing nut and screw off bearing nut. Take off lockwasher .
- To dismantle the bearing bracket, remove dowelling (tapered pins) on bearing bracket flange. Screw in
(tighten) hexagon nuts to break the tapered pins out of their seats. Loosen adjustment screws on the
bearing bracket flange.
- Screw off hexagon nuts of the bearing bracket fastening, mount puller (see sketch 7.4-2) and draw off
bearing bracket together with antifriction bearings .
- Remove hexagon socket screws and take off bearing cover . Dismantle antifriction bearings from
bearing bracket.
Removal of shaft seal and balance device

- Remove fastening nuts at the seal cover and take off seal cover with all the stationary components of
the mechanical seal.
- Draw shaft sleeve with the rotating parts of the mechanical seal fastened to it off the shaft (the shaft
sleeve is supplied with a groove to apply the tool).
- Unscrew hexagon socket screws fastening stuffing box housing , loosen stuffing box housing and pull it
off. Be careful: Remaining medium will flow out.
- Mount device and draw balance drum and balance drum liner together with the shaft protection sleeve
off the shaft. See sketch 7.4-3. Take off keys.
Removal of bearing - drive side

- Unscrew hexagon socket screws from bearing cover.
- Bend lockwasher tang out of shaft nut and screw off bearing nut. Take off lockwasher.
- To dismantle the bearing bracket, remove dowelling (tapered pins) on bearing bracket flange. Screw in
(tighten) hexagon nuts to break the tapered pins out of their seats. Loosen adjustment screws on the
bearing bracket flange.
- Unscrew hexagon nuts of the bearing bracket fastening. Loosen and remove bearing bracket together
with bearing. Press out antifriction bearing outer race with rolling elements.
- Draw anti-friction bearing inner race off the shaft. If required use suitable puller.
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Removal of shaft seal - drive side

- Remove fastening nuts at the seal cover and take off seal cover together with the stationary
components of the mechanical seal.
- Draw shaft sleeve together with the rotating parts of the mechanical seal fastened to it off the shaft (the
shaft sleeve is supplied with a groove to apply the tool). Be careful: Remaining medium will flow out.
- Loosen and remove stuffing box housing by removing the hexagon socket screws from suction casing.
Dismantling of the hydraulic pump part
Mark the stage casings, diffusers and impellers with the stage number during dismantling, as
they must be refitted in the same place.
- Remove nuts from the tie bolts and withdraw the tie bolts.
- Loosen and remove the delivery casing by carefully tapping with a rubber hammer and levering
between the release pins. Be careful: Remaining medium will flow out.
- Remove last diffuser from delivery casing.
- Slide the impeller off the shaft, remove key.
- Loosen and remove stage casing together with diffuser . Be careful: Remaining medium will flow out.
- Slide next impeller off the shaft, remove key.
- Dismantle stage by stage in the same way. Support shaft adequately to prevent bending.
- Withdraw carefully shaft with first stage impeller out of suction casing, slide impeller off the shaft and
remove key.
- Press diffusers out of the stage casings.
- If required (in case of wear, see 7.5): The wear rings in the suction casing / stage casings and the
interstage bushes in the diffusers can be replaced.
After disassembly
All pump parts should be cleaned and prepared for short term storage by applying a rust preventive to
all machined surfaces which are not made of stainless steel. Recommended rust preventives are given
under 3.2.3 part II. Protection of the interior of the pump.
Handle the pump shaft with care and wherever possible store shaft by hanging vertically to maintain
straightness.
Inspect all parts for wear or damage, see 7.5.
7.5 Overhaul - Inspection of wearing parts

Carry out all checks with the greatest possible care. Examine all parts for wear and re-machine or
replace as the case may be. Negligence leads to a premature failure of the pump.
Impellers
Inspect impellers for wear or damage. Look for cavitation marks (pits) in the suction area, erosion of
vanes and cracks in the shroud. Smooth minor irregularities with a fine file or emery paper.
Wear rings and clearances
Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum diametrical
clearances between impeller and wear ring is given in the table below.
Replace impeller and wear ring when pump performance drops below acceptable system standards or
the maximum clearances have been reached or exceeded.
The permissible clearance between impeller and stage casing/wear ring can be taken from the following
table.
REMARK: Each clearance enlargement causes efficiency loss in pump.
Pump size 40 50 80 100 150 200 Material index

Min. clearance 0.3 0.35 0.4 0.45 cast iron or soft nitrided steel
(with new parts) 0.45 0.5 0.55 0.6 stainless steel
Max. clearance 0.6 0.7 0.8 0.9 cast iron or soft nitrided steel
(with worn parts) 0.9 1.0 1.1 1.2 stainless steel
* clearance in relation to diameter
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Balance drum / Balance drum liner

Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size.
Replace balance drum/balance drum liner when the maximum clearances given in the table have been
reached or exceeded.
Pump size 40 50 80 100 150 200 Material index

Max. permissible 0.3 0.4 0.6 cast iron or soft nitrided steel
Clearance(worn parts) 0.4 0.5 0.7 stainless steel
*clearance in relation to diameter
Balancing
It is recommended that impellers are individually balanced on a balancing machine. Dynamic balance to
ISO 1940, Q = < 2,5.
The assembled rotor is not balanced as a unit, since the deflection of the rotor is different during
balancing in air to the deflection under the influence of hydraulic axial and radial forces in the close
clearances within the pump.
Shaft
Handle the shaft with care and support it evenly to maintain straightness. Avoid bumping, hitting or
springing the shaft.
True running of the shaft Support shaft at bearing area (use V-blocks or rollers) and check for
concentricity (max. permissible run-out 0.025 mm). If the run-out is outside the permissible value replace
the shaft.
Antifriction bearings
Rinse bearings in light oil. In case of major overhaul or damage, replace it.
In case of renewed taper roller bearings: Use only paired bearings. Never replace
only one bearing of a unit.
The bearing design number is given in the pump parts list.
Shaft seal
Mechanical seal
The front sides of the sealing rings (running faces) should show no sign of scoring. Renew stationary
and rotating seal rings which are scored or crazed, as a unit, never replace only one ring. Check shaft
sleeve for perfect surface quality, especially at the seat of the rotating unit; renew if necessary.
Assembly: In case of re-assembly use new gaskets and O-ring seals. We recommend the use of new
rotating and stationary seal rings.
Assembly must be done very carefully and under conditions of extreme cleanliness.
The seal parts must by no means be subjected to any pressure or shock (danger of
break).
Seal faces should not be lubricated with oil or grease as this may prevent introduction of the sealed fluid
in operation, leading to overheating and failures. Remove protective films from new parts direct before
assembly.
Rotor concentricity check (shaft with rotating parts)
Concentricity should be checked with the shaft in unloaded and loaded condition. Assemble the
complete rotor. Place a washer * between the last impeller and the balance drum during assembly. A
sleeve * of the appropriate length is fitted instead of the axial bearings.
Do not fully tighten the nuts that locate the bearings. Support shaft at bearing area (use V-blocks or
rollers). Check the concentricity in the unloaded condition. The measuring points are: diameter of
impeller clearances, the impeller hubs, the shaft sleeves, the balance drums and the coupling shaft end.
The permissible run-out is 0.05 mm (0.002 in.).
If the concentricity check in the unloaded condition is satisfactory, tighten the nuts to lock the rotating
parts on the shaft. Repeat concentricity check at the same points. If the run-out now exceeds tolerance,
all surfaces which are at right angles to the axis of the shaft and which are used to absorb or transmit
axial forces, such as shaft shoulders, impeller hubs, balance drums and sleeves, must be checked for
squareness.
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The max. permissible variance in the vicinity of the shaft outer diameter (shaft shoulders, hubs, sleeves
etc.) should not be more than 0.01 mm (0.0004 in.). If this value is exceeded, re-machine: e.g. turn on
mandrel (without clamping) or grind with the minimum possible reduction in the hub and/or sleeve
length.
Repeat concentricity check as described above. Upon satisfactory completion of concentricity check,
dismantle rotor. Mark impellers in sequence so that they can be refitted in the same order when
assembling the pump. Remove the special components used for the concentricity and keep to use in
future overhauls.
7.6 OVERHAUL - ASSEMBLY OF THE PUMP

References Refer to specific drawings (section drawing(s), parts lists, installation plan).
A pump should only be assembled by qualified specialists with suitable tools and by strictly observing
the instructions.
All assembly works have to be carried out with the greatest possible care. Negligence
leads to premature failure of the pump.
Preliminary work
- Clean pump parts
- Prepare lubricants (e.g. oil, Molykote, Never Seez)
- Only use glycerine or "Klüber PROBA 270" paste for O-ring seals
- Always renew seal rings and gaskets
Pay attention to possibly hazardous situations during assembly, i. e. take care of a firm stand,
secure assembly parts against dropping, support or prop loose parts etc.
If the pump is assembled horizontally, the stage casings should not be supported underneath before the
tie bolts are tightened, so that the stage casings can be “suspended".
- Clean shaft, impeller bores and coat the contact surfaces slightly with lubricant.
- Insert key for the first impeller, and push impeller onto shaft stop
- Insert diffuser in the first stage casing and place O-ring seal on the spigot of the stage casing.
- Slide shaft with impeller into the stage casing from the drive side.
- Insert key and push on next impeller from the non-drive side.
- Insert diffuser in the next stage casing and place O-ring seal on the spigot of the stage casing.
- Insert key and push on next impeller.
- Fit another pre-assembled stage casing (with diffuser and O-ring seal).
- Assemble remaining stages in the same way.
- Slide delivery casing with inserted last diffuser and O-ring seal on the spigot of the last stage casing .
- Place O-ring seal on the spigot of the suction casing and slide suction casing onto the spigot of the first
stage casing.
Adjust and support pump suction and discharge casing on a smooth steel plate.
- Fit tie bolts , discs and nuts . Lubricate threads and support sufaces of nuts and
clamp the whole hydraulic assembly together evenly and crosswise.
Assembly of the balance device
- Insert O-ring seal in the groove of the balance drum bore and slide balance drum onto shaft.
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- Push balance drum liner with O-ring seal into delivery casing and allow the cylindrical dowel pin
preventing rotation to engage in the hole.
Assembly of the shaft seal housings
On both sides of the pump
- Insert key that drives the shaft sleeves into shaft.
- Insert O-ring seal on the spigot of the stuffing box housings . Locate stuffing box housings on delivery
casing and suction casing using hexagon socket screws.
- In case of cooling: Insert O-ring seals into the grooves of the cover and push cover into stuffing box
housing.
- Insert O-ring seal in the groove of the shaft sleeve bore and push shaft sleeve onto shaft.
Measurement and adjustment of the nominal axial position of rotor

Measurement is not necessary, if the installation length of the pump parts have not changed through
remachining during repair, but it is essential, if new parts (shaft, impellers, stage casings) have
been fitted, otherwise continue with paragraph "Rotor centering procedure".
In order to achieve the most favourable hydraulic efficiency of the pump, the impellers and diffusers
must be placed in the optimum position to each other. For this purpose and in order to avoid lateral
distortion of the rotor, the theoretical axial position of the rotor is to be measured and set. The
construction tolerances make it possible to keep the correction of the axial rotor position within very low
limits.
Remark: All assembly works for the measurement have to be carried out without use of seal rings and
with greatest possible care.
- On the drive side:

- Assemble bearing bracket on both sides of the pump, tighten nuts evenly and crosswise.
- Push rotor until stop in the direction of the non-drive side.
- On the non-drive side: Determine measurement „A“ (see sketch 7.6-2) from the support shoulder of
the thrust bearing in the bearing bracket bore to the front face of the shaft protection sleeve with depth
gauge.
- The inboard thrower must be longer than the measurement „A“ by the value „B“ given in the following
table.
Pump size DS 40 50 80 Dimension in

Dimension B = 5.3 ± 0.1 6.0 ± 0.1 6.5 ± 0.1 mm
Remark: New throwers are supplied with oversize, they must be machined to the calculated dimensions.
When repair work is done the nominal dimension can be gained by applying supplementary discs.
The thrower sleeve shoulders must be parallel to each other within 0.01 mm after
Machining
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- On the drive-side: Check the length dimension of the thrower while the rotor is moved to the non-drive
side. See sketch 7.6-3.
To do so measure with depth gauge from the circlip in the bearing bracket (stop anti-friction bearing
outer race) to the front face of the spacer sleeve dimension “C”. The measuring result should
correspond to the dimensions given in the following table.
Pump size DS 40 50 80 Dimension in

Dimension C = 3.0 ± 1 3.5 ± 1 4.0 ± 1 mm
- If the dimension has to be corrected, the nominal dimension can be gained by applying supplementary
discs or by re-machining of the thrower on its support shoulder (spare part supplied with oversize).
Rotor centering procedure
The disassembly of the hydraulic pump part requires that the rotating element radial center
position be determined and adjusted, otherwise continue with paragraph „Assembly of shaft seal
non-drive side“
Serious damage can be caused if the pump is started with off-center rotor
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- On the non-drive side: Remove Bearing housing again. Push thrower with normal dimension onto
shaft and mount bearing housing again.
- Loosen all adjusting screws and put bearing housings in the lowest position possible.
- Tighten fastening of bearing housing and loosen them once again, so that the bearing housing can be
shifted by the adjusting screws which are at the bearing housing flange.
- Horizontal adjustment: Adjust bearing housing by the lateral adjusting screws. Measure between
shaft and bearing housing bore by means of an inside spring caliper until shaft is in the horizontal
center. See sketch 7.6-4. Tighten and secure lateral adjustment screws in such a way as to fix the
bearing bracket in horizontal position and allow vertical movement.
- Vertical adjustment: Attach a measuring gauge vertically near the bearing (the measuring pin has to
be positioned at right angle to the shaft) to ascertain at the bearing area by what dimension the shaft
can be lifted. Divide the result by two and note. See sketch 7.6-5
Do not bend the shaft!
Mount antifriction bearings (refer to section “Assembly of antifriction bearings”).

Check of free running state of the rotor
Due to manufacturing of the turbinepump parts within given tolerances the rotor
theoretically should be in center position, i.e. could usually be turned by hand. To do
so, attach lathe carrier at coupling shaft end and check free running.
- Turn-on rotor and look for touching during running down.
Causes and measures in case of touching of the rotor
1. Center position of the rotor not correctly adjusted, adjust once again.
2. Tightening the screws in practice may, however, cause a different prestress in each screw by differing
friction values in the thread and the nut support. Due to the differing prestress a deformation (bending)
of the stage casing package, which is clamped together, may occur. This may cause a touching of the
rotor parts at the stationary casing parts. With increasing stage number this will be more and more likely.
If it is found that the rotor can only be turned under difficulty or not at all, the bending
of the stage casing package needs correction by tightening the tie bolts with differing
torques. As there is no proper way of predicting how the bending of the stage casing package will work
out, the tie bolts to be tightened more strongly will have to be found by trying.
After check of free running
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If check of free –running is satisfactory dowel bearing housings in new position. Existing taper pin
holes can be reaimed to the next size taper pin or, if required, drill new holes (mark old holes).
Assembly of antifriction bearings
On both sides of the pump
- Loosen all fastening and adjusting screws for the bearing housings. Insert taper pins through bearing
housing flange. Support bearing housing and seat taper pins, then properly tighten bearing housing
fasteners evenly and crosswise.
Assemble thrust bearing – non-drive side
- Build in outer race of inboard taper roller bearing with bearing support ring into bearing housing bore
(make sure that one bore of the bearing support ring points downwards). Warm taper roller bearing inner
races with rolling elements in an oil bath to approx. 80-100 oC and push them up to shaft stop (against
thrower. Fit outer race of outboard taper roller bearing.
In case of renewed taper roller bearings:
Use only paired taper roller bearings, never replace only one bearing of a unit.
The bearing design number is given in the pump parts list.
- Install spacer disc, lock washer and shaft nut. Apply lubricant to the contact face of the bearing nut.
Tighten shaft nut and bend lockwasher tang into one of the shaft nut slots.
Do not over tighten bearing nut.
- Install ring with hexagon socket screws and tighten fasteners with torque wrench
evenly and crosswise. During tightening turn rotor by hand. After tightening the rotor reaches its final
axial running position.
Assemble radial bearing – drive side
- Heat inner race of roller bearing in oil bath up to 80 oC and and push them up to shaft stop (against
thrower. Build in outer race with rollers into bearing housing bore.
- Install spacer disc , lock washer and shaft nut. Apply lubricant to the contact face of the bearing nut.
- Tighten shaft nut and bend lockwasher tang into one of the shaft nut slots.
Do not over tighten bearing nut.
Check and correct the thrust bearing axial clearance (end play)
To allow the forming oil films between bearing parts and for heat expansion, it is
necessary to provide a correct bearing end play. The bearing end play must be
checked after every disassembly of the taper roller bearings.
- Place clock gauge axially on the front of the shaft on the non-drive side; check axial clearance of the
taper roller bearing unit by axially moving the rotor into its final positions. See sketch 7.6-6. Tap lightly
on the bearing bracket (non-drive side) with a rubber hammer to straighten twisted rolling elements.
- If there is no noticeable clearance the bearing elements may be twisted, turn rotor slowly in both
directions and measure once again. If the measure axial clearance is smaller than 0.04 mm (0.0016 in.),
the fault may be corrected by tightening the thrust bearing shaft nut more strongly. Correct mistake.
- Remove device for bearing end play measurement.
If the taper roller bearing temperature after overhaul rises >90 oC (195 oF), as a first
measure check bearing end play.
TMC-IMO-VER1.0-2007
MC
Final assembly
- On the drive side bearing housing: Fit gasket on the bearing cover . Install bearing cover and tighten
bearing cover fasteners evenly and crosswise. Push outboard thrower onto shaft, adjust gap between
bearing cover and thrower to 1 mm and tighten setscrew .
- On the non-drive side bearing housing: Push shaft seal ring onto shaft and lube seal ring lip. Fit
gasket on the bearing cover , install bearing cover and tighten bearing cover fasteners evenly and
crosswise. Insert key for fan into shaft, slide on fan and place circlip in shaft groove. Place fan cover and
fasten with cylindrical screws.
Install pump
- Move the pump to installation place and mount pump onto baseplate. Connect main lines.
Coupling
- Mounting the coupling half: see sketch 7.6-7
To do so, remove heat-sensitive parts (e.g. rubber buffers and
seal rings etc.) and heat up the coupling half to approx. 80 oC
(180 oF) by means of uniform dry heat (e.g. oven or hot plate).
Slide the coupling half onto the shaft and fit removed parts
again after it has cooled down. Couplings with bores up to a
diameter of 50 mm (2 in.)can also be fitted cold with an
appropriate attachment.
The bearings must by no means be subjected
to any pressure or shock
Ancillary equipment
- Install auxiliary lines (balance-, circulation-, cooling lines...)
and instruments (thermometers, constant level oiler, pressure
gauges...)
Do not mix up connections. Carefully check piping system.
Driver
- Couple the driving unit.
- Check alignment of coupling and tighten foot fasteners with torque wrench (see 5.2), check free
running of the rotor.
- Fit the coupling guard.
Electrical connections for motors and controllers must only be produced by an

electrician.
When recommissioning, all steps described in section 6.1 must

be repeated.
TMC-IMO-VER1.0-2007

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5 INSTALLATION OF THE PUMP................................................................................................... 12

7 MAINTENANCE AND OVERHAUL..................................................................................... 27

1. SUBJECT: GENERAL REMARKS Page 2 of 41

1.1 About this manual

How to use this manual

1.3 Type of operating manual (Acc. to DIN 8418 )

SUBJECT: GENERALREMARKS Page 3 of 41

1.4 SERVICE DATA - SERVICE CONTROL

SUBJECT: SAFETY Page 4 of 41

2.1 Marking of instructions in the operating manual

Warnings of electrical voltage are marked specifically by

- Indications which are directly attached at the machine itself such as

- arrow for rotational sense

- marking for fluid connections etc.

have to be kept in good, legible condition, as they have always to be observed.

2.2 Qualification and training of personnel

2.3 Danger on non-observation of the safety regulations

- Failure of important functions of machine/plant

- Failure of required procedures of maintenance and repair

- Endangering of people by electrical, mechanical and chemical impacts

- Endangering of environment by leakage of dangerous materials

SUBJECT: SAFETY Page 5 of 41

2.5 Safety instructions for user / operator

2.6 Safety instructions for maintenance, inspection and assembly jobs

- Pumps or aggregates delivering media hazardous to health have to be decontaminated.

2.7 Prohibition of unauthorized rebuilding measures or alterations

2.8 Inadmissible operating modes

SUBJECT: TRANSPORT AND STORAGE Page 6 of 41

3. TRANSPORT AND STORAGE

Fastening of the sling ropes on crates

SUBJECT: TRANSPORT AND STORAGE Page 7 of 41

We recommend rust preventatives

SUBJECT: TRANSPORT AND STORAGE Page 8 of 41

II. Protection of the interior of the pump

e.g. - pump casings

III. Proceeding in case of longterm preservation

1.b Centrifugal pumps with mechanical seals

IV. Maintenance of the stored centrifugal pumps

SUBJECT: TRANSPORT AND STORAGE Page 9 of 41

SUBJECT: DESCRIPTION Page 10 of 41

4.1 Description of the pump

4.2 Bearing and lubrication

4.3 Absorption of the Axial Thrust - Balance drum

SUBJECT: DESCRIPTION Page 11 of 41

SUBJECT: INSTALLATION OF THE PUMP Page 12 of 41

5 INSTALLATION OF THE PUMP

5.1 Mounting (see dimension drawing / installation plan)

SUBJECT: INSTALLATION OF THE PUMP Page 13 of 41

Grout in the foundation bolts

Completion of grouting (when properly aligned)

SUBJECT: INSTALLATION OF THE PUMP Page 14 of 41

Problems can arise, if materials are of poor quality, which may

Tightening torques for foundation bolts (Table 5.1-1)

5.2 ALIGNMENT OF COUPLING

SUBJECT: INSTALLATION OF THE PUMP Page 15 of 41

Coupling alignment procedure

SUBJECT: INSTALLATION OF THE PUMP Page 16 of 41

5.3 SUCTION AND DISCHARGE PIPEWORK

SUBJECT: INSTALLATION OF THE PUMP Page 17 of 41

SUBJECT: INSTALLATION OF THE PUMP Page 18 of 41

ALARM / SHUT OFF may have to be set accordingly.

5.4 ANCILLARY EQUIPMENT