Horizontal & SuHorizontal & Sump Pumpmp Pumps

CENTRIFUGAL PUMPS

F a c t o r y A d d r e s s : C o r p o r a t e A d d r e s s :

A-5, Sector XXII, Meerut road, WPIL Limited

Ghaziabad – 201002, (U.P), India Trinity Plaza,3rd

floor

Phone:+91-120-3015784 84/1 a, Topsia road (south)

Kolkata 700046, India

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WPE ES IOM Manual

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1 . I N T R O D U C T I O N2 . P U M P E R E C T I O N3 . C O M M I S I O N I N G4 . M A I N T E N A N C E5 . S E C T I O N A L D R A W I N G6 . B I L L O F M A T E R I A L7 . C A U S E O F F A I L U R E8 . P O S S I B L E C A U S E9 . G U A R A N T E E C A R D

WPIL designs are being regularly

improved and are thus subject to

changes.The pumps designed as

per customer’s requirement will

not exactly match data provided in

this manual.

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WPE ES IOM Manual

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I N T R O D U C T I O N P r e f a c e

The booklet covers the instructions for the following models of W P E pumps.

Brg.Frame unit Pump models

15 11 32/130,40/130,50/130,65/130,32/200,40/200,50/200,65/200

12 32/160,40/160,50/160,65/160,80/160,32/260,40/260,50/260

18 80/200,100/200,65/260,80/260,100/260,125/260,40/320,50/320,65/320,80/320,100/320

22 150/260,125/320,150/320,100/400,125/400,150/400

� This manual contains important and useful information for the proper

functioning and maintenance of this pump. It also contains important

instructions to prevent possible accidents and serious damage and to

ensure the safe and smooth functioning of this pump.

� Read this manual carefully before commissioning the pump. Familiarize

your self with the operation of the pump and strictly obey the

instructions!

G u a r a n t e e W P I L shall not be bound to any Guarantee other than the guarantee

accepted by W P I L. In particular, W P I L

will not assume any liability for

explicit and/ or suitability of the articles supplied.

The guarantee shall forthwith and legally defunct in case:

� Service and/ or maintenance has not been carried out strictly in

accordance with the instructions.

� Installations and/ or commissioning has not been carried out in

accordance with the instructions.

� Necessary repairs have not been carried out by our personal or have

been carried out without our prior written consent.

� The articles supplied have been changed without our prior written

consent.

� The spare parts used are not original WPIL Pump parts.

� The articles supplied are used amateurishly, carelessly, improperly

and/or negligently.

� The articles supplied become defective due to out side circumstances

beyond our control.

Furthermore, all deliveries are subject our “G e n e r a l c o n d i t i o n s o f d e l i v e r ya n d p a y m e n t

“, which will be forwarded to you, free of charge and request.

I n s p e c t i o n o f d e l i v e r e d i t e m s

� Check the consignment immediately on arrival for damage and

conformity with the advice note.

� In case of damage and/or missing parts, have a report drawn up by the

carrier at once.

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WPE ES IOM Manual

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L i f t i n g If a pump or a complete pump unit has to be lifted, the slings should be fixed

as shown in figure 1. And figure 2.

F i g u r e 1

.

F i g u r e 2

N o t e : P r o p e r c a r e s h o u l d b e t a k e n t o p r o t e c t p u m p a n d / o r p r i m e m o v e r a n d / o rp a i n t a t c o n t a c t a r e a o f s l i n g o r r o p e a t t h e t i m e o f l i f t i n g.

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WPE ES IOM Manual

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S t o r a g e

In case the pump is not immediately being used, the pump shaft has to be

rotated manually twice a week.

D E S C R I P T I O N O F T H E P U M P

Every WPIL pump has a name plate giving following details:

While you correspond with us for your

requirements of spare parts or for any

technical information, please always quote

this details in your letter.

C o n s t r u c t i o n a l D e t a i l s :WPIL water pumps are single volute casing pumps with axial suction branch and top

centre line delivery branch. All pumps supported by integrally cast foot in the casing

and all water pumps are centerline mounted.

Bearings are cooled when liquids are handled at temperatures above 100˚c

D i r e c t i o n o f R o t a t i o n Clockwise, pump viewed from driven end.

S u i t a b l e s p e e d s All the WPE models are suitable for the speed of 1450 rpm. Besides that the following

speeds are recommended.

WPIL PUMPS

Ghaziabad

CENTRIFUGAL PUMP

SL.NO : TYPE :

SIZE : MM TOTAL M

HEAD

SPEED: RPM CAPACITY :

M³/HR

DRIVE : HP JOB NO :

Max speed Pump Models

Upto 3600

rpm 32/130,40/130,50/130,65/130,32/160,40/160,50/160,65/160,32/200,40/200

Upto 2900

rpm 50/200,80/160,80/200,100/200,32/260,40/260,50/260,65/260,80/260,100/260

Upto 1800

rpm

125/260,150/260,40/320,50/320,65/320,80/320,100/320,125/320,150/320,

80/400,100/400,125/400,150/400

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WPE ES IOM Manual

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P U M P E R E C T I O N 1 . 0

A s s e m b l i n g t h e s e t o n t h e B a s e p l a t e:

1.1 If the assembly of the pump with the driver on a common base plate is done in

our works, the whole set will be carefully mounted and aligned. It is necessary

to check once more the alignment of the coupling before putting the pump

into operation.

The eye bolts which may be fitted to the driver must never be used to lift the

complete set as they are meant to carry the weight of the driver only.

1.2. If you furnish the driver yourselves, the clearance between the motor and pump

coupling halves as shown on the arrangement drawing must be strictly observed.

Difference in level between the shaft centre lines of pump and driver must be

equalized by suitable pickings (plain parallel shims). When the pump and motor

holding – down bolts are finally secured, care must be taken to avoid distortion.

A l i g n m e n t o f c o u p l i n g

� Place a ruler (A) on the coupling. The ruler should touch both coupling halves

across the whole width( see figure ).

� Do the same check against both sides of the coupling near the axis.

� For all security the alignment is also checked with a pair of out side caliper (B) at

2 – diametrically opposite points of the side surfaces of the coupling halves.

A

B

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C O M M I S S I O N I N G

C h e c k p u m p

� Construction with stuffing box: check whether the gland nuts have not been

over tightened. If necessary, loosen the gland nuts and retighten them by

hand.

� Check whether the shaft turns freely. Do this turning the shaft end at the

coupling a few times by hand.

P r e p a r a t i o n o f l u b r i c a t i o n

The bearings of pumps provided with grease-lubricated bearings are filled with

grease at the time of delivery.

Pump provided with oil lubricated bearings are supplied without oil. See the

enclosed chart for specifications of oil to be used.

� Fill the oil sump through the oil filling orifice up to the bottom of the

constant level oiller.

� After that fill the constant level oiller entirely.

P r e p a r i n g t h e u n i t o f c o m m i s s i o n i n g

Proceed as follows, both when the unit is put into operation for the first time

and after the pump has been overhauled.

� Fully open the stop value in the suction pipe. Closed the delivery stop

value.

� Fill the pump and the suction pipe with liquid to be pumped.

� Turn the pump shaft a few times by hand and more liquid, if

necessary.

C h e c k i n g t h e d i r e c t i o n o f r o t a t i o n

� The sense of rotation of the pump is indicated the arrow. Check

whether the sense of rotation of the motor corresponds with that of

the pump.

� Let the motor run for only a short time and check the sense of

rotation.

� If the sense of rotation is not correct, change connecting wire of

motor so as to match with rotation of the pump.

� Mount coupling guard. S t a r t i n g t h e p u m p

� Open the stop valve in the supply piping for flushing for flushing or

cooling liquid, if the pump is supplied with a flushing or cooling

system.

� Start the pump.

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� As soon as the pump is under pressure, slowly open delivery stop

valve until the working pressure is attained. A d j u s t m e n t o f s h a f t s e a l i n g S t u f f i n g B o x P a c k i n g

After the pump is started, the stuffing box will show a certain amount

of leakage. Because of the expansion of the packing fibers, this

leakage will gradually decrease. Make sure that the packing never

runs dry. To prevent this, loosen that gland nut to the extent that the

stuffing box leaks drop wise. As soon as the pump has reached the

proper temperature (and leakage is still too much) the gland can be

adjusted permanently.

� Tighten both gland nuts, one after the other, a quarter turn.

� Wait 15 minutes after each adjustment before making the next

adjustment.

� Continue in this way until an acceptable drop wise leakage has

been attained (20-30 drops/ minutes).

M e c h a n i c a l s e a l� A mechanical seal may never show visible leakage.

C o n t r o l .

If a pump is in operation pay attention to the following:

� The pump should never run dry.

� Never use a stop valve in the suction pipe to control pump capacity.

The stop valve should always be fully opened during operation.

� Check whether the absolute inlet pressure is sufficient, so that no

vapour can be formed.

� Check whether the pressure difference between suction and delivery

pressure corresponds with the specifications for the duty point of the

pump.

D I S M A N T L I N GSince the pumps are offered of back pull out type of design. While

dismantling the pump, casing will remain in its place with the suction and

delivery piping. The rotating

Assembly can be pulled back easily. If spacer coupling is used, then the driver

also

Need not to be removed, enabling easy re-assembling of the pump without

affecting the alignment. We recommend to mach-mark the parts before

removing the spacer so as to ensure the original state of mounting when re-

assembling.

• Drain the liquid handled by the volute casing(C 1) and oil from bearing

bed(C 27).

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WPE ES IOM Manual

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• Remove spacer coupling or if there is no such coupling, loosen driver and

move it aside.

• Loosen sealing liquid and coolant pipes if it is there and undo the

fastening bolt on the support foot.

• Undo stud nuts on volute casing (C 1).

• Using the 2 forcing screws on the stuffing box(C 11) with draw the volute

casing..

• After undoing the impeller nut (C 6) withdraw the impeller with gasket.

• After that undo the stuffing box studs from lantern(C 34), withdraw the

stuffing box along with packing, Lantern ring( C 4),Pressure Ring(C 33) and

Gland ( C 13) .

• Remove the Shaft sleeve (C 14).

• Remove the lantern from bearing housing.

• Remove Deflector (C 31 ) and Inner Bearing Cap(C15) from bearing

housing.

• Remove the Outer Bearing Cap(C 20).Remove pump shaft(C 24) with

Bearings towards drive side.A S S E M B L I N G

For assembly proceed with reverse sequence. After mounting the shaft,

check the axial flow of the rotor from 0.01mm to 0.7mm.

If new bearings are mounted on the shaft, they must first to be heated up to

80˚c in an oil bath. The bearings if installed in our works, have normal

clearances, however, use of bearings with C3 play is permissible.

.

L u b r i c a t i o n s

The pump is furnished with two deep groove ball bearings (table 1.) G r e a s e L u b r i c a t i o n s.

The grease lubricated bearing have been lubricated before shipment. For this

bearings following bearing greases are recommended which are available in

the market.G r e a s e S p e c i f i c a t i o n sName of the firm Speed 1450 rpm Speed 2900 rpm/3600 rpm

Indian oil Servo gem 3 Servo gem 2

Caltex Starfak 3 Starfak 2

Hindustan petroleum Natra 3 Natra 2

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Table – 1

The lubrication in Table 1 apply if the temperature is below 70˚C.

Each temperature rise of 15˚C will reduce the lubrication interval to a half.

O i l l u b r i c a t e d b e a r i n g s .� The bearing housing has been emptied of oil prior to shipment and must be

refilled before starting.

� Pour oil in the bearing housing half way up the sight glass.

� During operation the level may slightly fall. Refilling during operation.

� When the pump is put into operation after prolonged shut down, flush

bearings and bearing housing with petrol or benzyl in order to remove

impurities. During the flushing procedure rotate the shaft slowly.

For lubrication of our pumps we recommend the lubricants shown on this lubrication table

O i l C h a n g e

It is recommended that for a new pump the oil should be changed after 100

hours of operation for the first time and thereafter at intervals of 6-12 months add

oil when necessary.

Frame

unit Bearings

Amount

of oil in

liters

Qty of grease for re-

lubr of each bearing

(g)

15 6305 – 2 Nos 0.550 100

18 6307 - 2 Nos 0.700 150

22 6309 - 1 No

3309 – 1 No 0.850 200

Firm

L u b r i c a t i n g o i l f o r T e m p e r a t u r e u p t o 8 0 ˚ CSpeed up to 1500 rpm Speed above 1500 rpm

Indian Oil Servo System 150 Servo system 68, 46

Hindustan Petroleum Esstic 55, Terresso 56 Esstic 50, Terresso 52

Mobil

Mobil Vactra oil Heavy

Mobile D.T.E. oil Heavy

Vac HLP 49

Mobil Vactra oil Medium

Mobile D.T.E. oil Medium

Vac HLP 36

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S T U F F I N G B O X

M a i n t e n a n c e a n d r e - p a c k i n g

When a new pump is being put into service or the stuffing box has just been

re-packed, watch the packing performance more closely than normal. Shut

off the cooling water to the gland (if applicable).

During the first hours, the stuffing box is allowed to leak quite a good deal,

about 100 drops a minute. If the leakage degreases, slack the packing gland.

If you want to reduce the leakage, tighten the packing stepwise at intervals of

about 10 minutes and continue until packing performance is satisfactory. A

small leakage of single drops should be allowed from the stuffing box for

ascertainment of lubrication and of the correct packing tightness. A suitable

leakage is 5 – 30 drops a minute. If the packing cannot be made to seal

without intense tightening, it is best to re-pack. When re-packing remove all

the old packing rings and cleans the stuffing box thoroughly. At the same

time check to see that the water channels are clear and the shaft is free of

warpage and score marks.

When selecting the packing type, observe the quality and temperature of the

liquid being pumped and the shaft sleeve material.

Carefully form the packing into the right shape over the shaft sleeve.

First insert the cut ends into the stuffing box and then push the whole ring to

the bottom of the stuffing box. Put the rings one by one in the stuffing box,

with the cut ends spaced 90 degrees apart. (See figure)

P A C K I N G O F S T U F F I N G B O X:

Frame unit Packing ring

a x d / L in mm

No of packing

ring Size in mm

Total length of

packing in mm

15 8 x 8 x 150 4 (1 x L x 3) 8 600

18 10 x 10 x 188.5 4 (1 x L x 3) 10 754

22 10 x 10 x 220 4 (1 x L x 3) 10 880

ad

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O I L S E A L SS t a n d a r d – DIN 3760

Because of design and

manufacturing tolerances it

is recommended to use

metric Oil seals according

to the following tables.

D a i l y m a i n t e n a n c e

� Regularly check the outlet pressure.

� Bearing Temperature.

� Noise and Vibration.

� Voltage and Current.

� Check the pressure of the flushing liquid. This pressure must be 1.5

bar higher than the pressure at the impeller hub.

S h a f t s e a l i n g

G l a n d p a c k i n g

� Do not tighten the gland nuts any more after the running in period and

adjustment.

� If in time in gland packing starts to leak excessively, new packing rings have to

be mounted instead further tightening the gland nuts. M e c h a n i c a l s e a l

A mechanical seal generally requires no maintenances. However, it should

never be allowed to run dry. If there are no problems it is not advisable to dismantle

the seal as the facing surfaces are running one another. Dismantling always means

replacement of the mechanical seal.

When the mechanical seal is leaking it has to be replaced.

L u b r i c a t i o n o f t h e b e a r i n g

G r e a s e l u b r i c a t e d b e a r i n g s

.

Bearing housings with grease packed deep – groove ball bearings require no

maintenance.. The bearings are filled with grease during assembly. In case the pump

is overhauled, the bearing housing and the bearings have to be cleaned and provided

with new grease.

Frame

unit

Size of Oil seal used in Bearing cap

Drive end Non drive end

15 25 x 37 x 7 25 x 37 x 7

18 35 x 47 x 7 35 x 47 x 7

22 45 x 60 x 10 45 x 60 x 10

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During operation the constant level oiler should never be empty, so take care to top

up timely. The oil should be changed once a year. If the oil temperature is higher

than 80 ˚C, the oil should be change more often.

S E C T I O N A L D R A W I N G

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B I L L O F M A T E R I A L C O D E N O P A R T N A M EW 1 Volute Casing

W 2 * Impeller

W 3 * Stuffing Box

W 4 * Gasket – Shaft/ Sleeve

W 5 * Impeller Nut

W 6 * Impeller Key

W 7 * Lantern Ring

W 8 * Wear Ring

W 9 Casing Drain Plug

W 10 * Gasket - Stuffing Box/Casing

W 11 * Sleeve

W 12 Stud – Gland/Stuffing Box

W 13 * Oil Seal – Inner Bearing Cap

W 14 Plug – Oil Drain

W15 Bearing Bed

W 16 Oil Level Sight Glass

W 17 Support Foot

W 18 Hex Bolt – Support Foot

W 19 Outer Bearing Cap

W 20 * Oil Seal – Outer Bearing Cap

W 21 Key – Coupling

W 22 Shaft

W 23 Hex Bolt – Outer cover/Bed

W 24 * Gaskets – Outer Bearing Cap

W 25 * Bearing - Coupling End

W 26 Vent

W 27 * Bearing – Pump End

W 28 Bearing Cap Inner

W 29 * Deflector

W 30 Gland

W 31 Stud – Bed/Stuffing BOx

W 32 * Gland Packing

W 33 Stud – Stuffing Box / Casing.

*R e c o m m e n d e d s p a r e s f o r 2 y e a r s n o r m a l o p e r a t i o n .

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C A U S E S O F F A I L U R E

In general failures in a pump unit are attributable to the following causes:

� Failures in the pump

� Failures or faults in the piping systems

� Faults due to a wrong installation or commissioning

� Faults due to a wrong pump selections

A number of the most frequently occurring failures as well as their possible causes

are set forth in the below table.

M o s t f r e q u e n t l y o c c u r r i n g f a i l u r e s P o s s i b l e c a u s e sPump doesn't deliver any liquid

1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20

21 29

Volume flow of the pump is

insufficient

1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20

21 28 29

The discharge head of the pump is

insufficient 2 4 5 13 14 17 19 28 29

Pump stalls after it has been put into

operation 1 2 3 4 5 6 7 8 9 10 11

The power consumption of the pump

is higher than normal

12 15 16 17 18 22 23 24 25 26 27 32 34

38 39

The power consumption of the pump

is lower than normal 13 14 15 16 17 18 20 21 28 29

The stuffing box is leaking excessively 6 7 23 25 26 30 31 32 33 43

Shaft packing or mechanical seal have

to be replaced to often 6 7 23 25 26 30 31 32 33 34 35 36 41

Pump vibrates or makes noise 1 9 10 11 15 18 19 20 22 23 24 25 26 27

29 37 38 39 40

Bearings wear too soon or gets hot 23 24 25 26 27 37 38 39 40 42

Pump runs with difficulty, gets hot or

stuck 23 24 25 26 27 34 37 38 39 40 42 P o s s i b l e c a u s e s :

1. Pump or suction pipe not sufficiently filled or de-aerated.

2. Gas or air coming from the liquid.

3. Air lock in the suction pipe.

4. Suction pipe leaks air.

5. The pump sucks in air through the stuffing box.

6. The sealing or flush water pipe to the stuffing box is not connected or blocked.

7. The lantern ring in the stuffing box has been mounted wrongly.

8. The manometric suction head is too high.

9. Suction pipe or suction strainer is blocked.

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WPE ES IOM Manual

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10. Insufficient immersion of foot valve or suction pipe during operation of the pump.

11. NPSH available too low.

12. Speed too high.

13. Speed too low.

14. Wrong sense of rotation.

15. Pump doesn't work at the right duty point.

16. Liquid density differs from the calculated liquid density.

17. Liquid viscosity differs from the calculated liquid viscosity.

18. Pumps works when the liquid flow is too low.

19. Wrong pump selection.

20. Obstruction in impeller or pump housing.

21. Obstruction in the piping.

22. Wong installation of the pump unit.

23. Pump and motor nor well alignment.

24. Rotating part running out of true.

25. Imbalance in rotating parts (for instance impeller, coupling).

26. Pump shaft is running out of true.

27. Bearing faulty or worn out.

28. Seals rings faulty or worn out.

29. Damaged impeller.

30. Pump shaft or shaft sleeve at shaft packing or running surfaces of the mechanical

seal are worn out or damaged.

31. Worn or dried up shaft packing.

32. Not well packed stuffing box or bad mounting of the mechanical seal.

33. Packing type of the mechanical seal not suitable for the operation liquid or

operation circumstances.

34. Gland of seal cover has been tightened too much or crookedly.

35. No water cooling of stuffing box at high temperatures.

36. The sealing or flushing liquid to the stuffing box or the mechanical seal is polluted.

37. Axial retaining of impeller or pump shaft is defective.

38. The bearings have been mounted wrongly.

39. Too much or too little bearing lubrication.

40. Wrong or polluted lubricant.

41. Impurities in the liquid get into the stuffing box.

42. Too high axial force because worn dorsal blades or excessive inlet pressure.

43. Excessive pressure in packing space due to much play in the smothering bush,

blocked by-pass pipe or worn dorsal blades.

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For any correspondence / ordering spares , please quote the

following

CUSTOMER :

PROJECT :

WPIL REF. :

PUMP MODEL :

PUMP SERIAL NO. :

Contact WPIL

For any complaints and suggestion regarding Pumps

Email us: [email protected]

Phone: +91-120-3015784

Fax : +91-120-3015740

Factory Address :

WPIL LIMITED

A-5, Sector XXII, Meerut road,

Ghaziabad – 201002, (U.P), India

Corporate office address :

WPIL limited

Trinity Plaza, 3rd Floor,

84/1 a, Topsia Road (South)

Kolkata 700046, India

P: +91.33.3021.6800

F:+91.33.3021.6835

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WPE ES IOM Manual

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WPIL PUMP BASKET

18

INSTALLATION, OPERATION AND

MAINTENANCE MANUALCENTRIFUGAL PUMPS

TYPE U

Factory Address: Corporate Address:

A-5, Sector XXII, Meerut Road, WPIL Limited

Ghaziabad - 201002, (U.P.), India Trinity Plaza, 3rd Floor,

Phone:+91-120-3015784 84/1 A, Topsia Road (South)

Kolkata 700 046, India

WPIL LTD. [email protected] 201119

What do you want to do?

• Foreword & safety regulations

• Receiving & Checking

• Storage & Shifting

• Preparation for installation

• Installation Procedure

• Pump start-up and operation

• Maintenance of the pump

• Contact Us

Click on the option you need above,

for any further assistance, contact WPIL on

[email protected]


Foreword & safety regulations

Foreword & safety regulations

1. Foreword

2. Safety regulations

3. Safety instructions

4. Manufacturer’s regulations

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Receiving & Checking

Receiving & Checking

1. Unloading & inspection.

2. Shortages & damages.



Storage & Shifting

Storage & Shifting

1. Environmental briefing.

2. Recommended storage procedure.

3. Recommended shifting procedure .



Preparation for installation

Preparation for installation

1. Required tools, material & equipment.

2. Installation drawings.

3. Preparing the pump foundation.

4. Layout & inspection of pump parts for installation.

5. Hoisting instructions.

6. Layout of pipe work valves and accessories



Installation Procedure

Installation Procedure

5.1 Leveling & grout type

5.1.1 Leveling of base plate

5.2 Installing the pump assembly

5.3 Couplings

5.3.1 Flexible coupling

5.3.2 Coupling alignment

5.3.2.1 Radial Alignment

5.3.2.2 Angular Alignment

5.3.2.3 Alternative Method for Alignment

5.4 Installing the accessories

5.4.1 Priming connection

5.4.2 Air vent connection

5.4.3 Pressure gauge connections

5.4.4 Stuffing box packing

5.4.5 Mechanical seal



Pump start-up and operation

Pump start-up and operation

1. Pre-start checks.

2. Important operating instructions.

3. Trouble shooting chart.



Maintenance of the pump


7.1 Preventive maintenance table.

7.2 Recommended spare parts & ordering procedure .

7.2.1 Procedure for Odering Spare Part

7.2.2 Recommended list of spare parts subject to most wear

7.2.3 Recommended list of spare parts to be stocked if down time is critical

7.3 Major maintenance of pump.

7.3.1 Packing box assembly/Mechanical Seal

7.3.2 Bearings

7.3.3 Pump assembly (U) removal

7.3.3.1 Complete rotating assembly removal

7.3.3.2 Dismantling of rotor shaft

7.3.3.3 Method of removing dowel bushing

7.3.3.4 Re-Assembly of the rotor assembly

7.3.4 Re-Assembly of the pump unit

7.3.5 Dismantling of Re-Assembly of U pumps

7.3.6 Lubrication chart



7.3.6.1 Recommended grease lubricants

7.3.6.2 Recommended oil lubricants

7.4 Reference drawings, material of construction & technical details.



FOREWORD

1.1 FOREWORD

This manual provides instructions for installing, operating and maintaining WPIL Horizontal

Centrifugal Pumps. These instructions are written only for those who have a working knowledge of

Horizontal pumps and a familiarity with both the terminology and proper field practices used in

pump industry. Cautions and warnings are included, but they are not substitutes for the careful

work of the experienced.

If installation & maintenance work is neglected, or carried out incorrectly, we will not be able to

fulfill our warranty obligations as agreed and documented in the purchase contract.

Although we used the most current information available at the time this manual was published, all

information contained herein is subject to change without notice. We have made every effort to

avoid errors, but we cannot guarantee that this manual is error-free.

We appreciate your interest in our product. If you have questions about the contents of this manual,

please contact our field service department.

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By furnishing this manual, WPIL does not

accept liability for successful pump installation,

operation or maintenance; that liability belongs

to those who actuallyinstall, operate and

maintain the pump.

29

SAFETY REGULATIONS

1.2. SAFETY REGULATIONS

This section contains safety regulations which must be always followed when operating our pumps. The regulations are highlighted in the text using the following symbols:

The words WARNING and CAUTION are always in front of the text to which they refer. The word NOTE is after the associated text.

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WARNING

We wish to point out that we accept no liability for damage and operatrional faults arising from non-adherence to the instructions in the operating and maintenance manual.

=Working safety symbol = “WARNING”

For working and operating procedures which is must.

= CAUTION

To prevent damage to the EQUIPMENT.

30

SAFETY REGULATIONS

It is essential to observe the regulations highlighted this way.

Particular attention must be paid to the safety equipment installed in the pump. If the safety equipment is not working or malfunctioning, the pump must not be operated.

The following instructions for guaranteeing protection at work and safety must be observed:

- Operators must have the necessary specialist knowledge.

- Maintenance work may only be carried out by authorized persons.

- The laws and regulations valid at the place of use must be observed when operating the

pump. In the interest of occupational safety, operators, supervisors and machine operators

are responsible for observing the regulations.

- Perform functional inspections before starting work.

- Tools and other objects may only be kept in their correct places; otherwise they can

jeopardize safe operation.

- Operating media (e.g. oils, lubricants and cleaning agents) for maintenance, servicing and

repair work and oil changes must be collected in suitable containers and disposed of

correctly, (in accordance with statutory guidelines applicable in the country).

- Wear protective gloves when carrying out cleaning work, particularly when using solvents or

petroleum ether. Avoid naked flamers and smoking during cleaning.

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SAFETY INSTRUCTIONS

1.3. SAFETY INSTRUCTIONS

1. The pumps may only be operated and maintained by persons who are qualified and

competent to operate such machines.

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WARNING

The electrical machines and units are equipment with an industrial heavy-current connection.

These items of equipment have dangerous conductive with rotating parts during operation.

Serious material or health damage may be caused by removal of safety facilities, incorrect use and wrong operation.

The persons responsible for the pump must therefore guarantee that:

1. Only qualified persons are assigned to work on the pump.

2. This manual is available to operating persons and that they follow it.

3. Non-qualified persons do not operate the pump and are not allowed in its proximity.

32

SAFETY INSTRUCTIONS

2. The operator must be instructed about his pump’s power supply and how to switch it off.

3. The operational reliability of the safety equipment must be checked daily.

4. The operator must report to his superior as quickly as possible for any fault or irregularity which

occurs. This applies to both the mechanical and electrical units.

5. It is absolutely essential that the operator shuts down the pump immediately if faults occur which

jeopardize safety.

These include:

1. Failure of the safety facilities

2. Damage to important pump components

3. Damage to electrical units and lines as well as insulation

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WARNING

The electrical connection must be made by a qualified electrician in accordance with the local regulations.

The mains voltage must be the same as the voltage stated on the rating plate. The “electrical circuit diagrams” must be observed with regard to electrical

connection of the pump.

If the motor was switched off by the triggering of a safety element, it should not be switched back on again. The fault must be located and remedied. Switching back on without fault correction presents a risk of explosion.

33

SAFETY INSTRUCTIONS

6. The operator is forbidden to modify electrical connections. Only trained specialists may perform

this work.

7. Work on the pump may only be carried out if the current is switched off and when the moving

parts are no longer turning. Unauthorized switching-on must be prevented by suitable measures.

8. The pump may only be switched on when it is installed and flooded.

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Dry running is not permissible.

Briefly switching on for maximum 10 seconds is possible without any danger.

Do not switch on if there’s a fault.

WARNING

Never put hands and objects into the pump while turning.

WARNING

Wear protective gloves when carrying out cleaning work, particularly when using solvents or petroleum ether.

Naked flames and smoking are forbidden.

Operating media (e.g. gear oils, transformer oils, lubricants and cleaning agents) for maintenance work and servicing and

oil changes must be collected in suitable containers and disposed off correctly.

34

MANUFACTURER’S REGULATIONS

1.4. MANUFACTURER’S REGULATIONS

1.4.1 General

These instructions must always be kept at hand where the pump is in use. It is essential that these instructions be read before work is started by all persons involved in working with or on the pump (make entry in the machine operator list).

Person(s) who will only occasionally work on the pump (e.g. for assembly and maintenance) must also read and understand the operating and maintenance manual.

It is essential to follow the instructions in the operating and maintenance manual of the pump. This applies strictly to the general and special safety instructions at the start of this manual and in the appropriate chapters.

If in doubt, consult the person responsible for safety and accident prevention in your division.

1.4.2 Correct behavior

Use the pump only for the intended liquids and data sheet parameters.

Any other use is regarded as a special application which must be clarified with the manufacturer.

The manufacturer is not liable for use of the pump for purposes other than those for which it was

designed.

The pump is operated from the control unit intended for this purpose.

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MANUFACTURER’S REGULATIONS

Faults which can impair safety must be remedied immediately.

1.4.3 Behavior during operation

All accident prevention regulations must be observed.

A further precondition for safe operation is that the additional instructions in this operating and maintenance manual are observed.

1.4.4 Original parts and safety

Original parts and accessories are designed specially for the pump by WPIL Limited.

We expressly point out that original parts and accessories not supplied by WPIL Limited are not tested and released by the company. The installation and/or use of such products can impair the active and/or passive performance / safety of the pump.

1.4.5 Maintenance and inspection list

Keeping the maintenance and inspection list (Chapter 7 of the operating and maintenance manual) will help you to monitor the stipulated inspection and maintenance work.

1.4.6 Damage

Damage must be immediately remedied by specialists only.

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Unauthorized modification / application of the pump

render the manufacturer’s liability VOID for any

resulting damage.

WPIL Limited shall not be liable for any damage arising from the use of non-original parts and accessories.

36

RECEIVING & CHECKING

2.1 UNLOADING & INSPECTION

All pump parts are precision machined parts. Unload with adequate care. Check the following:

Contents against packing list.

All components for damages.

Shafting for straightness and damage in case of broken crate or careless handling.

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RECEIVING & CHECKING

2.2 SHORTAGES AND DAMAGES

Any shortages or damages should be immediately noted on the receipted documents of freight

agent/carrier to facilitate prompt and satisfactory resolution.

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REPORT ALL TRANSIT DAMAGE / SHORTAGE

IMMEDIATELY ON FREIGHT AGENT / CARRIER

RECEIPT.

Late reports of shortage/transit damage will

cause controversy and delay prompt &

satisfactory resolution.

38

STORAGE & SHIFTING

3.1 ENVIRONMENTAL BRIEFING

All pump parts are precision machined. All parts supplied should be stored indoors in a dry (45%

RH) and non-corrosive environment.

The effective life of preservatives applied at the factory is 60 days including transportation period,

unless specifically agreed other-wise.

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HIGH-HUMIDITY / COASTAL & CORROSIVE ENVIRONMENTS

A.) Inspect pump and parts periodically to ensure that

preservatives are intact.

B.) All machined surfaces and exposed shafting must be

coated with rust preventive agents suitable for the local

environment.

C.) Turn pump rotor manually each week a few turns.

39

STORAGE & SHIFTING

3.2 RECOMMENDED STORAGE PROCEDURE

• Storage area must be level and not at risk of flooding.

• All openings need to be sealed against ingress of dirt, particulate matter and water.

• All small parts need to be stored in covered boxes with preservative paper.

• Rubber parts like o-rings, gaskets and bearings need to be stored in closed containers.

• Keep heavy components off the ground by using supports.

• Shafting need to be removed from boxes, coated with preservative and then re-boxed with preservative paper.

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DO NOT DISCARD ORIGINAL PACKING BOXES. RE-PACK AND STORE & MOVE IN ORIGINAL PACKING

BOXES.

INSPECT ALL PARTS PERIODICALLY TO ENSURE

PRESERVATIVES ARE INTACT AND NO SIGN OF

CORROSION IS VISIBLE.

40

STORAGE & SHIFTING

3.3 RECOMMENDED MOVEMENT / SHIFTING PROCEDURE

Pump assembly, thrust bearing assembly, all shaftings & small parts must be moved in boxed

condition only.

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DO NOT MOVE LOOSE PARTS. STICK TO

ORIGINAL FACTORY PACKAGING METHODS

FOR MOVEMENT.

41

PREPARATION FOR INSTALLATION

4.1 REQUIRED TOOLS,MATERIALS AND EQUIPMENTS

The materials and equipment necessary for installation of the pump will vary with the size of the

pump and type of the installation. The list of lifting equipments and hand tools at Table below is

offered as a guide only.

S.No. TOOLS & MATERIALS QUANTITY REMARKS

1 Washing Oil, Kerosene For washing of parts

2 Emery Cloth Paper For cleaning of parts

3 Molycote (anti-galling grease) For assembly

4 Sealing tape/Thread compound for pipe For auxiliary piping

5 Line Marker 2 Sets For alignment of foundation

6 Chisel 3 Sets For foundation preparation

7 Lifting Nylon Slings of suitable capacity

and 3 m long

2 nos. For installation & rigging

8 1 / 5 / 10 lb Hammer 2 nos. For assembly

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The installation rig should be rated to hold at least 1.5 times the weight of the complete pumping unit i.e. the assembled pump and

driver.

42


9 File Set 2 sets For assembly

10 Screw Driver 2 each For assembly

11 Adjustable Wrench 1 no. For assembly

12 Pipe Wrench 2 nos. For auxiliary piping / Line Shaft.

13 Allen Key(2 mm to 10 mm size) 1 set For assembly

14 Wire Brush 2 nos. For assembly

15 Single ended / double ended wrench(10mm

to 36mm)

2 each For assembly

16 Plumb Bob with string 1 no. For installation

17 Nylon hand hammer 2 nos. For installation

18 Eye bolt of various sizes For rigging

19 D-shackle of various sizes (5 /7.5 M) 1 set For rigging

20 Socket wrench 1 set For assembly

21 Position marker punch 1 set For assembly

22 Gap gauge (feeler gauge) 2 sets For erection

23 Scraper 2 sets For assembly

24 Marking String - For assembly

25 Ring spanner 2 nos. each For assembly

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26 S.S. shims of various sizes (0.1 mm to 2 mm) - For assembly

27 Mobile hoist/ travelling crane 1 no. For assembly depending on size &

weight of the pump

28 Bearing pullers 1 no. For Bearing removal

Measuring tools required during installation:

Sno. Tools & Materials Quantity Remarks

1 Precision Class Spirit Level Gauge (Accuracy 0.02

mm/ M)

1 no For level checking

2 Steel Tape (5, 10M) 1 each For measurement of foundation

3 Dial Gauge with Magnet Holder & Clamps

(Minimum division 0.01mm)

1 set For alignment checking

4 Gap Gauge (feeler gauge) 2 sets For assembly

5 Edge 1.5 M long 1 No. For Leveling

6 Straight Steel Scale (1 M) 1 each For assembly

7 Straight Edge (I–beam type) 1.5 m long,

Accuracy-0.05mm/M

1 no. For level checking

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4.2 INSTALLATION DRAWINGS

Collect and arrange the following drawings:

• Foundation drawing (refer pump General Arrangement drawing),

• Installation dimensional drawing (refer pump General Arrangement drawing & pump cross-

sectional drawing),

• Functional unit layout, (as per design by you), and

• Piping diagram (as per design by you).

Finalize the method of installation based on these documents before starting work.

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4.3 PREPARING THE PUMP FOUNDATION

The foundation must be built to support the weight of the entire pump unit when the pump is full of

water. It should be rigid enough to withstand and prevent vibrations. The loading details of the

pump are given in General Arrangement Drawing.

WPIL recommends that a concrete foundation be used wherever possible.

Steel I-beams or timbers may also be used, but they should be strong enough to prevent spring

action and braced (tied together) to prevent lateral movement.

In case of concrete foundation, the top surface of the foundation should be left rough to allow

proper binding of final grout mixture. Also the top surface level should be lower in height by at least

20 to 35 mm to permit leveling of base plate.

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4.4 LAYOUT & INSPECTION OF PUMP PARTS FOR INSTALLATION

• All pump accessories should be checked for correctness and cleanliness.

• All small components and fasteners should be separated assembly-wise as per cross-

sectional drawing & checked for correctness and cleanliness.

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4.5 HOISTING INSTRUCTIONS

Nylon slings (of rated load capacity) for lifting the pump assembly should pass at positions on the

pump branches as shown in Fig. 4.5.a

Fig:- 4.5a

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Horizontal/Vertical Pump Lifting Arrangements

48


To lift the prime-mover (electric motor), pass sling as shown in Fig 4.5.b

Fig: 4.5b

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Never lift the entire pump assembly by the eye-bolts or from the bearing housing or from the shaft extension.

49


4.6 LAYOUT OF PIPE WORK, VALVES and ACCESSORIES

It is important to ensure that pipe work, valves etc. connected to the pump are adequately

supported. Ensure that the pump does not carry the weight of the pipe work when filled with water

or tend to be dragged in any direction.

4.6.1 SUCTION PIPING

To avoid the formation of air pocket, the installation of suction pipe work must be arranged under

the following conditions:

• Always as few bends as possible

• Suction pipe work must be perfectly air tight

• There must be a gradual rise in the suction pipe work towards the pump

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No strain is put on the pump casing flanges by the pipe work else would disturb the pump alignment leading to vibrations.

Never connect a pump to the piping; always connect pipe to the pump

50


• In case of an elbow is required at the pump suction flange, it should have a long radius. Location of the elbow from the pump flange should be more than 2D of straight pipe.

• In case of an expander is required at the pump suction flange, it should be eccentric type to avoid the air pockets.

• In case of strainer is provided, for clear water the total area of these holes should exceed three times the area of the bore of the pump suction branch.

Typical good and bad suction arrangements are shown in Fig 4.6.1.a & b and typical layouts are shown in Fig. 4.6.1.c & d

Good suction layouts, showing pipes rising all the way to the pump.

Bad suction layouts, which will cause air pockets and failure to pump.

Fig. 4.6.1.a

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Fig. 4.6.1.b

Typical Layout – Flooded Suction (Fig. 4.6.1.c)

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Showing how an air pocket may be formed when the suction pipe is bigger than the pump branch.

avoided.

Showing how the fault in the illustration on the left may be avoided.

52


Typical Layout – Suction Lift (Fig. 4.6.1.d)

4.6.2 DELIVERY PIPING

• Pipe work, valve, fitting etc. are located in the delivery pipe line should be adequately supported to avoid any strains on the pump flange.

• If an expansion joint is used it is recommended that this should be located at a distance not less than 2D from pump flange.

• The intermediate spool piece between pump and expansion joint needs to be anchored.

• Improper anchoring may subject to large reaction forces which could be detrimental to the installation.

• A check valve is recommended in the case of back flow/high pressure surge is anticipated.

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INSTALLATION PROCEDURES

5.1 LEVELING & GROUT TYPE

The purpose of grouting is to prevent lateral shifting of the base plate, not to fix irregularities in the foundation. Base plates are normally fabricated M.S. channel width plates at top and bottom accurately machined to have parallel plane surfaces. The base plate looks similar to as shown in Fig. 5.1.a

Base Frame with Channel (Fig. 5.1.a)

5.1.1 LEVELING OF BASE PLATE

1. Mark the base plate/base frame and foundation bolts position as per GA Drawing.

2. Grout foundation bolts, as per GA drawing, using quick setting cements.

3.WPIL recommends that 20-30 mm of epoxy grout is maintained under the base frame.

4.In case epoxy grout is not available, level using leveling wedges. Fill the gap between sole plate and foundation with quick setting concrete. Refer fig. 5.1.1.a & b

5.Level base plate/base plate with the help of straight edge and spirit level in two directions at 90 degrees by either leveling wedges or leveling nuts on anchor bolts.

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6. Allow curing time for grout as per manufacturer’s recommendations. Setting time is usually 48 hrs and the grouting becomes hard in 72 hrs.

7. In case of vertical installation, the pump should be mounted following the practices outline for base plate mounted pumps similar to horizontal pumps.

8. If the pump is driven via a universal joint drive shaft, there may be a requirement to offset the pump shaft w.r.t. the driver. Optimal offset will typically be in the range 0 to 4º depending on shaft design. Consult the separate user instructions before installation.

9. Any support for the universal joint drive shaft, Plummer blocks must not exhibit resonant frequencies in the range of 0.8 to 1.2 of nominal pump speed.

10. In case of vertical pump, the alignment of the unit is achieved by adding or removing shims between the motor stool and the pump casing. The motor has a spigot fit in to the motor stool and it is therefore not possible to achieve any horizontal movement at this interface.

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Before leveling, the sole plate should be high enough in grout thickness.

Preferred levelness is dead-level. Maximum acceptable tolerance is 0.15 mm/meter.

55


Fig. 5.1.1.a

Fig. 5.1.1.b

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FOUNDATION BOLT FIXING DETAILS WITH BASE PLATE

56


5.2 INSTALLING THE PUMP ASSEMBLY

The horizontal & vertical pumps are supplied in assembled condition from the works (as shown in Fig. 5.2.a & 5.2.b). The accessories like couplings, coupling guard, motor stool & pump stool (in vertical pump) etc. are supplied separately, are to be assembled with the pump and motor shaft respectively at site and to be installed on the base frame/base plate. The following steps shall be followed in installing the pump assembly.

• Sling and hoist the pump with its half coupling and gently lower in position on the leveled base plate.

• Check that no gap exists between pump feet and the respective machined pads on the base plate.

• Locate the pump fixing bolts and tighten down.

• Similarly locate the prime mover with its coupling half in position on the leveled base plate.

• Rotate each shaft independently by ensuring that the bearings run freely and that shafts are true within 0.1mm. Coupling pins should not be fixed during this check.

Fig. 5.2.a

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Vertical Pump Assembly (Fig: 5.2b)

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5.3 COUPLINGS

5.3.1 FLEXIBLE COUPLING

For horizontal pumps, the couplings used are Flexible pin bush type similar to as shown in Fig. 5.3.1a & b. Both couplings are identical except 5.3.1b with the exception of bore and the pins can be inserted from either side.

Fig. 5.3.1.a

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‘A’ Type Flexible Coupling

Ref. Description

2 Coupling Pin

3 Coupling Bush

5 Distance Sleeve

272 Locking Washer

276 Flexible Coupling (Pin Half)

277 Flexible Coupling (Bush Half)

59


Fig. 5.3.1.b

5.3.2 COUPLING ALIGNMENT

The pump unit has been manufactured to allow field alignment. The unit must be properly aligned at the time of installation. The importance of correct alignment can not be over emphasized. Alignment should be checked and corrected as required after:

1. Mounting

2. Piping is connected

3. Pump or driver is moved for any reason.

Angular and parallel mis-alignment are corrected by shifting the motor and adding or removing shims from under the motor feet.

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‘B’ Type Flexible Coupling

Ref. Description

2 Coupling Pin

3 Coupling Bush

54 Coupling Key

272 Retaining Washer

275 Locking Nut

276 Flexible Coupling (Pin Half)

277 Flexible Coupling (Bush Half)

60


5.3.2.1 RADIAL ALIGNMENT

The radial alignment (intersection of axis) refer fig. 5.3.2.1a, for the rotating unit are carried out with the help of dial gauge.

• Clamp the dial indicator to one of couplings or to the shaft behind it, with the plunger resting on the rim of the other half coupling.

• Set the pointer to zero.

• Rotate the coupling and note the readings at each quarter revolution (90º).

• Any variation in readings indicates a deviation in alignment. The position of one of the units must be adjusted until the readings at each quarter revolution are within the specified tolerances given below.

Fig. 5.3.2.1.a

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To check intersection of axes (Shaft in line at coupling end)

For detecting this type of error

61


5.3.3.2 ANGULAR ALIGNMENT

The angular alignment (parallelism of axis) refer fig. 5.3.2.2a, for the rotating unit are carried out with the help of dial gauge.

1.Clamp two dial gauge indicators at diametrically opposite points on one half of the coupling, on to the shaft behind it, with plungers resting on the back of the coupling.

2.Inscribe a line across both of couplings for reference, readings are to be taken only when the two marks coincide.

3.Rotate the couplings until the gauges are in line vertically and set the gauges to zero.

4.Rotate the coupling through half revolution.

5.If the alignment of the pump and its driving unit is correct the reading of both gauges should be the same, though not necessarily zero.

6.Equally positive or negative readings are acceptable.

7.Adjust the position of any one of the units to correct the readings.

8.Rotate the couplings until the gauges are in line horizontally and reset the dial so that the pointers are at zero.

9.Repeat the operations from point 4 to 7.

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Coupling up to Ø300mm 0.05mm (0.002”)

Coupling > Ø300mm 0.07mm (0.003”)

RADIAL & ANGULAR ALIGNMENT NOT TO EXCEED

0.5mm (0.004”) ON DIAL GAUGE

62


Fig. 5.3.2.2a

5.3.2.3 ALTERNATIVE METHOD FOR ALIGNMENT

Angular and parallel misalignment can alternatively quickly be checked by using the straight edge and feeler gauge as described below.

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To check the parallelism of axes (Angular alignment)

For detecting this type of error

63


Fig. 5.3.2.3a

Check for angular alignment by inserting the taper or feeler gauges between the coupling faces at 90º intervals. The unit is in angular alignment when these four measurements are the same, or within recommended tolerances.

Check for parallel alignment by placing a straight edge across both coupling rings on all four sides. The unit is in parallel alignment when the straight edge rests evenly across both coupling rings in all four directions.

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5.4 INSTALLING THE ACCESSORIES

5.4.1 PRIMING CONNECTION

Priming connection has been provided in the upper half of the casing to fill the casing with water from some outside source until suction pipe and casing are completely filled with the water. Priming may also be accomplished by the use of vacuum pump. Sometimes put valves are also used for priming purpose depending upon the size of the pump.

5.4.2 AIR VENT CONNECTION

The air vent connection is provided at the top of the casing near the priming plug to provide the air release valve for the removal of air during priming. It is necessary to exhaust air from suction pipe and pump casing, as any air that remains in trapped will interfere with operation or hinder pump from lifting water and will loose the priming.

5.4.3 PRESSURE GAUGE CONNECTION

Connect a compound gauge to suction of pump and pressure gauge to discharge flange of the pump. It is advisable to furnish shut-off valves between flange gauged connections and gauges. The gauges are necessary for an adequate check on pump performance.

5.4.4 STUFFING BOX PACKING

Packing and repacking of stuffing box should be done with great skill and care. Normally the pump is dispatched from works along with packing. However, the time between the date the pump is dispatched from works and date it is commissioned is more than three months, replace the packing. For various pump models, refer the packing sizes as per the following Table 5.4.4. For installation purpose, refer the pump assembly drawing (Fig. 7.3.3). Mechanical seal is optional and factory assembled.

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THE PACKING RING JOINTS SHOULD BE

STAGGERED AND EACH RING SHOULD

BE PUSHED IN TO POSITION

SEPARATELY.

65


PUMP SIZE & TYPE SHAFT SLEEVE

DIA. AT PACKING

STUFFING BOX DATA

HORIZONTAL VERTICAL SIZE OF PACKING

SQ. (mm X mm)

No. OF RINGS PER

BOX

8 LN 18 8 LNV 18 101.6 15.88 5

8 LN 21 8 LNV 21 114.3 15.88 5

8 LN 29 8 LNV 29 114.3 15.88 5

10 LN 18 10 LNV 18 88.9 15.88 5

10 LN 22 10 LNV 22 114.3 15.88 5

10 LN 26 10 LNV 26 114 15.88 5

12 LN 14 12 LNV 14 88.9 15.88 5

12 LN 17 12 LNV 17 101.6 15.88 5

12 LN 21 12 LNV 21 114.3 15.88 5

12 LNH 21 12 LNHV 21 114.3 15.88 5

14 LN 19 14 LNV 19 95 19.05 5

16 LN 23 16 LNV 23 114 15.88 5

16 LN 35 16 LNV 35 165.1 19.05 5

20 LN 26 20 LNV 26 152.4 19.05 5

20 LN 28 20 LNV 28 152.4 19.05 5

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24 LN 34 24 LNV 34 140 19.05 5

24 LN 42 24 LNV 42 190.5 19.05 5

30 WLN 30 30 WLNV 30 130 20 5

30 LN 41 30 LNV 41 203.2 19.05 5

Table 5.4.4

5.4.5 MECHANICAL SEAL

The typical mechanical seal assembly is shown in fig. 5.4.5.a The correct functioning of the seal must be checked regularly. No adjustment is possible locally. When leakage reaches an unacceptable level, the seal will need replacement.

Fig. 5.4.5.a

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PART DESCRIPTION

119 SEAL RING

220 MATING RING

301 O-RING

321 O-RING

412 SPRING

431 GRUB SCREW

449 SPRING HOLDER

554 DRIVE COLLAR

67

PUMP START-UP & OPERATION

6.1 PRE-START PROCEDURES

Before the pump is brought in to the service, suction and delivery pipe work should be flushed and the sump clear of all debris like foreign material, silt and other deposits. This is done to prevent damage to the pump internals.

Consult the applicable manufacturer’s instructions for detailed information for the prime mover (motor, engine or steam turbine) coupling, drive-shaft, electric driver, gear-head or mechanical seal applicable to the pump. Prior to start-up, check/do the following:

1. Open the vent connection on top of the pump upper casing to allow the trapped air to escape. Let liquid run out until casing is free from air bubbles.

2. In the case of vertical installation, open vent connection at the front of the upper half casing and disconnect the seal flush line at the mechanical seal/ stuffing box to allow the trapped air to escape. Let liquid run out until free from air bubbles.

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IF PUMP IS STORED FOR MORE THAN

THREE MONTHS, THE BEARING SHOULD

BE DISMANTLED, CLEANED & RE-

GREASED.

ENSURE THAT THE PUMP IS GIVEN THE

SAME ROTATION AS THE PUMP

DIRECTION ARROW CAST ON THE

PUMP CASING/ NAME PLATE.

WHENEVER COUPLING GUARD IS

REMOVED OR DISTURBED, ENSURE

THAT THE PROTECTIVE GUARD IS

SECURELY REFITTED PRIOR TO

STARTUP.

ENSURE THE INLET PIPE AND PUMP

CASING ARE COMPLETELY FULL OF

LIQUID BEFORE STARTING

CONTINUOUS DUTY OPERATION.

68


3. That the pump operates with suction lift and is fitted with foot valve. Fill suction pipe and casing with liquid at a pressure of 1 to 2 bar from external source.

4. In case pump operates with suction lift without foot valve, the pump casing vents on suction volute must be connected to an external vacuum pump priming system.

5. In case of mechanical seal pump, all piping to the seal should be connected and properly lubricated.

6. Check that all cooling, heating and flushing lines are operating and are regulated for required flow.

7. Check that allowable runout shaft with seal is 0.050 mm.

8. Check wiring of the driver.

9. Check rotation of driver with the coupling halves disconnected i.e. under no-load condition.

10. Check that all connections to driver and starting device are as per the wiring diagram.

11. Check that voltage, phase, and frequency of the supply line are as per the motor name plate.

12. Rotate the shaft manually to ensure that the impellers rotate freely.

13. Check driver bearings for proper lubrication and oil level in housing.

14. Check that auxiliary seal components are properly vented.

15. Check discharge piping and pressure gages for proper operation.

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6.2 IMPORTANT START-UP INSTRUCTIONS

Following these helpful guidelines will assure longer life for your pump.

1.Check the tightness of pump set holding down bolts. (Refer torque as per the table 7.3.3.1)

2.Pump/base plate should not be used as pipe anchor.

3.Suction and discharge piping should be anchored as close as possible to the pump flanges to reduce vibration and prevent strain on the pump casing.

4.Expansion joints, if used, they must be properly tied and located on the side of the pipe anchor away from the pump.

5.Ensure adequate liquid is available in the sump and that sump levels are within the recommended values to meet NPSHR (Net positive suction head).

6.If the pump loses its prime or breaks suction, immediately shut it down and investigate the cause.

7.Ensure that suction valve is fully open.

8.Ensure that delivery valve is closed. The pump may be started with a fully open delivery valve provided the system operating pressure is standing on the discharge side of the pump NRV (if fitted).

9.Issue permission to startup after obtaining clearance from the concerned official to whom the essential system condition is known.

10.Start the pump through panel or local station.

11.Allow pump to reach its full speed and check the pressure gauge reading.

12.At this point the pump should generate a pressure higher or equal to its rated pressure.

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DO NOT RUN PUMP DRY!

The impellers and bearing have small clearances and may bind / seize and

cause serious trouble.

70


13.If the generated pressure is lower the rated pressure stop the pump immediately and investigate.

14.Rectify the fault and re-prime the pump before restart.

15.If the pressure is within the satisfactory limits, slowly open the delivery valve to permit charging the line.

16.Care to be taken to avoid prolonged operation at near closed valve condition. It should not be more than five minutes.

17.Ascertain the pump total head from the pump test sheet or pump name plate.

18. If the pump capacity is much higher than the supplied pump, it is better to throttle the pump than to let it break suction. Only pumps may be throttled, however, the throttling should be limited to 50 percent of design flow.

NOTE: Throttling may affect the driver load.

19.When the pump is stopped, the flow of liquid backing down through the pump will cause the pump to rotate backward.

20.The bearing should be watched for signs of over heating. The bearing temperature may be allowed to rise 50ºC above ambient but not to exceed 80ºC for both oil & grease lubricated bearings.

Normally recommended intervals between oil/grease changes are 4000 hours or at least every six months. The quality of grease should be of lithium soap base.

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NEVER START THE PUMP AGAIN WHILE THIS

BACKWARD ROTATION IS HAPPENING!

If you do, you will place a severe strain on the

shafting and it may break. Always allow the pump to

stop completely before restarting it.

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21. Do not operate the pump for long period at low capacity on account of overheating from churning.

22. If necessary, bypass arrangements may be adopted to save the pump operations at low capacity.

23. The gland should be checked to make sure that they are not cracked and rubbing on shaft sleeves causing overheating and overloading of motor.

24. When the pump is in operation, there should be some leakage at the stuffing box packing (Fig. 6.3.a). For cooling and lubrication, allow approximately 60 drops of liquid to escape each minute.

Fig. 6.3.a

25. In case of mechanical seal fitted with the pump, the seal leaks slightly at start-up, allow a reasonable amount of time for the seal to adjust itself. Liquids with good lubricating qualities normally take longer to wear in the seal than liquid with lesser qualities. When a seal starts out with a slight leak and gets progressively less with running, it indicates leakage across the seal faces and continued running will usually eliminate this. Where leakage occurs immediately and remains constant, unaffected by running, it usually indicates a secondary seal damage (shaft packing), or the seal faces are warped out of flat. See Section 6.3 (Troubleshooting), for possible causes and remedies.

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NEVER MIX GREASES CONTAINING DIFFERENT

BASES, THICKENERS OR ADDITIVES.

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26. After the pump set has run out for an hour, all readings should be suitably logged in site records.

27. The pump set should be allowed to run for another hour or so to observe any undue change in parameters or until such time as the pump stabilizes.

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NEVER RUN A MECHANICAL

SEAL DRY EVEN FOR A

SHORT TIME.

TOLERANCE : VIBRATION LEVELS

95 Microns peak to peak when run at 1450 rpm. Measurement shall

be on pump bearing housing. Refer Hydraulic Institute Standards

(ANSI/HI-1994) for different speeds.

EXTERNAL FLUSH OR QUENCH SHOULD BE

STARTED BEFORE THE PUMP IS RUN AND

ALLOWED TO FLOW FOR A PERIOD OF FIVE

MINUTES AFTER THE PUMP HAS STOPPED.

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Trouble shooting chart

6.3.1 NO LIQUID DELIVERED

6.3.2 INSUFFICIENT PRESSURE

6.3.3 INSUFFICIENT CAPACITY

6.3.4 PUMP LOSES PRIME AFTER STARTING

6.3.5 PUMP OVERHEATS AND SEIZES

6.3.6 SHORT BEARING LIFE

6.3.7 VIBRATION AND NOISE

6.3.8 STUFFING BOX LEAKS EXCESSIVELY

6.3.9 SHORT SEAL LIFE

6.3.10 MECHANICAL SEAL LEAKS

6.3.11 USING TOO MUCH POWER

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PUMP START-UP & OPERATION (Trouble shooting chart)

6.3.1 NO LIQUID DELIVERED

TROUBLE INDICATOR

POSSIBLE CAUSES RECOMMENDED REMEDIES

NO LIQUID DELIVERED

• Lack of priming

• Loss of Prime or Air leaks

• Suction valve closed

• Impeller plugged

• Suction lift too high

• Foot valve/strainer clogged

• Speed too slow

• Wrong rotation

• Parallel operation of pumps unsuitable for operations

• Pump or suction pipe not completely filled with liquid. Fill pump and suction pipe completely with liquid.

• Check for leaks in suction pipe joints and fittings. Vent casing to remove accumulated air. Check and replace packing and shaft sleeve for wear if required.

• Open valve.

• Open pump and inspect for obstruction.

• Check the liquid level in the sump, static lift may be too high. Maintain the required level/suction pressure to meet the NPSHR of the pump. Measure with mercury column or vacuum gauge while pump is in operation. If static lift is too high, liquid to be pumped must be raised or pump lowered.

• Inspect and clean the foot valve and/or strainer. Area through foot valve should preferably 2 times, if strainer is used, area should be 3-4 times the area of suction pipe.

• Check motor voltage or frequency may be low. Check the pump’s speed is consistent with manufacturer’s recommendations.

• Rotation must be as indicated by arrow on pump nameplate. Check engagement of motor coupling.

• Check the system head curve with the pump curve and see the suitability of the pump.

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6.3.2 INSUFFICIENT PRESSURE

TROUBLE INDICATOR


INSUFFICIENT PRESSURE

• Speed too slow

• Air leaks in suction piping

• Mechanical defects

• Wrong rotation


• Check the piping joints for air leakage. Check for gaskets in place and tighten the bolts to prevent air leakage.

• Defective impeller, wearing rings or packing. Inspect impeller, wearing rings and packing. Replace if vane sections eroded or damaged. Replace wearing rings, packing if worn out.


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6.3.3 INSUFFICIENT CAPACITY

TROUBLE INDICATOR


INSUFFICIENT CAPACITY

• Speed too slow

• Lack of priming

• Suction lift too high

• Air leaks in suction piping

• Air leaks in to pump through stuffing boxes

• Foot valve/strainer partially clogged

• Excessive amount of air/gas in liquid

• Suction valve throttle

• Impeller passage partially plugged

• Total head of system higher than designed head of pump

• Wrong rotation

• Parallel operation of pump unsuitable


• Pump or suction pipe not completely filled with liquid. Fill pump and suction pipe completely with liquid.

• Check the liquid level in the sump, static lift may be too high. Maintain the required level/suction pressure to meet the NPSHR of the pump.

• Check the piping joints for air leakage. Check for gaskets in place and tighten the bolts to prevent air leakage.

• Inspect and replace the incorrect/worn out packing.

• Inspect and clean the foot valve and/or strainer. Area through foot valve should preferably 2 times, if strainer is used, area should be 3-4 times the area of suction pipe.

• Inlet of suction pipe insufficiently submerged. The inlet pipe to be sufficiently submerged at least 2-3 feet in liquid.

• Check and open valve.

• Dismantle the pump, inspect passage, clean if required.

• Take suitable measure to reduce the friction losses or static lift or replace the pump.



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6.3.4 PUMP LOSES PRIME AFTER STARTING

TROUBLE INDICATOR


PUMP LOSES PRIME AFTER STARTING

• Pump or suction pipe not completely filled with liquid

• Suction lift too high or water level too low

• Excessive amount of air or gas in liquid

• Air or vapor pocket in suction line

• Air leaks in to suction line

• Air leaks in to pump through mechanical seal, sleeve joints, casing joint or pipe lugs

• Inlet of suction pipe insufficiently submerged

• Check and fill liquid completely.

• Check NPSHA > NPSHR, proper submergence, loses at strainers and fittings.

• Check and purge from pipes.

• Check suction line design for pockets.

• Check air tight pipe then joints and gaskets.

• Check air tight assembly then joints and gaskets.

• Check cut out system design.

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6.3.5 PUMP OVERHEATS AND SEIZES

TROUBLE INDICATOR


PUMP OVERHEATS AND SEIZES

• Operation at very low capacity

• Parallel operation of pump unsuitable for operation

• Misalignment

• Rotor out of balance

• Bearing worn out

• Lack of prime- Fill pump and suction pipe completely with liquid. Suction lift too high- If static lift is too high than liquid to be pumped must be raised or pump to be lowered.


• Check for misalignment both angular and radial and correct to tolerance limit.

• Check and balance the rotor with in the specified grade.• Check the bearing lubrication and replace

the bearing.

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6.3.6 SHORT BEARING LIFE

TROUBLE INDICATOR


SHORT BEARING LIFE

• Operation at high capacity

• Misalignment due to pipe strain

• Shaft bent

• Rotating part rubbing on stationary part internally

• Bearings worn• Shaft running off

centre because of worn bearings or misalignment

• Impeller out of balance resulting in vibration

• Excessive trust caused by mechanical failure inside the pump

• Excessive grease in ball bearings

• Lack of lubrication for bearings

• Improper installation of bearings

• Damage bearings due to contaminations

• Wrong direction of rotation

• Measure value and check maximum permitted.

• Check the flange connections and eliminate strains using method permitted.

• Check shaft run-outs within acceptable values (0.05 mm).

• Check for signs of this and correct it.

• Replace bearings• Check misalignment and correct if necessary.

Check bearings for excessive wear.

• Check and balance the impeller to the required grade (ISO 6.3 Grade).

• Check wear condition of impeller, its clearances and liquid passages.

• Check method of re-greasing.

• Check hours run since last change of lubricant.

• Check method of assembly or state of cleanliness during assembly and type of bearing used.

• Check contamination source and replace damaged bearings.

• Reverse two phases on motor terminal box.

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6.3.7 VIBRATION AND NOISE

TROUBLE INDICATOR


VIBRATION AND NOISE

• Inadequate grouting

• Misalignment

• Motor imbalance Driver

• Foreign Material in unit

• Mechanical Defects

• Rotor out of balance

• Clogged impeller or foreign material in pump

• Foundation not rigid

• Vortex problems in sump

• Resonance

• Excessive grease or oil in antifriction bearing housing

• Motor noise• Cavitation due to low

submergence or operation beyond maximum capacity rating

• Foreign material in pump

• Entrained air

• Check base plate grouting, re grout if required. Also piping supports for anchoring.

• Check for misalignment both angular and radial. Correct to tolerance limits.

• Isolate driver from pump unit, if vibration continues. Inspect driver and determine the cause utilizing vibration frequency analyzer and/or pump assembly. Consult motor/pump manufacturer.

• Inspect volute, impeller and suction piping for foreign material and remove. Also repair any accompanying damage.

• Shaft running off center because of worn bearings or misalignment. Inspect impeller bearings and shaft for damage and repair or replace as required.

• Balance the impeller to the specified grade.

• Back flush. Pull, check for damage and replace.

• Check the proper tightness of the foundation bolts and check for no gap between the base plate and finished floor level. Re grouting is recommended.

• Increase pump submergence. Apply sump modification such as; relocate pump in sump, lower the inlet velocity in sump.

• System frequency at or near pump speed—Loosen anchor bolts. Change pipe loading.

• Fill the quantity of grease as recommended.

• Check for bearing failure. Install RTD’S in bearing housing. Monitor bearing oil level.

• Insufficient NPSH available. Evaluate system head conditions and reduce pump capacity, if possible. Change pump’s impeller to lower NPSH design to meet the system NPSH available.

• Back flush or pull and inspect.

• Air separation can also cause hydraulic noise. Bleed off entrained air.

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6.3.8 STUFFING BOX LEAKS EXCESSIVELY

TROUBLE INDICATOR


STUFFING BOX LEAKS EXCESSIVELY

• Packing is worn out or not properly lubricated

• Packing is improperly inserted

• Packing is not right kind for liquid handle

• Shaft scored

• Inspect packing, lubrication line and lantern ring location to ensure flow.

• Inspect packing for correct size and avoid overlaps.

• Packing selection should be checked against manufacturer recommendation.

• If shaft/sleeve scored excessively, repacking alone may not stop excessive leakage. Hence replace shaft/sleeve.

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6.3.9 SHORT SEAL LIFE

TROUBLE INDICATOR


SHORT SEAL LIFE • Abrasive particles in fluid

• Seal running too hot

• Equipment mechanical misaligned

• Prevent abrasives from accumulating at seal faces. Flush line maybe required. Use abrasive separator or filter.

• Increase cooling of seal faces (for example, by increasing flush line flow). Check for obstructed flow in cooling lines.

• Align properly. Check for rubbing of seal on shaft.

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6.3.10 MECHANICAL SEAL LEAKS

TROUBLE INDICATOR


MECHANICAL SEAL LEAKS STEADILY (OPTIONAL)

• Faces not flat• Blistered carbon graphite

seal faces

• Secondary seals nicked or scratched during installation

• Worn out or damaged O-rings

• Compression set of secondary seal (hard and brittle)

• Chemical attack (soft and sticky)

• Spring failures• Erosion damage of

hardware and/ or corrosion of drive mechanism

• Check for incorrect installation dimensions.• Check for gland plate distortion due to over-

torquing of gland bolts. Improve cooling flush line, if overheated. Check gland gasket for proper compression. Clean out any foreign particles between seal faces and re-lap faces. Check for cracks and chips at seal faces during installation. Replace primary and mating rings, if damaged.

• Replace secondary seals.

• Check for proper seal selection with seal manufacturer.

• Check for proper lead-in on chamfers, burrs, etc.

• Review with seal manufacturer for alternate materials selection.

• Replace parts.


SEAL LEAKS INTERMITTENTLY

• Faces not flat• Blistered carbon graphite

seal faces

• Secondary seals nicked or scratched during installation

• Worn out or damaged O-rings

• Compression set of secondary seal (hard and brittle)

• Chemical attack (soft and sticky)

• Spring failures• Erosion/Corrosion

damage of hardware

• Check for incorrect installation dimensions.• Check for gland plate distortion due to over-

torquing of gland bolts. Improve cooling flush line, if overheated. Check gland gasket for proper compression. Clean out any foreign particles between seal faces and re-lap faces. Check for cracks and chips at seal faces during installation. Replace primary and mating rings, if damaged.

• Replace secondary seals.

• Check for proper seal selection with seal manufacturer.

• Check for proper lead-in on chamfers, burrs, etc.


• Replace parts.• Review with seal manufacturer for alternate

materials selection.• Check for square-ness of stuffing box to shaft. • Align shaft, impeller and bearing to prevent

shaft vibration and/or distortion of gland plate and/or mating ring.

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6.3.11 USING TOO MUCH POWER

TROUBLE INDICATOR


USING TOO MUCH POWER

• Speed too high

• Improper impeller trim

• Total head of system lower or higher than pump design head

• Pump out of alignment or shaft bent

• Pumping sand, silt, or foreign material i.e. heavier liquid than allowed for

• Check voltage and frequency on motor.

• Pull pump and inspect. Modify existing impeller to provide actual system requirements.

• Take suitable measure to reduce the friction losses or static lift or replace the pump.

• Check alignment of pump and driver, also foundations.

• Test liquid for viscosity and specific gravity.

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MAINTENANCE OF THE PUMP

7.1 PREVENTIVE MAINTENANCE TABLE

It is recommended that a maintenance plan and schedule is adopted, in line with the user instructions. It should include the followings :

S# Stage Preventive maintenance checks/actions

1 Pump start-up • Static lift/water level in the sump is adequate and that sump

water level are within the recommended value.

• If the pump sets have been stored for more than three

months, the bearing housing should be cleaned and old

grease should be washed out. Re-grease the bearing housing

DE and NDE side as per recommendation specified in manual.

Refer lubrication chart (7.3.6).

• Ensure that the pump is properly primed by opening the vent

on pump top casing and shut the vent after ensuring that the

entrained air is removed.

• Ensure that pump shaft is free in rotation.

• Startup the prime mover on no load condition to check the

direction of rotation.

• Ensure that suction valve is fully open.

• Ensure that delivery valve is closed. The pump may be started

with a fully opened delivery valve in case NRV is fitted.

• Start the pump through panel or local station.

• Allow pump to reach its full speed and check the pressure

gauge reading. At this point the pump should generate a

pressure higher than its rated pressure. If the pressure is

lower than rated pressure, stop the pump and investigate.

Rectify the fault and re-prime the pump before re-start.

• If pressure is within satisfactory limits than slowly open the

delivery valve, to permit charging the line.

• Gradual opening to maintain equilibrium is recommended.


• Care to be taken to avoid prolonged operation at near close

valve condition.

• The pump set should be allowed to run for one hour or so to

observe any undue change in performance parameter.

• The delivery sluice valve should be closed prior to going in to

STOP mode.

• Do not go in to start mode when pump rotor is subjected to

reverse flow or reverse rotation.

2. Pump operation • Change grease in bearing housing every 1000 hours running.

• Grease motor bearings as per motor manufacturer’s instruction.

• Adjustment of gland packing / change of gland packing in case of leakage.

• Pack grease at every 500 hours of operation.

• Check temperature of motor bearings, motor winding and pump bearing. Bearings will normally run between temperatures of 30º to 60ºC.

• Any abrupt change in bearing temperature is much more indicative of trouble than a constant high temperature. If so than it is to be investigated and rectified.

• Check input current, voltage, frequency, sump water level, suction and discharge pressure gauge readings and enter all the observations in log book with date and time at-least once in a day.

• Tighten all loose bolts and check for excessive vibration.

• Check for some excessive leakage through stuffing box while the pump is in operation. If the leakage can not be reduced by gland adjustment than replace the packing as per 7.3.1

3. Temporary shut-

down

• The discharge valve should be closed before shutdown of the pump to prevent back flow.

• If NRV is installed in the delivery line then discharge valve can be closed after shutdown the pump.

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7.2 RECOMMENDED SPARE PARTS AND ORDERING PROCEDURE

7.2.1 PROCEDURE FOR ODERING SPARE PARTS:

• List the serial number and model of the pump (refer the name plate).

• List the part number (from the Bill of Material in cross sectional drawing).

• List the Quantity.

• List the complete Part Description (from the Bill of Material in cross sectional drawing).

7.2.2 RECOMMENDED LIST OF SPARE PARTS SUBJECT TO MOST WEAR.

• Impeller ring with grub screw/ casing ring.

• Line bearing in case of vertical pump assembly.

• Shaft sleeve with ‘O’ ring.

• Gland Packing.

• Complete Mechanical Seal (optional).

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To ensure continued satisfactory operation, replacement parts to the original design specifications should be obtained from WPIL. Any change to the original design specifications

i.e. modifications or use of a non standard part will invalidate the pump safety certification.

88


7.2.3 RECOMMENDED LIST OF SPARE PARTS TO BE STOCKED IF DOWN TIME IS

CRITICAL. (Refer Sectional Drawing Fig. 7.3.3 for part no’s.)

NAME OF PART PART No. QUANTITYCasing ring with anti rotation pin 03, 24 02Stuffing box packing rings (Sets) 15 02Shaft sleeve with ‘O’ ring 07, 18 02Seal cage/ Lantern ring (Sets) 16 02Water thrower/ Deflector 17 02Bearing lock nut with washer 13 01Bearing cover gasket - 02Casing split flange gasket - 01Bearing (DE & NDE) 09 02Mechanical seal (optional) - 02

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7.3 MAJOR MAINTANENCE OF PUMP

7.3.1 PACKING BOX ASSEMBLY / MECHANICAL SEAL

The major cause of the packing box troubles are due to excessively or unevenly tightened packing / correct fitment of mechanical seal especially during the first hour of operation.

WE WOULD CALL THE ATTENTON OF THE USER ON THE FOLLOWING RECOMMENDATIONS.

Over tightening would immediately damage the packing.

To replace a damaged / worn out packing, following steps should be taken:

• Remove split packing gland, old packing ring & finally lantern and end packing.

• If pump is fitted with mechanical seal, then remove gland plate and mechanical seal, (refer fig. 5.4.5a).

• Prepare bevel-cut packing ring, carefully made according to the dimension of recesses. This packing ring should be same grade as original packing.

• Insert the packing ring by staggering the bevel-cut and fit it in original position. Reinstall the split packing gland and tighten it gradually.

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Put a warning board on starting device with words.

MACHINE UNDER REPAIR :

DO NOT START/CONNECT

90


7.3.2 BEARINGS

GREASE LUBRICATED BEARINGS:

• Only Bearing grade grease should be used .Never use pink greases. Use Lithium based Grease suitable for use up to 100 degree Celsius.

• Pack grease moderately to avoid overheating of Bearings.(preferably every 500 hrs).

• All pumps with grease lubricated bearings are greased at the factory. As a secondary precaution, check and re-grease the bearing before starting the unit so as to ensure proper lubrication. This is recommended if the pump has been stored for three months or more.

• One third to half of the volume in the housing should be filled with grease for normal applications. This will give the most ideal operating conditions. Greasing has to be done by a grease gun through the grease plug provided in the bearing housing.

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Complete Overhauls

This depends on hours of operations of the pump/ the severity of the condition of service.

Do not open the pump for inspection unless there is an indication of trouble inside the pump or in the bearings.

91


7.3.3 PUMP ASSEMBLY (U) REMOVAL

Refer to the sectional drawing before dismantling of the pump (Fig. 7.3.3).

Fig. 7.3.3

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Typical View of U Pump Assembly

92


Cross Sectional Assembly

Fig: 7.3.3

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7.3.3.1 COMPLETE ROTATING ASSEMBLY REMOVAL

Care must be exercised in dismantling operation to prevent damage to parts of the pump.

Following points must be kept in mind during dismantling of the pump.

• Following Table 7.3.3.1 should be used for applying the fasteners torque.

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The pump is separated from the drive after the pump has been electrically isolated & pump

casing is drained down.

For convenience at re-assembly, layout all parts in the order in which they are removed.

Protect all machined faces against metal to metal contact and corrosion.

94


Screw/bolt sizeTorque Nm (lbf-ft)

Pump feet fasteners All other fastenersM8 (5/16 in.) - 10 (7)M10 (3/8 in.) - 20 (15)M12 (1/2 in.) 63 (46) 34 (25)M16 (5/8 in.) 170 (125) 84 (62)M20 (3/4 in.) 340 (250) 165 (120)M24 (7/8 in.) 590 (435) 285 (210)

Table 7.3.3.1

• Withdraw the coupling guard and remove the coupling nut, bolts, distance pieces, washers applicable to flexible pin bush type coupling. For any other type of coupling, refer the manufacturer brochure.

• Remove the sealing pipe (item 20) connected to the pump top half casing (item 02).

• Withdraw dowel pins fitted in bearing housing (item 10) and loosen studs and nuts.

• Remove bearing housing studs and nuts.

• Remove hexagonal screws for bearing end covers (item 11,12) and slide the end covers from location to reset on the shaft.

• Disconnect the glands (item 14) from casing by unscrewing nuts from gland’s studs.

• With a suitable punch, drive out the two straight roll pins which are used at the horizontal split to align the upper (item 02) and lower casing halves (item 01).

• Remove the bolts which hold the upper and lower half of the casing together.

• By use of jacking screws located on the casing ease off the top half through equal jacking up and sling the top half casing (item 02) through the eye bolts provided at the top of the casing. Lift and place on the wooden supports.

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• Remove split flange gasket carefully and store.

• Sling the rotor assembly and carefully lift out from the bottom half casing in a perfectly horizontal plane as the coupling weight will tend to move the rotor towards the prime-mover during hoisting operation.

7.3.3.2 DISMANTALING OF ROTOR SHAFT

The rotor assembly is removed as described in 7.3.3.1.Under mentioned procedure should be followed for dismantling:

• Lift out the rotor assembly. Use care in slinging, handling and supporting of the rotor for subsequent dismantling.

• Remove the impeller wearing ring (item 06) by removing the locking grub screw (item 22).

• Withdraw the pump half coupling from the shaft (item 04) by means of puller and withdraw the coupling key.

• Withdraw the DE bearing housing (item 10). Note that the bearing is in interference fit with the bearing housing (item 10) hence withdraw should be square with the bore/shaft.

• Withdraw the DE bearing (item 09) from bearing housing by suitable puller.

• Remove DE & NDE bearing housing end covers (item 11,12) and slide bearing housing off the bearings.

• Remove water thrower (item 18) from the shaft.

• Remove gland packing (item 15) and lantern ring/seal cage (item 16).

• Withdraw the sleeve nut (item 08).

• Remove both the sleeves (item 07) from the shaft.

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Casing neck rings will be dislodged with the rotor. Hence care to be taken during hoisting

to prevent falling off.

96


• Remove impeller (item 05) and impeller key (item 24).

• Withdraw the NDE bearing housing (item 10).

• Release the bearing lock washer at the NDE and remove bearing nut (item 13).

• Remove the NDE bearing (item 09) and distance piece.

• Remove water thrower (item 18), gland packing (item 15) & lantern ring/seal cage (item 16).

• The rotor is fully dismantled for inspection and repair.

7.3.3.3 METHOD OF REMOVING DOWEL BUSHING :

As shown in sectional drawing (fig. 7.3.3) accurate alignment between the casing and bearing brackets is obtained with the use of straight hollow dowel bushings. The dowel bushings have internal threads which are used for milling the dowels see fig. 7.3.3.3a which shows the dowel bushing puller installed in position as shown, tighten the hexagon head bolt to remove dowels.

Fig. 7.3.3.3a

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All individual parts, all important joints and all wearing surfaces should be carefully examined and parts appreciably worn should be renewed.

97


7.3.3.4 RE-ASSEMBLY OF THE ROTOR ASSEMBLY:

To assemble the pump reverse the dismantling procedure as described in 7.3.3.2 & 7.3.3.1 respectively, except the following instructions.

• All bearings, wearing rings, gland packing ,sleeves should be checked and changed unless found in good. The gland packing details should be referred as per 5.4.4.

• Impellers should be checked, before assembly, for dynamic balancing to grade 6.3 of ISO 1940.

• Shaft to be checked for its trueness on V roller support on an inspection table. Pump shaft run out should be checked within 0.05 mm.

• At bearing, impeller and coupling locations, the maximum permissible run out is 0.05 to 0.07 mm total indicated reading.

• The clearance between impeller and casing neck ring should be maintained to the recommended values. Renewal is recommended when the worn value is twice the clearance. The diameter clearance value normally lies between 0.4 to 0.6 depending on the model size and may be obtained from the pump manufacturers for the given pump model.

• When reassembling the impeller on the shaft, it is important to mount the impeller so that the vane tips point away from the apparent flow direction. The rotor always rotates towards increasing sections of the volute as shown in fig. 7.3.3.4

• Install the rotor in the casing and check to see that the rotor rotates freely by hand, wearing surfaces at the impeller should not touch. Align the pump carefully and install the packing and seal cage.

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FIG. 7.3.3.4

7.3.4 RE-ASSEMBLY OF THE PUMP UNIT:

The rotating element is now fully assembled as described in rotor assembly 7.3.3.4. The further steps for pump assembly shall be followed as under.

• Clean the casing and remove any protrusions on split flange of casing.

• Ensure threads, gaskets and ‘o’ ring (item 19) mating faces are cleaned. Apply thread sealant to non face sealing pipe thread fittings.

• Fit casing gasket to the bottom half horizontal flange using a small amount of contact adhesive to prevent movement when the top half is fitted. Do not apply adhesive to the top surface of the gasket.

• Hoist the rotor assembly (as described in 7.3.3.4) and gradually lower in to the bottom half casing (item 01). Care to be taken to see that neck rings and bearing housing get positively located at spigot area.

• Unlock the rotor assembly from the sling after locating in bottom half casing.

• Fit the NDE bearing housing. Note that bearing is interference with the bearing housing. Hence fitment should always be square to the bore/shaft.

• Fit the DE bearing housing. Note that bearing is interference with the bearing housing. Hence fitment should always be square to the bore/shaft.

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• Apply grease of the recommended type to the bearings.

• Locate dowel pins in bearing housing and insert studs through bearing housing and tighten nuts both on DE & NDE sides.

• Fix hexagonal screws to bearing housing end covers and tighten in position.

• Now rotate shaft and ensure free rotation.

• Apply a light layer of grease on split flange bottom half and locate gasket in position, ensuring that bolt holes are all clear from any obstruction.

• Fix dowel pins to casing top half.

• Hoist the top half casing (02) and slowly lower on to the bottom half. Ensure perfect match of the bolt holes. The dowel pins to be tapped in position.

• Torque up the fixing screws. Firmly secure casing with nuts and bolts as per sequence as shown in fig. 7.3.4

• Torque up the fixing screws.

• Rotate the shaft and ensure the free rotation.

• Connect water seal pipes and other accessories.

• Fit the coupling and align the pump and motor unit.

• If mechanical seals are fitted, a small amount of silicon rubber sealant along the horizontal joint line on the stuffing box face and fit the seal cover complete with gasket or ‘o’ ring.

• Care must be taken to ensure the seal seat bore is concentric to the shaft sleeve and it can be achieved using filler gages between the stationary seal seat bore and the shaft sleeve.

• Torque up the seal cover screws and check shaft/sleeve does not rub on seal cover or stationary seal seat bore.

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7.3.5 DISMENTALING AND RE-ASSEMBLY OF U PUMPS

In U pump models, the horizontal pump unit is installed vertically along with pump and motor stools directly coupled with motor (fig. 7.3.5.a). In some cases intermediate shafts and bearings are used between the pump and motor. Since the horizontal pump unit is installed vertically hence the dismantling and re-assembly procedure will remain same except the following steps.

• Isolate the electrical connections of the motor.

• Remove the motor half coupling bolts and free the coupling.

• Hoist the motor from the motor stool after removing the motor stool bolts on motor side.

• Remove the motor stool from the pump after removing the motor stool bolts from pump side.

• Remove the upper half casing after disconnecting the sealing lines and other accessories.

• While lowering the casing upper half over the lower half, take care to ensure that the wearing rings are correctly located in the upper half bores.

• The remaining steps shall be followed as per 7.3.3.1, 7.3.3.2, 7.3.3.3, 7.3.3.4

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RECOMMENDATION

For Grease/Oil Lubrication, Refer Table 7.3.6.1 & 7.3.6.2

101


Fig. 7.3.5.a

Fig. 7.3.5.a

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102


7.3.6 LUBRICATION CHART

7.3.6.1 Recommended Grease Lubricants

Manufacturer Grease Ball & Roller BearingsESSCO Petroleum Co. Ltd. Beacon 2 or Beacon 3Mobile Companies Throughout the world Mobilux Grease No. 3 or Mobilplex 48Shell Companies throughout the world Shell Alvania Grease 3Caltex Caltex Multifak 2Castrol Castrol Spheerol AP 3Indian Oil Servogem 3

Table 7.3.6

7.3.6.2 Recommended Oil Lubricants

Table 7.3.6.1

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It is unsafe to mix greases of two or more grades for use in ball bearings.

103


7.4 REFRENCE DRAWING, MATERIAL OF CONSTRUCTION & TECHNICAL DETAILS

Reference drawing, material of construction & other technical details refer the following drawing for respective jobs

General arrangement drawing.

Cross-sectional drawing.

For any correspondence/ordering spares, please quote the following.

CUSTOMER :

PROJECT :

WPIL REF. :

PUMP MODEL :

PUMP SERIAL No. :

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Contact Details

Contact WPIL

For any complaints and suggestion regarding Pumps

Email us: [email protected]

Phone: +91-120-3015784

Fax: +91-120-3015740

Factory Address:

WPIL LIMITED

A-5, Sector XXII, Meerut Road,

Ghaziabad - 201002, (U.P.), India

Corporate Office Address:

WPIL Limited

Trinity Plaza, 3rd Floor,

84/1 A, Topsia Road (South)

Kolkata 700 046, India

P: +91.33.3021.6800

F: +91.33.3021.6835



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Date post:	17-Feb-2016
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