Professional Documents
Culture Documents
EN - MC Blance Drum-Antifriction Bearing-40,50,80 - Rev02
EN - MC Blance Drum-Antifriction Bearing-40,50,80 - Rev02
MC
Customer/Contractor: -
Cu. Order No.: -
End User: -
Plant: -
Site: -
Item No.: - -
Sulzer Equipment No.: - -
Sulzer Order No.: -
Pump type: MC
BA/e 4330 W ä
Warranty Statement
质保声明
Guarantee is assumed according to the contractual agreements. The normal Sulzer 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.
苏尔寿将根据合同约定提供质保。正常的质保范围包括泵的制造缺陷或材料缺陷,不包括
由存储不当、错误的安装和操作以及非指定用途的使用所造成的损坏。
During the guarantee period, modifications, disassembly or repairs can only be worked out by our
service personnel or with our written approval
在质保期间,泵装置的更改、拆卸和维修必须由苏尔寿的售后服务人员进行操作。其它人员进行操作
前必须获得苏尔寿的书面授权。
SULZER CONFIDENTIAL
Content
1. GENERAL REMARKS
1.1 About this manual
1.2 Guarantee
1.3 Type of operating manual
1.4 Service data - Service control
2. SAFETY
2.1 Marking of instructions in the operating manual
2.2 Qualification and training of personnel
2.3 Danger on non-observation of the safety regulations
2.4 Safety-guided working
2.5 Safety instructions for user / operator
2.6 Safety instructions for maintenance, inspection and assembly jobs
2.7 Prohibition of unauthorized rebuilding measures or alterations
2.8 Inadmissible operating modes
2.9 Explosion protection
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
3.2 Preservation and storage
4. DESCRIPTION
4.1 General
4.2 Description of the pump
4.3 Bearing bracket and lubrication
4.4 Absorption of the axial thrust - balance drum
5. INSTALLATION
5.1 Mounting of the pump
5.2 Alignment of coupling
5.3 Suction and discharge pipework
5.4 Ancillary equipment
5.5 Minimum flow device
6. OPERATION
6.1 General
6.2 Commissioning
6.3 Pump start-up and operation
6.4 Inadmissible operating modes
6.5 Shut-down
6.6 Restart procedure
6.7 Service control
6.8 Operating faults
7. MAINTENANCE
7.1 Pump general
7.2 Shaft seal
7.3 Bearing / Lubrication
8. OVERHAUL
8.1 Dismantling of the pump
8.2 Inspection of wearing parts
8.3 Assembly of the pump
8.4 Tools
8.5 Screw tightening torques
ENCLOSURES
Table of enclosures for operating manual
4000/e0-1-00-000
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 Sulzer 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 and VDMA 24 292)
Documents no.: see cover sheet
Service address: see cover sheet
Issue: 2005
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.
Revision history
2
2015-02.12 Add fasteners & auxiliary piping info Amanda Gu
1 2014-05-08 Add min. speed and max. run up time limit Yan
Remark
In the case of further questions, of spare part orders and other correspondence please mention always the
SULZER Serial No. and pump type. Both can be gathered from the rating plate of the pump.
0000/e1-0-00-000
1.4 Service Data – Service Control
Sulzer Order-No.:
Item-No.:
1.4.2 Lubrication
Oil (according to DIN 51 511) SAE 15W- 40 see also 7.3
o
Oil temperature C 40 - 90
Quantity of oil per bearing housing Liter (drive side) / (non drive side)
1.4.3 Cooling
3
Total Cooling water requirement m /h
Pressure normal / max. bar 2/7
o
Temperature outlet max. C 40
Parts to be cooled
3
Cooling water requirement m /h
0000/e1-4-02-000
1.4 Service Data – Service Control
1.4.5 Flushing (shaft seal)
Flushing / Sealing medium
3
Quantity min. m /h
Pressure bar
o
Temperature of flushing medium C
1.4.7 Quench
Quench medium
3
Quantity min. m /h
Pressure bar
o
Temperature of quench medium C
0000/e1-4-02-000
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 available
constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or
assembly/disassembly of the pump.
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.
0000/e2-0-00-000 Page 1
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.
0000/e2-0-00-000 Page 2
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
A. 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.
B. 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.
C. Lifting
Check of the load suspension devices / ropes
It has to be assured that admissible, undamaged ropes and lifting Sling rope as
devices will be used. The loading capacity of the lifting devices and market on
crate
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.
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
M000/e3-0-00-000 Page 1
3.2 Preservation and storage
A. General remarks
This information will enable you to store your pump effectively and safely. Should further information be
desired, or should particular problems arise which are not covered sufficiently please contact your nearest
Sulzer representative.
The following storage instructions apply only to the pump and may not be appropriate to furnished auxiliary
equipment. Follow manufacturer’s instructions for all other components of the pump system.
The preservation measures required for storage depend on the despatch preservation applied. The pump
unit can be stored in a dry warehouse without maintenance measures up to the time given by the dispatch
preservation.
C. Intermediate storage
Pumps which are not installed and commissioned immediately after delivery can be stored for the period
determined by the dispatch preservation.
ATTENTION 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
ATTENTION
proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed:
ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand,
etc.) the connection flanges of the pumps have to be plugged airtight.
0000/e3-0-00-000
Long term storage may be required for:
1. New pumps witch are not commissioned.
The pump can be stored as described in Intermediate storage. After the dispatch preservation time
measures have to be taken to protect the equipment against corrosion damage.
2. Stand by pumps or pumps affected by a longer shut down of the plant.
The long term storage procedure depend on the material used in pump construction (cast iron, steel,
stainless steel, special alloys), medium delivered and environmental conditions (freeze damage) see
following table.
Material of Medium delivered
construction Neutral Aggressive
Hydrocarbon, ... Water, ... Seawater, ... Acids, ...
Cast iron B A - -
Steel B A - -
Stainless steel B B A
Special alloys B B A
A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium and
after draining (and drying) be protected with a preservative. For this purpose the disassembly of the
hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure
described below in section 2. to 4.
B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure for
the bearing housing as described in the sections below.
Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the manufacturers.
2. Protection of not painted outer parts of the pump
Pump outer parts: e.g. - raised faces of flanges
- pump shaft
- 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 (see section V.).
We recommend rust preventatives
- Tectyl 506 from VALVOLINE
- Rust Ban 397 from ESSO
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.
3. Protection of the interior of the pump
If the hydraulic pump part (casing parts, impeller, wear rings…) are made of non-corrosive stainless or
special alloy, no protective measures (instead of flushing, case A) are required. Note: Bearing housing and
bearings have always to be protected.
Pump interior parts: e.g. - pump casings
- stuffing box chambers
- bearing housing, bearings, ...
2
For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm /s
should be used.
0000/e3-0-00-000
We recommend the rust preventatives
ATTENTION The rust preventative for the pump interior have to be selected according to the gasket or
seal materials used.
Gasket or seal material: Rust preventative
Perbunan (NBR), Viton (FPM), Teflon (PTFE): - Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
0000/e3-0-00-000
Filled pump parts
At the parts which are filled with rust preventative (pump casing / bearing housing) the condensate should be
drained every 6 months; rust preventative should be added, if required.
According to manufacturers indications, the rust preventative has to be drained and refilled
ATTENTION
every 12 month. 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.
F. De-preservation procedure
Surface protected parts
In most cases the protection film must not be removed. If required remove rust preventative by the following
cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be used.
Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety
precautions specified by the manufacturers.
Note: Do not use nitro thinners!
Pump casing
Drain pump casing thoroughly, it may be required to lift the pump to fully drain the pump casing (see job
specific drawings). If required flush pump casing, turn pump rotor by hand in the proper direction of rotation.
For absolutely cleaning (pumping of clean product) the disassembly of the hydraulic part of the pump
becomes necessary in most cases.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer seals
are subject to material specific and time-based alteration (aging) witch might reduce the efficiency of the
seal, therefore we recommend after a storage time for more than 3 years to change the seal rings.
Packing: Before commissioning, make sure that the preservation packing is removed and replaced by
packing rings of the quality provided for operation.
Bearing housing
Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the
preservation oil thoroughly. Flush bearing housing with lubrication oil and allow to drain. Mount constant
level oiler (if removed) and refill bearing housing with lubricating oil as given in the pump operating manual.
Dispose of rust preventive oil according to statutory regulations. Do not put into waste water
by any means.
G. Additional Information
When the pump is removed from storage special care have to be taken. Clean pump and equipment
surfaces (piping, coupling, driver,…) and inspect:
Minimum checks Additional recommended checks
Inspect for completeness Inspect bearings (if any sign of
Check all pressure case (plugged) openings and contamination be detected, replace brg.)
connections for tightness Inspect shaft seal and change all elastomer
Check for any sign of cracks or damage seal rings
Check pump rotation, check for correct gap Install additionally suction strainer
between stationary and rotating parts …
Check coupling alignment
Check all fasteners for tightness
Check service data (are the pump suitable)
ATTENTION If the pump has been stored for more than 3 years we recommend to open and inspect at
least bearings and shaft seal before start-up. If the pump has been stored for more than 5
years we recommend to disassemble the pump and change all gaskets and seal rings.
0000/e3-0-00-000
4. DESCRIPTION
4.1 General
Pumps of the SULZER series MC are horizontal, radially split, multi-stage, high pressure ring section pumps
designed for boiler feed and other high pressure applications.
These pumps are suitable for pumping clean and slightly polluted liquids. The permissible
ATTENTION operating pressures and permissible operating temperatures depend upon the material
specification. See 1.4.8 for safety limit data.
The materials of construction have been selected for the liquids specified in your order.
ATTENTION Before the pump is operated with other liquids or at other temperatures it is essential that the
manufacturer be consulted.
Explosion Protection
In accordance with EU Directive 94/9/EC (ATEX), the pumps may – based on their designation – be
used in the following areas:
Group II
Category 2 Category 3
G (zone 1) D (zone 21) G (zone 2) D (zone 22)
G – potentially explosive gas atmosphere
D – potentially explosive dust atmosphere
Temperature classes
Ensure that the pumps are classified according to their group and provided with the appropriate certificates.
Each group is determined by the ambient gas or ambient dust and temperature class, at a max. ambient
o
temperature of 40 C.
The maximum temperature permissible for the conveyed material must also be observed for the temperature
class in question. The responsibility for observing the conveyed material temperature always lies with the
operator.
Temperature class T1 T2 T3 T4 T5 T6
o o o o o o
Maximum temperature 450 C 300 C 200 C 135 C 100 C 85 C
o o o o o o
Max. medium temperature 430 C 280 C 180 C 115 C 80 C 65 C
Group
Category
Temperature class
4330/e4-1-00-000 page 1
4.2 Description of the pump
Casing
The casing is radially split and consists of suction casing, stage casings (ring section casings) as required
and discharge casing. The elements are sealed by O-rings and held together by external tie bolts.
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
Accurate machining provides precision fits and clearances for assembly and operation. Machined shoulders
provide positive location of mounted parts.
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 shaft seal housings are fitted with a cooling chamber as required. In order to prevent
ATTENTION 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.
4330/e4-1-00-000 page 2
4.4 Absorption of the Axial Thrust - Balance drum
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
(603.01) rotating with the shaft and a balance drum
c liner (605.01) fixed in the discharge casing. The
pressure difference between the pressure within
the pump "a" (discharge pressure) and the
605.01 pressure in the balance chamber "b" (suction
pressure + frictional resistance in the balance pipe)
a
b creates an axial force "F" on the balance drum.
F This axial force is opposite in direction to the pump
603.01 A axial thrust. The magnitude of the force "F"
depends on the area "A" of the balance drum
which is sized in such a way that the axial thrust at
the operating point is almost completely
compensated.
The residual axial thrust is compensated by a
thrust bearing. The pressure difference between
"a" and "b" also sets up a flow through the
axial thrust clearance "c" into the balance chamber.
Sketch 4.4-1 Balance drum working principle A perfect balance is only achieved if there is no
pressure build-up in the balance chamber "b" 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
ATTENTION are not strictly observed.
To prevent a pressure build-up in the balance chamber there must be a drain for the
ATTENTION 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. Choose corresponding
ATTENTION nominal diameter.
ATTENTION 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
closure.
Damages on the balancing device may lead to a heating of the balancing liquid causing inadmissible
pressure in the balancing tube. A security valve has therefore to be built into this tube. Adjust
opening pressure at 5 bar over inlet pressure.
4330/e4-1-00-000 page 3
5. INSTALLATION
ATTENTION 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.
4330/e5-1-00-001 page 1
Tools and Equipment Required
The following tools will be required temporarily for the installation work:
- 2 Dial gauges
- 1 Spirit (machinist’s) level
- 1 Set of standard hand tools
- Suitable lifting devices for installation and repair work.
- Suitable lighting
4330/e5-1-00-001 page 2
Installation
- Attach wire rope slings to the pump unit (see 3. Transport and lifting) and lift the pump unit carefully.
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.
D. Levelling
Use mechanical installation report TC 0000/5-1-00-000.
- 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).
ATTENTION 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.
Preferred variance : 0.2 mm over 1 m (0.003 in./ft.).
Maximum allowable variance: 0.5 mm over 1m (0.006 in./ft.).
- 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 thickness. See sketch 5.1-2.
- Loosen adjusting screws and check levelling. If required correct levelling.
spirit level
pump flange
adjusting screw foundation bolt baseplate
shim shim
concrete
shaft foundation
Sketch 5.1-1 Levelling the unit Sketch 5.1-2 Grouting foundation bolts
4330/e5-1-00-001 page 3
F. Completion of grouting (when properly aligned)
Grouting of the machine into the foundation is a very important part of the installation.
ATTENTION
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 grout hole
baseplate
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. chamfer strip
- Finish grouting the baseplate in conformity with the grout
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
ATTENTION foundation
during the first 48 hours. During this time the
temperature of the foundation should not fall below 10 oC
o
(50 F). The optimum temperature for the setting process is
o o o
20 C +/-10 C (65 +/-15 F). 5.1-3 Grouting of baseplate
4330/e5-1-00-001 page 4
Title:
Test Certificate
Mechanical Installation
Plant / Location:.........................................................................................................................................
Aggregate Specification:...........................................................................................................................
Pump type:...................................................... Driver:..............................................................
Serial-No.:....................................................... Type / No.:.......................................................
Measures Confirmations
1. Foundation construction
Main dimensions and connections checked Yes No Date: Sign:
3. Foundation bolts
Foundation bolts grouted Yes No Date: Sign:
Foundation bolts tightened after setting Yes No Date: Sign:
4. Grouting baseplate
Levelling checked Direction longitudial crosswise
Measured: ................. ................
Baseplate completely filled with grout Yes No Date: Sign:
5. Piping connection
Coupling alignment checked Yes No Date: Sign:
Pump foot and driver tightened Yes No Date: Sign:
Stress control of main piping performed Yes No Date: Sign:
Piping cleaned and connected (main and auxiliary) Yes No Date: Sign:
4330/e5-1-00-001 page 5
5.2. Alignment of coupling
A. General
If the Sulzer scope of supply does not include the coupling / coupling protection, ensure that only
approved materials and designs are used for applications in potentially explosive areas.
ATTENTION When applicable, ensure that any rotor locking devices are removed before attempting to
turn rotors.
ATTENTION Bearings must be lubricated BEFORE attempting to turn rotors. Avoid any unnecessary
turning of machine rotors.
ATTENTION Whenever practical, the pump must be filled with product before turning by hand.
Stainless steel fitted pumps are particularly susceptible to “pick-up” and turning by hand
ATTENTION should be avoided whenever possible.
Scope
This section describes recommended procedures for aligning the motor (driving machine) to the pump
(driven machine) for the pumpset supplied.
1. Determine which machine is to be levelled and positioned correctly and then used as the reference
machine (normal pump). The position of this machine will then remain fixed, and the adjacent
machine(s) will be moved as necessary to align with it. See sketch 5.2-1.
2. Ensure that the reference machine (pump) is level and positioned correctly.
3. Work outwards from the reference machine, and position the next machine A in the train with the
correct gap between coupling flange faces or shaft ends (as applicable) and align the shaft to the shaft
of the reference machine.
4. Where a further machine B is included in the drive train, use machine A as the reference machine to
position and align B to A. In the same way, position and align C to B, etc.
B A Reference A B
Machine
C Reference
D B A
Machine
4330/e5-1-00-001 page 6
B. Misalignment types
There are three basic types of misalignments between the pump and driver shafts:
C. Assembly
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 maintenance manual.
D. 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 yet, 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 .
E. 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.
Thread size Tightening torque
nominal diameter Drive side Non-drive side
Non- drive end Drive end
mm in. Nm lbf.ft Nm lbf.ft
M 16 (0.6) 60 44 40 30
M 20 (0.8) 120 88 80 60
M 24 (0.95) 220 160 140 100
M 27 (1.05) 350 255 220 160
M 30 (1.18) 480 350 320 230
M 33 (1.30) 680 490 450 325
M 36 (1.42) 900 650 600 435
M 42 (1.66) 1500 1080 1000 725
M 48 (1.88) 2400 1740 1600 1160 Tightening torque Tightening torque
M 56 (2.20) 3900 2820 2600 1900 acc. to table acc. to table
M 64 (2.51) 5900 4270 3900 2800
Sketch 5.2-5 Pump foot tightening torques
Table 5.2.1
4330/e5-1-00-001 page 7
F. Compensation of thermal growth
Temperatures have a considerable influence and should therefore be considered during the alignment.
The shaft centreline of each pump and driver will rise when they reach operating temperature. Therefore,
the difference between the two anticipated growths should be incorporated into the cold alignment so that
the shafts will come into alignment when operating temperature is attained.
The unit with the greater thermal growth must be set lower than the other unit, by the difference between
their thermal growth.
Pump thermal growth
At pumps with feet bottom (not at axe level) and
ATTENTION operating temperatures above 80 oC the thermal
Shaft
growth should be considered according following table.
Pump size H Thermal growth H in mm
o Thermal
MC with operating temperature C
growth H
> 80 > 100 > 130 > 150 > 170
40 – 180 160 0.10 0.13 0.18 0.22 0.25
50 – 220 185 0.11 0.15 0.21 0.25 0.29 Shaft
80 – 260 240 0.14 0.20 0.28 X X
100 – 300 275 0.17 0.23 0.32 X X
150 – 360 325 0.20 0.27 X X X Thermal growth X
negligible
200 – 400 360 0.22 0.30 X X X
X = Casing feet at axe level Sketch 5.2-6
Pump thermal growth
Driver thermal growth
ATTENTION The thermal growth of the driver equipment must be obtained from manufacturer
instructions.
Thermal growth varies with temperature, load and ambient conditions. With drive equipment by gear or
steam turbine an additional lateral and/or axial thermal growth have to be considered.
4330/e5-1-00-001 page 8
H. Alignment
General
Any change in elevation can be accomplished by shimming between equipment feets and baseplate
pedestals. The maximum number of shims is four. After alignment tighten pump foot fasteners according
to the given torques (see pump foot tightening torques) and re-check alignment.
The coupling alignment certificate TC 0000 / 5-2-00-000 have to filled in during each alignment check /
procedure (see next pages).
ATTENTION Each alignment check / control has to be done only with pump in cold condition and under
consider of the thermal growth of pump and driver. Hot alignment procedure after stop
from hot service are not allowed.
Alignment of coupling must also be monitored during pipework connection and re-checked after
pipework connection to ensure that pipework connection does not adversely affect alignment. If alignment
is affected, the pipe connections must be re-made until alignment remains correct.
Do not adjust driver OR driven machine positions to correct alignment errors caused by
ATTENTION
pipe connection.
Adjustment device
For axial and lateral moving of heavy equipment (motor) a device has normally been fitted at the
baseplate machine fastening pedestals. See sketch 5.2-8. Loosen equipment fastening screws and move
the machine by tightening the adjusting screw into appropriate direction. Note: Before moving the
machine be sure oposite adjusting screw are loosened.
ATTENTION After alignment and tightening the machine fasteners loosen all adjustment screws.
Machine feet
View "X"
X
Sketch 5.2-8 Adjustment device
4330/e5-1-00-001 page 9
Tolerances
The maximum admissible axial misalignment is 0.05 mm
(0.002 in.) on diameter, although ≤ 0.03 mm (0.0012 in.) is
preferrable.
The maximum admissible radial misalignment is 0.1 mm
(0.004 in.) on diameter, although ≤ 0.05 mm (0.002 in.) is
preferrable.
Clock gauge alignment
Alignment should be carried out with clock gauges in radial
and axial direction (see sketch 5.2-9). Ensure that the
supports for each indicator are sufficiently rigid to eliminate
Sketch 5.2-9 Alignment of spacer couplings
any sag that may cause spurious readings.
All readings for radial and axial misalignment are
determined in the gauge positions: top, bottom, right and
o
left, i.e. every 90 , while both shafts are simultaneously
turned.
Optical Alignment
Instead of using a clock gauge assembly, optical (laser)
alignment equipment may be used. 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.
Sketch 5.2-10 Optical Alignment
4330/e5-1-00-001 page 10
Title:
Test Certificate
Coupling alignment
Plant / Location:.........................................................................................................................................
Aggregate Specification:...........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Alignment before pipework connection: Remark:..............................................
Alignment after pipework connection: ...........................................................
Alignment before commissioning: ...........................................................
Alignment after commissioning (maintenance): ...........................................................
1. Axial distance check
Coupling gap (mm)
Specified gap:
Pump Driver Pump
Tolerance:
Driver
Spacer coupl. Non-spacer coupl. Actual gap:
Coupling type:.................................................... Spacer: ...............mm Yes No
2. Check of radial misalignment (see also 2.1)
Radial misalignment (mm)
Measuring p. Left Right Top Bottom
Measured:
Pump Driver
Prescribed: 0 ... 0.1 (0.05 preferable)
4330/e5-1-00-001 page 11
5.3. Suction and discharge pipework
A. General
Welding, burning and grinding work should only be carried out on the pump where specifically
authorised, e.g. there may be a risk of fire and explosion.
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,
ATTENTION especially with "emergency trip out", back-flow preventors (check valve) have to built in.
B. Assembly
The pipework must be supported in an adequate manner to ensure that no inadmissible
ATTENTION
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.
A
Pipe Pipe
4330/e5-1-00-001 page 12
Stress free connection for flexible suction and discharge pipes (cold condition)
Pipe nominal diameter up to 200 (8 in.) over 200 (8 in.)
Radial misalignment A max. 0.5 mm (0.02 in.)
Angular displacement S max. 0.2 mm (0.008 in) max. 0.4 mm (0.016 in.)
• If the pipe is considered as not flexible, so 50 % of the tolerances of flexible piping can de used. Be
sure the max. admissible nozzle loads ( see installation plan) are not exceeded.
Adjustments must be made to the piping, if these limits are exceeded or serious damage
ATTENTION
to the pump may result.
D. Pipe fittings
Discharge line 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.
Suction line In the suction line a shut-off valve should be installed for extended shut downs, repairs and
for pump draining. It must be fully open during operation, and must not be used for pump regulating.
ATTENTION 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.
E. 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.
Sketch 5.3-3 Flooded suction (Suction head) Sketch 5.3-4 Suction lift
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 adjucent to
the pump suction nozzle. The suction valve should be positioned with the handwheel horizontally or
vertically downwards to prevent air pockets forming. Install between flow disturbances as fittings or
elbows a straight pipe with length of 5 to 8 time pipe diameter.
Multi-pump installations should have separate suction pipes to each pump. Excepted are
ATTENTION
duty and standby pumps which may have common suction pipework since only one pump
operates at any time.
4330/e5-1-00-001 page 13
F. 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.
G. Suction strainer
In order to prevent any of the above impurities entering the pump, we
recommend 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
ø 0.2 mm 0.315 mm
diameter. (0.008 in.) (0.015 in.)
Monitor the pressure drop across the strainer by a differential pressure
Sketch 5.3-5 Wire cloth
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
ATTENTION
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.
ATTENTION 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 exceed NPSHrequired , lower regulation limits for ALARM / SHUT OFF may have
to be set accordingly.
H. Pressure test
ATTENTION The pipework should be pressure tested in accordance with the statutory regulations.
4330/e5-1-00-001 page 14
5.4. Ancillary equipment
A. 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).
ATTENTION Do not mix up connections. After laying the pipes (and also after repairs), check the pipe
runs. All the auxiliary flushing piping and C&I cable tray can’t be treaded and climbed to
prevent the destroyed and accident.
The following instructions may be used as a guide insofar as they apply to the pump as delivered.
B. 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.
The applicable standards and guidelines in respect of terminal connections should be observed. If
provided on baseplate the earthing lug must be connected.
4330/e5-1-00-001 page 15
F. 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.
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.
- Heating: Connections and scope see installation plan or separate drawing respectively. Don't confuse
inlet and outlet connection. (Inlet highest, outlet lowest point of heating chamber). In the supply pipings
regulating valves are installed. Lead reflux in a collecting piping, if necessary via steam trap.
- 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.
4330/e5-1-00-001 page 16
5.5. Minimum flow device
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.
-------------------------------------------------------------------------------------------------------------------------------------------
General
In the partial load region (when operating the pump near zero flow) almost the total pump
ATTENTION
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.
If the shut-off device in the delivery pipe is tightly throttled or closed during pump operation, the
delivery fluid inside the pump will heat up after just a short time. This may cause the surface
temperature on the pump casing to rise above the permissible temperature class. If necessary,
provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with
emergency switch-off).
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.
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 leak-off non-return valve and leads back to the suction tank.
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
ATTENTION 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 shut-
down 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.
ATTENTION Separate pipes must be laid for minimum flow pipe and balance pipe if both are required
to be led back to the suction tank.
minimum flow line
Never operate below pump
ATTENTION
minimum flow. Minimum flow
operation causes in higher internal wear
therefore operation at minimum flow should be Suction tank
maintained for no longer than 2 hours in any 24 Minimum
flow valve
hours of operation.
4330/e5-1-00-001 page 17
Sketch 5.4-1 Typical piping layout for minimum flow line
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
Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work
immediately if any danger arises.
ATTENTION The items described individually have to be carried out, as far as applicable, step by step
during commissioning. All fasteners should be checked and tightened to prevent leakage
according to operation conditions before pump hydro testing or start running.
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 table recommended lubricants.
c. Alignment Check alignment of coupling (see 5.2)
d. 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). ).
e. Filling the pump
ATTENTION In case of hot (or cold) product: extreme caution must be exercised when filling a pump that is
at ambient temperature. To prevent thermal shock the pump should slowly and controlled
3
filled up with small fill up rate 0.3 to 0.5 m /h (1.2 to 2 gpm) so that the pump case and internals can be
warmed up (or cooled down) uniformly.
Filling the pump - feeding operation Filling the Pump - suction lift
• Slowly open shut-off valve in inlet line • Fully open shut-off valve in suction pipe
• If existing (see installation plan) Open vent • If existing (see installation plan): Open vent (not
(not valid for self-venting casing) 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 pumped • Fill pump (suction pipe must have foot valve)
medium flows without bubbles • As far as existing: Close vent when pumped
• Fully open shut-off valve in inlet line medium flows without bubbles
ATTENTION Before starting the pump, the suction piping, pump case and shaft seal chamber must be
completely filled with liquid.
If there is danger of frost, protect the pump casing, bearing housing and cooling chambers
ATTENTION
against freezing.
f. Minimum flow line (if fitted) Open and lock the valve in the minimum flow line (see also 5.4 - para.
Minimum flow device).
g. 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).
M000/e6-1-00-000 Page 1
6.3 Pump start-up and Operation
Pump operation is based on the assumption that the pump system is always completely full of delivery
fluid. This prevents the existence of any potentially explosive mixture in the pump. If this is not
guaranteed, appropriate safety systems (e.g. liquid detectors or motor load controllers) must be provided on
the equipment.
a. Ancillary equipment If available, put ancillary equipment into operation (e.g. cooling, heating, sealant
pressure...), open the valves in the ancillary pipework (open Quench after pump start-up), vent pressure
gauge (see also 5.4).
b. Start-up with non-pressurized system Start-up with pressurised system
• Close shut-off valve in the discharge pipe (precondition is non-return valve in discharge
(minimum flow must be guaranteed). pipe)
• Start driver and bring the pump rotor • Start driver with open discharge valve and
immediately to operating speed. bring the pump rotor immediately to
• Open discharge valve slowly, until the operating speed
differential pressure drops to the value given
on the data sheet.
Operation below min speed (1400rpm) e.g. by variable speed drive or turbine drive, cau-
ATTENTION
ses serious damage to the pump. The max allowed run up time to min speed is 10 senconds.
Pump should produce pressure at discharge as soon as rated operating speed is reached. If
ATTENTION
not, shut down immediately and vent pump system.
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
ATTENTION
operation the valve in the suction line must be fully open.
Non-observance may result in an unacceptable temperature increase and cause the pump to run dry.
In extreme cases the pump casing may burst.
3
Capacity in (m /h)
4000/e6-0-00-000 page 2
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.
z exceeding of the max. admissible speed
z remaining of the min. speed (low speed rotation e.g. by turbine drive, high velocity flushing through the
pump, damage of discharge non-return valve causes serious damage to the pump)
z exceeding or remaining of the medium viscosity
z exceeding of the max. admissible inlet pressure
z exceeding of the max. admissible temperature
z exceeding or remaining under the operating range of the pump
z running of the pump without proper venting of pump interior
z running of the pump without required safety devices ( safety valves, electrical overload protection etc.)
z 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).
z operation of the pump with closed or throttled shut-off device in the inlet line (dry running)
z operation of the pump for the delivery of fluids, for which the pump are not suitable (chemical, solids,
gas content ...)
z operation of the pump with wrong sense of rotation
z 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.
4000/e6-0-00-000 page 3
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.
If any vibrations, unusual noises or faults are observed stop the pump unit at once.
ATTENTION
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.
The generated pressure must not fall below the value given in the pump data sheet, otherwise
ATTENTION
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
pump characteristic curve
The capacity is determined from the pump performance
curve and the generated head (m) as calculated above.
Operating range
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.
Maximum capacity
Head in (m)
Minimum capacity
3
Capacity in (m /h)
4000/e6-0-00-000 page 4
6.8 Operating faults
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 work. Driver out of service, speed too low Check - refer to manufacturer‘s
No discharge manual
pressure. Rotor blocked Check and correct
(Failure at start-up) Wrong direction of rotation Check-refer to pump rotation arrow
Pump not primed Vent pump
Suction valve/line blocked Inspect and correct
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 start-up Too much air or gas in the pumped Check operating data (1.4)
liquid
Leakage of air into pump suction Check and correct (seal)
3 Pump flow too small. Suction or Discharge valve not fully Check valve position and correct as
Differential pressure open required
too low. Suction strainer blocked Disassemble and clean strainer
Efficiency loss Minimum flow line open, minimum Check minimum flow line, minimum
flow valve damaged or bypass orifice flow valve, bypass orifice (5.4)
worn
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 (8.)
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 Piping should be properly supported
forces 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
(8.)
Unbalanced rotor – causes vibration Check balance of coupling, driver
and pump rotating parts
Shaft bent Disassemble and check shaft runout
(8.)
4000/e6-0-00-000 page 5
Symptoms Possible causes of faults Remedies
5 High shaft seal Seal flush insufficient (flow rate) or Check flow requirements
temperature. missing
High leakage of Wrong orifice size or worn orifice Check size, flow requirements
mechanical seal. Solids block seal rings/springs Disassemble and remove solids,
Short shaft seal life review application
Vaporisation in the seal ring area Check circulation flow or cooling
requirements (1.4, 7.2)
Seal fluid not suitable (abrasive) Review application, install filter or
separator
Seal rings, auxiliary gaskets (O-rings) Disassemble and replace damaged
or springs damaged seal parts (8.)
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 (8.)
Insufficient bearing cooling (air / Check air intake (environmental
water) temperatures under noise hoods).
Check cooling water requirement
(1.4)
Bearings damaged Disassemble and replace bearings
(8.)
Excessive pump thrust Check hydraulic balance device,
balance pipe. Disassemble and
inspect pump internal clearances (8.)
Shaft bent Disassemble pump and check shaft
runout (8.)
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 (8.)
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 Sulzer representative, make
- Corrosion Operating fluid differs from specified necessary correction to unit design.
- Erosion value (temperature, specif. gravity...) Refurbish pump with correct parts,
- Loss of material Materials of construction not clean system. Assemble filter or
compatible with medium delivered separator.
9 Pump Operating below minimum flow Review hints for minimum flow. (1.4,
overheating/seizure (pump dry running) 5.4) In case of seizure disassemble
and repair unit.
4000/e6-0-00-000 page 6
7. MAINTENANCE
7.1 Pump general
Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work
immediately if any danger arises.
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 sealing, auxiliary 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
5. Fastening elements > Check that all screw fasteners are correctly tightened
Safe operation can only be guaranteed if the pump unit is kept in perfect technical condition. This, in
turn, can only be achieved through constant monitoring and proper maintenance.
If any vibrations, unusual noises or faults are observed stop the pumpunit at once.
ATTENTION
Ascertain the cause and rectify (see 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 8. for
details on overhauling the pump.
The pressure in the balance chamber should always remain constant. If the balance
ATTENTION
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
With correct maintenance and unhindered heat dissipation, it is possible – in the area of the rolling
o
bearings - to maintain temperature class T4 (135 C) at the surface for ambient temperatures up to
o
+40 C. Special measures (cooling) must be taken for higher ambient temperatures, or for
o o
temperature classes T5 (max. 100 C) and T6 (max. 85 C).
0000/e7-1-1-000 page 1
Vibrations
These can be detected by hand or with electronic equipment (frequency or amplitude analyser).
Horizontal pumps, which are fastened to the foundation with anchors should not exceed a vibration speed
given in the following table.
Bearing vibration level unfiltered RMS / 10-1000 Hz
-1 -1
Operating speed up to 3000 min up to 3600 min
Continuous operation 4.5 mm/s (0.18 In/s) 5.6 mm/s (0.22 In/s)
Alarm at 7.1 mm/s (0.28 In/s) 9.0 mm/s (0.35 In/s)
Shut off aggregate 11.0 mm/s (0.43 In/s) 11.0 mm/s (0.43 In/s)
This values are valid for operation at rated point / preferred operating range (from >70% Flow
ATTENTION
to <120% BEP) only.
Flow < 70% BEP - part load operation acceptance criteria: +1.5 mm/s (0.06 In/s) RMS compared to the value
for preferred operating range.
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)
> W ear 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)
Pump safety can only be ensured if repairs are carried out by expert specialist personnel using original
replacement parts.
0000/e7-1-2-000 page 1
Inspection and check list
The intervals between the necessary overhauls may vary extraordinary, as the differing operating conditions
can have substantial influence on the service life of machine parts.
Under normal operating conditions and with pumps which are not neglected in maintenance and care, the
check and overhaul works are recommended in the following intervals.
Further
recomm.
see
6 monthly
Overhaul
Monthly
Weekly
During
Yearly
Measuring devices
Daily
(Pressure gauges, thermometers ammeters as far a existing and not
monitored by automatic switches alarm/emergency out)
Oil level > Oil sight glass / Constant level oiler 7.3 X
Leakage > Shaft seal / Mechanical seal cover 7.2 ➊
Maintenance works
➊ These parameters should be recorded in an operating log and used as a basis for maintenance works.
➋ Overhaul allows supervision of wear, early recognition of any sign of damage and replacement of
defective parts in time. All signs of wear and spare parts used should be recorded in the operating log.
0000/e7-1-3-000 page 1
Title:
Report Supervision check list
Plant / Location:.........................................................................................................................................
Aggregate Specification:...........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Run D D ........................................................................
Noise D D ........................................................................
Vibration D D ........................................................................
........................................................................
Comments:.................................................................................................................................................
...................................................................................................................................................................
...................................................................................................................................................................
Remark:
R 0000 / 7-0-00-001
Date: Sign: Page ... of ...
0000/e7-1-4-000 page 1
Title:
Report Inspection check list
Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
2. Gauges Remark:.....................................................
o
Temperature D D .................................. C D-side / ND-side
Oil level D D ................................... O.K. Yes / No
Oil refilled D D ................................... Refill QTY. liters
Oil leakage D D ................................... Yes / No
Remark:
R 0000 / 7-0-00-002
Date: Sign: Page ... of ...
0000/e7-1-5-000 page 1
Title:
Report Maintenance list
Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Maintenance interval No.: ....... Operating hours: .........h Number of starts: ........
Bearings:
D Lubricating oil change Lubricant type : .........................................
D Leakage checked Quantity: ...................................................
Mechanical part:
D Coupling alignment checked (reported)
D Bearings opened and checked
D Mechanical seal checked
D Balance device opened and checked
D General overhaul with pump hydraulic part opened and checked
D Rotor newly adjusted (axial / radial center position)
Parts changed:
D Mechanical seal - Drive side / Non-drive side
D Balance device
D Bearings - drive side / non-drive side
D Shaft
D Wear rings
D others: ..........................................
Comments:..............................................................................................................................................
................................................................................................................................................................
................................................................................................................................................................
Remark:
R 0000 / 7-0-00-003
0000/e7-1-6-000 page 1
7.2 Shaft seal
Single-acting mechanical seal
General remarks
Mechanical seals intended for use in potentially explosive areas must satisfy the “Ex” protection
requirements.
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
ATTENTION 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
- evaporation temperature considerably higher than operating temperature
- no impurities in the slide ring region
If auxiliary facilities like
- flushing
- blocking
- 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.
Failure of an auxiliary device (cooling, circulation, etc.) may cause the temperature of the casing
surface to rise to an unacceptable level. If necessary, provide the equipment with appropriate safety
systems (e.g. remote temperature monitoring with emergency switch-off).
Maintenance
The maintenance of the mechanical seal can be limited to the control of the auxiliary facilities, leakage and
temperature at the mechanical seal cover. In the case of normal flushing by circulation the seal cover must
not reach any higher temperature than the adjacent pump casing. In the case of cooling or heating the data
mentioned in paragraph 1.4 have to be observed.
A slight leakage of the mechanical seal is normal. It is impossible, however, to make special
ATTENTION
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. In this case defective parts have to be replaced. Auxiliary seals (such
as O-rings) have to be renewed during each assembly. Mechanical seal rings (stationary and rotating) have
always to be replaced as a unit.
0000/e7-2-01-002
7.3 Bearing / Lubrication
Anti-friction bearing with splash oil lubrication
General
ATTENTION 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 troublefree operation. The oil must not contain any foreign substances, acids or resins. Minimum
requirements of suitable lubrication oils are given in DIN 51 511, API-SF/CC, MIL-L-46152 B.
All lubricating oil suppliers are therefore in a position to classify their products accordingly and to propose a
product which satisfies these standards.
Failure in terms of lubrication (e.g. through lack of maintenance, use of inappropriate
lubricants/lubricant qualities, leakage, etc.) may cause the temperature of the casing surface to rise to
an unacceptable level. If necessary, provide the equipment with appropriate safety systems (e.g. remote
temperature monitoring with emergency switch-off).
Oil viscosity
Since, with anti-friction bearings, the self-heating of the bearing due to fulling plays an important role, and
2
since, on the other hand an oil viscosity of at least 12 mm /s at operating temperature of the bearing is
required for a sufficient lubrication film, the oil viscosity has to be selected as follows:
ATTENTION Multigrade Engine Oil SAE 15W-40 should be used. The max. allowable temperature values
are given in the table below. In case of deviations contact the service. If the temperatures
o
after overhaul rises over the given values for continues operation (> 90 C in the oil sump), as a first measure
check thrust bearing axial clearance (see 8.).
In the case of automatic constant–level-oilers pay attention to refill the reservoir (oiler tank).
4330/e7-3-01-001
Recommended lubricants
Proper lubrication is particularly important for the operational safety of centrifugal
pumps.
4330/e7-3-01-001
Oil level
Monitoring oil level in the constant level oiler bottle. The bottle should always until 2/3 be filled
ATTENTION up. A sudden oil level drop can indicate a leak. Stop operation and inspect unit.
Oil replacement
Warning: Lubeoil 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.
2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage bores and
size see installation plan or dimension sheet.)
3. Remove screw plug, drain oil thoroughly. Tighten screw plug again securely.
4. Fill bearing bracket with fresh oil as described.
Dispose of used oil according to statutory regulations. Do not put into waste water by any
means.
Filling-in of oil with constant level oiler (Type Adams)
Remove oil filling plug at the top of the bearing housing. Fill oil through the bearing housing fill opening until
the casing of the constant level oiler begins to fill up (swing back oiler bottle to check oiler case filling). Then
fill the bottle with the same oil and swing it back to its working position. Repeat this procedure until a
minimum of 2/3 of the bottle remains filled up. Screw in and tighten filling plug.
Maintenance: Check the supply in the bottle at times and refill, if necessary.
Constant level oiler working principle
When the oil level within the bearing housing drops, the opening to the supply bottle gets free. Oil flows from
the supply bottle until the former oil level is reached and the opening to the supply bottle is covered by the oil
level.
refill here
Oil level
casing
gasket
Make sure that the glass bottle is tightly closed, if necessary replace gasket. Turn bottle
ATTENTION handtight into threaded cover.
4330/e7-3-01-001
8. OVERHAUL
Sketch 8.1-1
4330/e7-5-01-002 Page 1
B. Removal of bearing – non-drive side
- Remove screws (900.01) for the fastening of the fan cover (832.01) and take off fan cover. Take circlip
(932.01) out of shaft groove by means of spring ring pliers, push fan (831.01) off the shaft and remove
key (940...).
- Remove hexagon socket screws (914.03) from bearing cover (360.02). Clean and lubricate shaft,
carefully push bearing cover together with labyrinth seal (423...) off the shaft.
- If required: Push labyrinth seal (420...) out of bearing cover bore. Note: The labyrinth seal consists of
two parts, a rotor and a stator, but is assembled as a single unit. Do not separate the rotor from the
stator.
- Remove shaft nut (920.16 or 920.15 depending on model).
Shaft nut (920.16): Locking pins pressed against the shaft by the adjusting screws, are in the bearing
fastening nut KMT (920.16). As the locking pins were fitted into the bearing nut by pressure fit, the
bearing nut will still rest tightly on the shaft thread after loosening the adjusting screws. Light tapping
on the shaft nut near the screw holes will loosen the locking pins a little so that the shaft nut can be
screwed off easily.
Shaft nut (920.15): Bend lockwasher tang out of bearing nut (920.15) and screw off bearing nut. Take
off lockwasher (931.01) and distance disc (551...).
Arrest the shaft before drawing off the bearing bracket on non-drive side to avoid damage
ATTENTION
to the mechanical seals. To do so mount a holding device on the drive side to fasten the
rotor to it by means of the shaft bore, see sketch 8.1-2.
- Screw off hexagon nuts (920.02) of the bearing bracket fastening, mount puller (see sketch) and draw
off bearing bracket together with antifriction bearings (320...).
- Draw spacer sleeve (525.02) together with labyrinth seal (423...) off the shaft or remove it from bearing
bracket bore. Dismantle antifriction bearings from bearing bracket.
Draw off bearing bracket with puller: Arresting the rotor on drive side:
Push bearing bracket together with Replace 2 fastening screws from bearing
antifriction bearings evenly off the shaft. cover opposite to each other by the holding
device and secure the rotor by the shaft
puller centering thread.
holding device
4330/e7-5-01-002 Page 2
Delivery cover (163.01)
- Unscrew hexagon socket screws (914.01)
fastening shaft seal housing (441...), loosen
shaft seal housing and pull it off. Be careful:
Remaining medium will flow out.
Balance drum (603.01)
- Mount device and draw balance drum
(603.01) and balance drum liner (605.01) Shaft
together with the spacer sleeve (520.02) off
the shaft. See sketch 8.1-3. Take off keys
(940.04, 940.02).
4330/e7-5-01-002 Page 3
F. 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 (920.01) from the tie bolts (905.01) and withdraw the tie bolts.
- Loosen and remove the delivery casing (107...) by carefully tapping with a rubber hammer and levering
between the release pins. Be careful: Remaining medium will flow out.
- Remove last diffuser (177.01) from delivery casing
- Slide the impeller (230...) off the shaft, remove key (940.01)
- Loosen and remove stage casing (108...) together with diffuser (171...). Be careful: Remaining
medium will flow out.
- Slide next impeller (230...) off the shaft, remove key (940.01)
- Dismantle stage by stage in the same way. Support shaft adequately to prevent bending.
- W ithdraw carefully shaft with first stage impeller out of suction casing, slide impeller off the shaft and
remove key.
- Press diffusers (171...) out of the stage casings (108...)
- If required (in case of wear, see 8.2): The wear rings (502...) in the suction casing / stage casings and
the interstage bushes (541...) in the diffusers can be replaced.
G. 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.
Handle the pump shaft with care and where ever possible store shaft by hanging vertically to maintain
staightness.
Inspect all pump parts for wear or damage, see 8.2.
4330/e7-5-01-002 Page 4
8.2 Inspection of wear parts
Carry out all checks with the greatest possible care. Examine all parts for wear and re-
ATTENTION
machine or replace as the case may be. Negligence will lead to a premature failure of the
pump.
A. Impellers
Inspect impellers for wear or damage. Look for cavitation marks (pits) in the suction area (especially in the
first stage impeller), erosion of vanes and cracks in the shroud. Smooth minor irregularities with a fine file
or emery paper, replace impellers, if necessary.
B. Wear rings and clearances
Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum (new)
diametrical clearances are given in the table below.
Replace impeller and wear ring parts, when pump performance drops below acceptable system standard
or the recommended maximum clearances have been reached or exceeded.
Remark: Each clearance enlargement causes efficiency loss in pump. Clearance
measurement: See sketch 8.2-1. Measure the clearance between corresponding sets of
rotating and stationary parts. Use several measurement locations, then calculate the
clearance as described below.
4330/e7-5-01-002 Page 5
D. Balancing
It is recommended that impellers are individually balanced on a balancing machine. Dynamic balancing to
VDI 2060, 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 bearing forces in the close
clearances within the pump.
E. Shaft
Handle the shaft with care and support it evenly to maintain straightness. Avoid bumping, hitting or
springing the shaft. Inspect shaft seats and shoulders for cleanliness, nicks and burrs; if necessary
replace them.
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.
F. Shaft seal
Remark: The Cartridge mechanical seal should be renewed as a complete unit. For repairs the damaged
seal cartridge should be shipped to the manufacturer or to one of the manufacturer’s service centers.
Cartridge dismantling: After loosening and moving the assembly bars out of the shaft sleeve groove the
mechanical seal can be disassembled into its single parts. WARNING: The mechanical seal cover is pre-
stressed by internal springs.
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. W e recommend the use of new
rotating and stationary seal rings.
Assembly must be done very carefully and under conditions of extreme cleanliness. The
ATTENTION
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.
G. Bearing
Antifriction bearings
Rinse bearings with light oil. In case of major overhaul or damage, replace bearings.
Remark: In case of renewed thrust bearings: Use only paired bearings, never replace only one bearing of
a unit. The bearing design number is given in the pump parts list.
H. Balance drum / Balance drum liner
Replace balance drum and balance drum liner, when pump performance drops below acceptable system
standard or the recommended maximum clearances have been reached or exceeded.
Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size (see
also sketch 8.2-1). Replace balance drum and balance drum liner as a unit.
4330/e7-5-01-002 Page 6
I. 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. See sketch 8.2-5
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.
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.
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. 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.
Washer
4330/e7-5-01-002 Page 7
8.3 Assembly of the pump
References Refer to specific drawings (section drawing(s), parts lists, installation plan).
These pumps 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.
A. 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.
B. Assembly of the hydraulic pump part (Refer to matchmarks during reassembly)
Note with pump sizes: 40-180 from 9 stages; 50-220 from 10 stages and 80-260 from 8 stages:
With pumps having a large number of stages, the pump casing must be adjusted to the deflection line of the
shaft. In such cases the correction is obtained by obliquely turning one or more of the stage casings. The
oblique stage casing carries the mark “OBEN" and the number of the stage in which it must be mounted
(counting from the suction end). See sketch 8.3-1.
oben
Sketch 8.3-1
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 (940.01) for the first normal impeller, and push impeller (231...) onto shaft stop (210...)
- Insert diffuser (171...) in the first stage casing (108...) and slide it into the centering element of the diffuser
device - if necessary, knock with a rubber hammer. Place O-ring seal (412.01) for sealing against next
stage casing.
- Insert key (940.01) and push on next impeller (230...) from the non-drive side.
- Fit another pre-assembled stage casing (with diffuser) - if necessary, knock with a rubber hammer. Place
O-ring seal.
- Assemble remaining stages in the same way.
- Slide delivery casing (107...) with inserted last diffuser (177.01) and O-ring seal (412.12) on the spigot of
the last stage casing (108...).
- Drive side: Place O-ring seal (412.01) on the spigot of the diffuser device (170....) and mount suction
casing (106...).
ATTENTION Adjust and support pump suction and discharge casing feet on a smooth steel plate.
- Fit tie bolts (905.01), discs (550.01) and nuts (920.01). Clamp the whole hydraulic assembly together
evenly and crosswise. See Table 8.5 for tightening torques.
C. Assemble balance device
- Insert key (940.02) into shaft. Place O-ring seal (412.08) into the balance drum (603.01) bore and push
balance drum onto shaft.
- Slide balance drum liner (605.01) with O-ring seal (412.07) into delivery casing bore and allow the
cylindrical dowel pin (561.02) preventing rotation to engage in the hole..
- Insert key (940.04) into shaft and slide on sleeve (520.01).
4330/e8-0-01-001 page 8
D. Assembly of the shaft seal housings
- Drive side: Insert key (940.04) for shaft sleeve.
- Insert O-ring seal (412.02) in groove of the shaft seal housings (441...). Locate shaft seal housings on
delivery casing (107...) and suction casing (106...) using hexagon socket screws (914.01). Note: Be sure
venting bores of seal chambers are on top.
E. Measurement and adjustment of the axial position of rotor
Measurement is not necessary, if the installation length of the pump parts have not changed through re-
machining during repair, but it is essential if new parts (shaft, impellers, stage casings) have been
fitted, otherwise continue with paragraph "Assembly of shaft seal non-drive side"
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.
ATTENTION Do not turn the rotor and do as less as possible move the rotor axial.
Remark: Mount all parts required for the measurement without O-ring seals.
- Drive side: Push mechanical seal shaft sleeve (523.01) and spacer sleeve (525.01) onto shaft stop.
- Non-drive side: Push mechanical seal shaft sleeve (523.01) on the shaft.
- Assemble bearing brackets (330...) on both sides of the pump and fasten with 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 8.3-3) from the support shoulder of the
thrust bearing in the bearing bracket bore to the front face of the shaft sleeve (523.01) with depth gauge.
- The spacer sleeve (525.02) must be longer than the measurement "A" by the value "B" given in the
following table
Pump size 40-180 50-220 80-260 Dimension in
± 0.1 ± 0.1 ± 0.1
Dimension B= 5.3 6 6.5 mm
- New spacer sleeves are supplied with oversize, they must be machined to the calculated dimension.
When repair work is done the nominal dimension can also be gained by applying supplementary discs.
Note: The spacer sleeve shoulders must be parallel to each other within 0.01 mm after machining.
A+B
Running position
Remachine shoulder
4330/e8-0-01-001 page 9
- On the drive-side: Check the length dimension of the spacer sleeve (525.01) while the rotor is moved to
the non-drive side.
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.
4330/e8-0-01-001 page 10
H. Assembly of bearing brackets
Mount bearing brackets on drive side and non-drive side.
- Lubricate spacer sleeve surface (525.02) and push inboard labyrinth seal (423...) onto the spacer sleeve.
Note: To avoid damage, press into place with the labyrinth seal rotor inside the stator.
- Slide spacer sleeve (525.02) in nominal dimension (together with labyrinth seal) into position on the shaft.
- In case of shaft seal housing cooling: Place O-ring seal (412.02 or 412.03) on the spigot of the seal
housing and O-ring seal (412.04) into the shaft seal housing groove.
- Mount bearing bracket (330...) to do so push inboard labyrinth seal (423...) into bearing bracket bore.
Note: Labyrinth seal stationary part with leakage groove or bore downwards. Lube threads and support
surfaces of nuts (920.02) and tighten fasteners evenly and crosswise. See Table 8.5 for tightening
torques.
I. Assembly of antifriction bearings
- Assemble thrust bearing – non-drive side: Build in outer race of inboard taper roller bearing (320...)
with bearing intermediate ring (make sure that one bore of the bearing intermediate ring points
downwards) into bearing bracket bore. W arm taper roller bearing inner races with rolling elements in an oil
o
bath to approx. 80-100 C and push it up to shaft stop. Fit outer race of outboard taper roller bearing.
In case of renewed taper roller bearings: Use only paired bearings, never replace one
ATTENTION bearing of a unit. The bearing design number is given in the pump parts list.
4330/e8-0-01-001 page 11
J. 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
ATTENTION provide a correct bearing end play. The bearing end play must be checked after every
disassembly of the thrust bearings.
- Place clock gauge axially on the front of the shaft on the non-drive side; check axial clearance of the
thrust bearing unit by axially moving the rotor into its final positions. See sketch 8.3-4. W ith taper roller
bearing: tap lightly on the bearing bracket (non-drive side) with a rubber hammer to straighten twisted
rolling elements.
Move rotor into its final axial positions, use device as shown. Tighten hexagonal nut ① (not too
strongly), ② loosen, read clock gauge, loosen ①, tighten ② and read nominal end play.
nominal dimension
0.04 to 0.06 mm
Sketch 8.3-4
- If there is no noticeable clearance the bearing elements may be twisted (taper roller bearings), turn rotor
slowly in both directions and measure once again.
- If the measure axial clearance is smaller than 0.04 mm, the fault may be corrected by tightening the thrust
bearing shaft nut (920...) more strongly. Correct mistake.
- Remove device for bearing end play measurement.
If the taper roller bearing temperature after overhaul rises >90 oC, as a first measure check
ATTENTION
bearing end play.
K. Final assembly
- Labyrinth seals: On both sides of the pump. Lubricate shaft surface and bearing cover bore. Push
outboard labyrinth seal (423...) onto shaft and into bearing cover bore. Note: To avoid damage, press into
place with the labyrinth seal rotor inside the stator. Mount stationary part of Labyrinth seal with leakage
groove or bore downwards. Check correct seat of inboard labyrinth seal.
Shaft seal
- Cartridge mechanical seal: If present tighten clamping device (shaft/shaft sleeve). Tighten nuts (920...)
of the mechanical seal cover evenly and crosswise. Tightening torque see table 8.6. Loosen the
assembly bars of the Cartridge mechanical seal at the seal cover, draw them out of the shaft sleeve
groove and reattach them.
- Standard mechanical seal: Now fasten shaft seal covers on the non-drive side and drive side by
tightening the fastening nuts (920.05) evenly and crosswise. Tightening torque see table 8.6.
Fan cooling
- Non-drive side bearing housing: Insert key (940.05) for fan (831.01) into shaft, slide on fan and place
circlip (932.01) in shaft groove. Place fan cover (832.01) and fasten with cylindrical screws (900.06).
4330/e8-0-01-001 page 12
Coupling: Mount the coupling half. See sketch 8.3-5.
coupling half nut
- Clean coupling bore and shaft extension, insert key that drives the
coupling into shaft. A thin coating of oil on the shaft surface and hub
bore is recommended, do not use molybdenum disulphide or similar
products.
- Remove heat-sensitive parts (e.g. rubber buffers and seal rings etc.)
o
and heat up the coupling half to approx. 80 C 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 can also be fitted cold with an pump shaft bar stud
appropriate attachment.
Sketch 8.3-5
The bearings must by no means be subjected to any
ATTENTION
pressure or shock.
Ancillary equipment
- Connect ancillary pipework (balance pipe, seal circulation pipes...) and instruments (thermometer,
constant level oiler, pressure gauges...)
ATTENTION Do not mix up connections. Carefully check piping system.
Driver
- Couple driver, check alignment of coupling (see 5.2).
- Fit coupling guard. Rinse bearing housing with oil and fill with lubricating oil, see 7.3.
Electrical installations / connections for motors and controlling devices may only be carried out by
qualified electricians.
4330/e8-0-01-001 page 13
8.4 Tools
A. Disassembly equipment for the balance piston and thrust bearing housing
Part Part Pump size 40-180 50-220 80-260
No.
1 1 Flange 200 x 25 x 165
Drawing No. 2-104 084 159
Article No. (tool set complete) 104 998 809 362
2 4 Stud (bearing hous. removal) M 10 x 165 M 12 x 200
3 2 Stud (balance piston removal) M 10 x 440 M 12 x 620
4 4 Disc A 10.5 A 13
5 4 Nut M 10 M 12
6 1 Hexagon screw M 20 x 1,5 (140 or 180 length)
7 1 Ball 12 mm diameter
1
6 7
5
Sketch 8.4-2 Balance drum (drum liner) removal
1 3
1
6 7
4330/e8-0-01-001 page 14
8.5 Screw tightening torques
Casing seal
Note: Tightening torques are only valid, if thread and support surface for nuts
(respectively screw head supports) are lubricated. Bolting sequence
A. Even loading
Suggested torque values are recommended to produce properly stressed
joints with a minimum probability of nuts, bolts or studs breaking or ➅ ➁
loosening. ➃ ➆
Avoid possible distortion by using correct tightening sequence during torque
development.
B. Thread lubes
Lubricate threads and support surface for nuts with graphite and oil, ➇ ➂
molybdenum disulfide, or another anti-seize lubricant of comparable quality, ➀ ➄
except in instances where the lubricant is incompatible with fasteners
application.
C. Torque development
Tighten opposing fasteners in an alternating sequence when developing
required torque.
Lubricate and install fasteners finger-tight. Develop the required fastener ➃ ➁
torque in a minimum of three steps with a maximum of 33 % torque value on
the initial pass.
screws 914.02
➃ ➀ ➃ ➅
➆ ➀
➁ ➂ ➁ ➇
➄ ➂
screws 914.03
Note: Refer also to 5.2 for tightening torques for pump feets
4330/e8-0-01-001 page 15
ENCLOSURES
PUMP
Performance data-diagram
Performance curve
Dimension drawings
Installation plan
Plant drawings
P + I Diagram
Device list
Sectional drawing
Centrifugal pump
Parts list - pump
SHAFT SEAL
ACCESSORIES
Drive
Coupling
Driver
Valves
Minimum flow regulation