Installation,Operation and Maintenance Manual MODEL DF€¦ · MODEL DF AXIALLY SPLIT CASING...

MODEL DF Installation,Operation and Maintenance Manual

AXIALLY SPLIT CASING HORIZONTAL DOUBLE SUCTION CENTRIFUGAL PUMP

MODEL DF AXIALLY SPLIT CASING HORIZONTAL DOUBLE SUCTION CENTRIFUGAL PUMP

Installation,Operation and Maintenance Manual

TABLE OF CONTENTS Safety Page

1. Safety Precautions

2. Exemption Clauses

3. General Safety Precautions

4. Important Warning Items

Chapter 1 Introduction

Chapter 2 Checking at Receipt of the Pump

2.1 Before Operating the Pump

Chapter 3 Installation

3.1 Foundation and Anchor Bolts

3.2 Preparations for Installation

3.3 Pump Installation

3.4 Centering

Chapter 4 Start and Stop

4.1 Precaution on Pump Operation

4.2 Pump Start

4.3 Pump Operation and Stop

Chapter 5 Control during Operation

5.1 Routine Inspection

5.2 Periodic Inspection

5.3 Maintenance of Coupling

5.4 Maintenance of Shaft Sealing Section

5.5 Bearing Maintenance

Chapter 6 Storage and Curing

Chapter 7 Counter-measures for Non-conformance

I

I

II

II

III

1

2

2

3

4

5

8

10

11

11

11

14

16

16

16

17

17

19

20

21



TABLE OF CONTENTS Chapter 8 Maintenance and Inspection

8.1 Precautions on Pump Disassembly and Assembly

8.2 Disassembly Procedure

8.3 Assembly Procedure

8.4 Disassembly and Inspection

8.5 Spare Parts

8.6 Parts Replacement

Chapter 9 Warranty and Service

9.1 Warranty Period

9.2 Warranty Range

9.3 Repairs at the User's Own Charge

9.4 Responsible Indemnity Range

24

24

25

25

26

26

27

28

28

28

28

28


- -


1.

•

•

Safety Precautions

Be sure to completely read this Operation Manual and other accompanying documents before installation,

operation,maintenance or inspection of this pump and to use this pump properly. Read all about the

knowledge, safety information and precautions concerning the equipment prior to using it.

In the Operation Manual,precautions have been classified into "DANGER","WARNING", "CAUTION", and

"NOTICE".

•

•

Even an item indicated by "NOTICE" has the possibility of causing a serious result depending on the situation.

You have to strictly observe the precautionary messages since they all explain important matters.

General safety precautions for this product will be explained after the next paragraph and should be observed,

together with the above.

! DANGER This indicates an urgent and dangerous situation, which may cause death or

serious injury unless it is avoided. This will be used only for an extremely

dangerous situation.

! WARNING This indicates a dangerous situation, which may result in death or a serious injury

unless it is avoided.

! CAUTION This indicates a dangerous situation, which may result in a slight injury of

intermediate degree unless avoided.

NOTICE This indicates a massage related to the safety of persons or the protection of

equipment (loss of property).

Safety Page

Ⅰ

1. Safety Precautions


- -


We are unable to take the responsibility for any incongruence created due to inobservance of the items

described in the Operation Manual.

Make the following checks for the sake of safety before starting the pump.

Make a centering check for the pump and the motor.

Check the oil and grease of the rotary section.

Check that the rotary section protective guards (shaft coupling guard, etc.) are securely installed.

Check that each alarm equipment can be actuated securely in the set condition.

Checking during operation

When making checks in the operating status, be careful about the rotary shaft.

In both operating status and stop status, don't insert hands or materials in the shaft coupling guard in any case.

Avoid touching the rotary shaft.

When checking the pump in the stop status, observe the following items for the sake of safety. Before removing

the shaft coupling guard, make sure that the motor power supply is already shut off. Make an indication

securely so that the power supply may not be turned on by mistake.

When modifying the pump main body or changing the set conditions of accessory equipment, be sure to make

contact with us to obtain our approval beforehand.

If you have any unclear matter, please ask us for information on it.

Ⅱ

2. Exemption Clauses

3. General Safety Precautions1.

1)

2)

3)

4)

2.

1)

2)

3)

3.

4.

Safety Page


- -


Ⅲ

The item in parentheses indicates the title of description.

4. Important WarningsClauses

! WARNING Don't operate the pump in any case while the shaft coupling guard is removed.

If any portion of the body is caught during the operation, this will result in a

serious injury. (Start, stop/pump start)

When removing the shaft coupling guard, be sure to turn off the motor power

supply beforehand.

If the power supply is not shut off, there is a possibility that the pump may be

suddenly started, thereby inviting great danger.

(Control during operation/periodic inspection)

•

•

NOTICE When the bearing is of oil lubrication, the lubricating oil is bled at delivery from

the factory. At installation, be sure to put the regular lubricating oil.

Operation without lubricating oil will cause burning to the bearing.

(Start, stop/pump start)

Before starting the pump, check the records of the pump installation status,

centering, equipment setting conditions, and bearing oil and grease.

(Start/stop/pump start)

•

•

• ! CAUTION Before operating the pump, read the instruction manual and other attached

documents thoroughly to operate it correctly.

Safety Page

- -



Thank you very much for purchasing the DF- type double suction volute pump.

Operate the pump correctly in accordance with this instruction manual.

This manual is intended to give a good understanding of how to correctly operate the DF-type double suction

volute pump.

This pump underwent strict product inspection at our factory and was pressure-tested by the factory testing

facilities and put into a trial run with the result that its operating status and performance were proved to satisfy

the various requirements provided in the specification and conform to the standard.

It is necessary to operate the pump correctly to obtain its full performance. Incorrect operation will lead to a

failure without obtaining its full performance. Please observe each limit value specified in this manual, avoid

operating it under compulsion, and operate it within each limit value at all time.

Perform correct inspection and maintenance to prevent accidents from occurring.

In case such a failure as makes the operation impossible occurs, inform us of it according to the following

procedure.

Contents of pump nameplate (type, head, capacity, rotation speed, manufacturing year, serial number)

Abnormal status (Inform is of its greatest possible details including the conditions before and after occurrence

of an abnormality.)

Chapter 1 Introduction1)

2)

3)

4)

a)

b)

1

- -



After you receive the pump, make the following checks.

Check on the pump nameplate that the type, capacity, head, rotation speed and power are in compliance with

the specification of the ordered product.

Check if any damage has not been caused during transportation.

Check if any bolt or nut has not become loose. (*1)

Check that all the accessories are included. If you find any fault, please ask our staff in charge for information.

If you store the pump for a long time (2 months or more) without operation after receipt of it, inform us of it.

Special rust preventive treatment will be required depending on the storage period.

2.1 Before Operating the Pump Chapter 2 Checking at Receipt of the Pump

1)

2)

3)

4)

5)

(*1) Regarding the accessories, make checks for looseness.

2

- -



3

Chapter 3 Installation

NOTICE As a rule, install a straight pipe section of 4 D or more on the suction side of the

pump. Installation of a bent pipe will cause vibrations or noise.

Perform piping with a rising gradient on the suction side of the pump so as not

to cause air to stay.

•

•

- -



CHAPTER 3 Installation

NOTICE The foundation should have sufficient rigidity. A low-rigidity foundation will shift

the pump installing position or cause vibrations.

Accordingly, the foundation must be rigid enough.

•

•

F i g. 3- 1

Determine the natural frequency of the foundation so that it may not be equal to the rotation speed of the pump.

Anchor bolts

As the anchor bolts to fix the foundation and the pump (pump base), the type shown in Fig. 3-2 is often used.

In the box extraction embedding method, box extraction holes are made for anchor bolts when the foundation

concrete is laid and then the anchor bolts are fixed after the pump is carried in. (Fig.3-2, a and b)

In the template using method, anchor bolt positioning is performed by the template (*1) before the pump is carried

in with the object of reducing the installation work period and the anchor bolts are fixed when the foundation

concrete is laid. (Fig. 3-2, c and d)

2)

☆

☆

F i g. 3- 2

(*1) We shall supply the template if you specify it.

1) The pump foundation

The pump foundation is usually prepared with concrete. The pump is fixed with anchor bolts embedded in this

foundation. In many cases, such a simple shape as shown in Fig. 3-1 is adopted for the foundation.

4

3.1 Foundation and Anchor Bolts

- -




If installation, operation, maintenance and inspection are appropriate, the pump can be stably operated for a

long time. Perform installation work according to the following procedure.

3.2 Preparations for Installation

! WARNING The lifting tackle of the upper casing is used to lift only the upper casing. Don't

lift the whole system (pump + motor + base) by this tackle in any case.

The motor lifting apparatus is used to lift the motor itself.

Don't lift the whole system in any case.

Check the equipment weight and the lifting angle before lifting and use proper

wire ropes.

Check that the crane lifting capacity is enough before lifting

•

•

•

•

NOTICE The steel liner is used to adjust the horizontal level of the pump and receive the

empty weight and operating load of the pump.

•

5


- -


6

2.1 General installation procedure

The following flowchart shows the general installation procedure.

Lifting-out work ・・・・・・・・・・・・・・・・・・・・・・ Installation drawing, foundation drawing

↓ Chipping work ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Foundation surface and others of pump and auxiliaries

↓ Foundation work ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Iron rod, flask, and concrete laying

↓ Equipment carrying-in work ・・・・・・・・・・・・・・・・・・・・・ Lifting

↓ Installation work ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Arrangement, assembly, and centering

↓ Small piping work ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Support

↓ Painting work

↓ Trail run ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Operation check

The above procedure varies depending on the site condition.

2.2 Preparations before installation

Examine the work plan and drawings thoroughly before starting the installation. If you have any unclear point or

doubt in the drawings, consult with the constructor or our staff at once.

2.3 Precautions on installation

When lifting the equipment, set wires carefully so as not to give damage to the equipment.

Take the wire set positions and the wire length into consideration so that the load may not lose its balance.

Refer to LIFTING PROCEDURE.

When lifting divided equipment and easy-to-transform materials, don't remove reinforcing materials until

assembly.

2.4 Liner for installation

It is necessary to place the steel liner to be used between the bottom surface of the base (or the bottom surface

of the base plate) and the foundation surface as near to the anchor bolts as possible. (Refer to Fig. 3-3.)


3.

3.

3.

1)

2)

3.


- -


7

2.5 Installation reference surface setting

Installation reference line setting

Check the reference line (flat surface, height) of the pump machine place and perform marking-off for the axial

center line, flange center line, and flange surface position from the foundation drawing for installation.

Installation height setting

Check that the bottom surface of the base can be installed by the mortar allowance height (check the drawing

dimensions) from the foundation floor surface.


3.

1)

2)

F i g. 3- 3

2.6 Foundation surface rough leveling

After rough leveling of the foundation, arrange a set of one temporary parallel liner and 2 taper liners on the

foundation on both sides of the anchor bolts.

At this time, remove laitance (weak concrete embossed and settled on the concrete surface) completely, and

also remove the oil existing on the foundation concrete surface completely.

3.


- -



Centering is already performed correctly at the factory. For reasons of handling it during transportation and

a difference in foundation surface between the factory and the site, the common base may be deflected if

the pump is installed as it is, and this may cause axial offset between the pump and the motor, thereby

making normal operation impossible.

Perform installation and centering according to the following procedure.

3.3 Pump Installation

•

•

•

•

NOTICE At installation, perform centering for the pump and motor for each process.

After stuffing concrete, be careful not to freeze it.

Frozen concrete becomes low in strength.

Don't apply the piping load to the pump. If the load is applied to the pump, this will

result in equipment damage, vibrations or noise.

Before pipe connections, clean the inside of each pipe. If any foreign material

stays there, the pump will be damaged.

3.1 Pump installation

Put the pump, motor and common base on

the temporary liner and also set the anchor

bolts in the anchor bolt holes. Make a

clearance of 30 to 50 mm to cause mortar to

flow between the bottom surface of the base

and the foundation floor. (Fig. 3-4)

3.

1) T a p er l i n e r

P ara l le l l i n e r

C o mmo n b a se

F i g. 3- 4

3 0 〜5 0mm

Determine the position and height of the pump discharge port.

Make the axial center between the pump and the motor level with a level gauge by using the work surface of the

casing.

At this time, the standard setting height (level) should be within the range of design value ±0.5 mm and the

standard horizontality should be 5/100 mm per meter. The height of the pump can be easily made by the taper

liner.

2)


8


- -



3.2 Anchor bolt fixing

In the status where the anchor bolts are set on the common base, cause concrete to flow into the anchor bolt

holes to fix the anchor bolts.

3.3 Pad creation and real liner installation

The pad is a basis for fixing the real liner and created by mixing common cement, sand and water at the rate of

1:1: small quantity, and a proper quantity of non-shrinking agent recommended by the maker.

After completion of compaction to the goal height, put the parallel liner.

Arrange the real liner so that the anchor bolt may be in the center of the real liner as shown in Fig, 3-5, and so

that the real liner may be as near to the bolt as possible on both sides.

Adjust the parallel liner position to the setting height from the reference level surface with the level gauge and

obtain the horizontality in the direction of the liner with the level gauge.

After the concrete is hardened and the setting at the installation is completed, tighten the nuts of the anchor

bolts.

3.

3.

1)

2)

3)

4)

F i g. 3- 5

9


- -



After completion of correct piping, set the axial offset and clearance difference between the pump and the motor

shaft coupling to the values. Make an adjustment by inserting shims (thick plates) between the motor and the

common base seat if required.

Rotate the rotary bodies of the pump and the motor by hand to check if they can smoothly rotate.

Perform centering with a dial gauge, bar micrometer, block gauge and thickness gauge or taper gauge.

3.4 Centering

10

3.4 Temporary centering (first centering) 3.

NOTICE

Make a centering check for each process. If this check is omitted, centering

may be impossible finally.

•

- -



It is desirable to operate the pump at a value close to the flow rate at which the maximum efficiency can be

obtained. In some cases, however, the pump must be inevitably operated at a smaller flow rate or larger flow

rate for the reason of use. In these cases, it is necessary to use the pump with a good understanding of

pump characteristics.

1.1 Operation at extremely small flow rate

If the pump is operated at an extremely small flow rate or cut-off point for a long time, vibrations and noise will

be increased and an overheat symptom will appear.

1.2 Operation at extremely large flow rate

Like operation at an extremely small flow rate, you must pay attention to an increase of vibrations and noise

and cavitation due to lowered suction performance. In this status, the pump performance will be remarkably

lowered, resulting in a failure.

2.1 Preparations before starting the pump

Check that pump centering is already completed.

Independent operation of the motor

To check the direction of rotation after completion of motor wiring, operate the motor without load. At that

time, check that the direction of rotation is equal to that indicated on the nameplate provided on the pump.

After checking, be sure to turn off the power supply.

Coupling between the pump and the motor

4.

4.


4.2 Pump Start

! WARNING Be sure to install the motor terminal box cover. If not, an electric shock may be

caused.

•

! WARNING Check that the motor power supply is shut off.•

4.1 Precaution on Pump Operation

NOTICE Don't put the pump into cut-off operation long time.

If the cut-off operation is continued longer, the water temperature in the pump

will rise, resulting in a failure.

•

4.

1)

2)

☆

3)

11

- -




Check the bearing lubricating oil (for the oil lubrication type).

The bearing lubricating oil is already bled at delivery from the factory. Be sure to supply oil up to the oil gauge

level before starting the pump.

For the oil and grease, refer to the nameplate provided on the pump or 5-5 Bearing Maintenance in Chapter 5.

Rotate the rotary body by hand to check that it can smoothly rotated.

If the rotation is not smooth or hard, this may be attributable to abnormal contact of the clearance section or

inclusion of foreign matters. Disassemble the pump if required.

Check the connections of the suction and discharge pipes and accessory small pipes.

Perform priming work by the suction-side valve or priming funnel or start the vacuum pump to fill the inside of

the pump with water up to the maximum level.

Check if the shaft sealing water (gland water injection or mechanical seal flushing) pipe valve can opened and

closed normally.

Pass water to check the condition as required. In the case of bearing cooling, check this condition.

Check that the suction-side value is fully opened and the discharge-side valve is fully closed.

When there is a valve for minimum flow, open the valve of the same pipe completely.

4)

5)

6)

7)

8)

Don't operate the pump without load in any case, otherwise damage will be

given to the slide section.

•

NOTICE

12

- -



13

CHAPTER 4 Start and Stop

With this, the preparations for starting are completed. Rotate the rotary body by hand to check the rotating

status.

Install the shaft coupling cover and take safety measures to provide for a pump start.

2.2 Pump start

Pump trouble tends to occur in the early stage of operation. Perform operations with special care at a trial run.

If any trouble occurs, stop the pump at once and take a proper measure for it.

Turn on the start switch and continue to operate the pump for 4 or 5 seconds, then turn off the switch.

Repeat these start and stop operations 2 or 3 times to check the following points.

Check if the spindle rotation is smooth.

Check if the bearing section is normal.

Check if any abnormal smell is not given out.

Check if any abnormal noise or vibration does not occur.

After that, increase the rotation speed to the specified speed level.

After turning on the start switch and increasing the rotation speed to the specified level, check the discharge

pressure. Then, open the discharge valve set the specified operating point to enter into continuous operation.

At this time, observe the suction/discharge pressure value, current value, vibration value, noise value, etc.

Note that a large variation or sudden change appears as an evidence of abnormal symptom.

4.

1)

1.

2.

3.

4.

- -



14


The allowable vibration value is shown in Fig. 4-1.

Check the condition of the shaft sealing section. Refer to 4.3 Pump Operation and Stop.

3.1 Operation

When there are a shaft sealing water pipe valve and a bearing cooling pipe valve, open them completely. Turn

on the start switch. After the rotation speed reaches the specified speed level, open the discharge valve to start

a wafer feed. At this time, pay attention to the current value and the vibration value.

Pay attention to the bearing temperature.

Pay attention to the values indicated on the pressure gauge and the ammeter.

2)

3)

4.3 Pump Operation and Stop

Fig.4-1

4.

1)

2)

- -



3.2 Stop

Close the discharge valve completely, then turn off the switch to stop the operation.

After the pump is stopped, stop the water feed from the outside.

In particular, continue a water feed to the shaft sealing section until the pump is completely stopped.

3.3 Emergency stop

If the pump is stopped because of a power failure, be sure to turn off the power switch. After that, close the

discharge valve. In the power ON status, the pump may be suddenly started when a power recovery is made

from the failure. This is very dangerous.


4.

1)

2)

4.

15


- -


16

Periodic maintenance will be effective in preventing a failure from occurring or minimizing its effect at pump

operation.

1.1 Operation log

We recommend you to inspect the daily operating status and record it in an "operation log" after the starting

day of pump operation.

When a large change is found in the record of pressure values and current values, this indicates a sign of any

failure. At that time, it is important to perform troubleshooting in an early stage and take a proper measure.

Inspection items:

Suction pressure, discharge pressure

Current value and its variation width

Bearing temperature

Vibration value

Noise value

Shaft searing section status

Bearing lubricating oil level and color

Operating time

Stopping time

Operating duration

Inspection time

1.2 Precautions on routine inspection

Keep the source valve of the pressure gauge closed except when reading the indicated value.

If this valve is always kept open, the life of the gauge will be shortened.

5.1 Routine Inspection

5.

・・・・・・・・・・・ 5.

Chapter 5 Control during Operation

! WARNING Be careful not to be caught by the rotary section.

If fingers or clothes are caught by it, it will result in a serious injury.

•

! WARNING Before starting inspection, be sure to turn off the motor power supply.

In particular, in the case of automatic operation, the motor may be suddenly

started. You must make sure of this point.

•

5.2 Periodic Inspection

MODEL DFAXIALLY SPLIT CASING HORIZONTAL DOUBLE SUCTION CENTRIFUGAL PUMP

- -


(*1) For use of water service, use edible grease.

17

CHAPTER 5 Control during Operation

Inspection Items and Intervals

Direct coupling status check

Refer to 3.4 Centering in Chapter 3.

4.1 Inspection and maintenance of ground packing

Routine inspection

Check if heat is not generated by excessive tightening or one-side tightening of the gland.

The status where a small quantity of water is always dripping is the ideal tightening level which prevents heat

generation and reduces the wear amount.

Extraction of gland packing

Screw a tool with a cork screw at its end into the gland packing for extraction.

Extract the lantern ring by using a tool suitable for extracting screw or notch.

Clean the stuffing box, packing gland, and lantern ring. At this time, clean the water injection hole and pipes,

too.

Inspect the wear amount of the shaft sleeve. If the wear amount is large, replace it with a new one.

(Refer to Chapter 8.)

Adjustment of gland packing

Use the specified gland packing. Refer to the equipment specification.

Regarding any type other than a ring molded product, adjust its dimensions as follows.

When cutting the gland packing, use a round bar (spare sleeve) with the same diameter as that of the shaft

and wind the gland packing around it while adapting itself. Then, cut it to obtain correct dimensions.

Pay attention to the cut end.

Apply a proper lubricant (*1) before stuffing.

Every 3 months ・ Replace ment of bearing lubricating oil. Only at a start of operation or in the ear ly stage after disassembly and inspection.

Every 6 months ・ Direc t coupling status between the pump and the motor (centering check)・ Bearing lubricating oil status

5 Every year ・ Inspect ion and replace ment of gland packing (mechanical seal)・ Inspect ion of bearing coupling bolt rubber ring・ Replace ment of bearing lubricating oil・ Inspect ion of others and acce ssories (measuring instruments, etc.)

1)

5.

1)

a)

b)

2)

a)

b)

c)

d)

3)

a)

b)

c)

d)

e)

5.3Maintenance of Coupling

5.4Maintenance of Shaft Sealing Section


- -


18


Gland packing stuffing

When opening the gland packing, open it by twisting the cut end.

If the cut end is opened straight, the opposite side will be damaged.

Shift the cut end by 90 to 180 each and tighten each ring for stuffing.

Perform stuffing by using the holder end of a hammer or a bushing, lantern ring, etc.

The cut end of the outside packing should be setting under side.

Check if the lantern ring is located at the specified position by measuring the length.

After stuffing, tighten with packing gland and leave it for a while.

Warm it slightly to provide for operation.

Running-in operation

Rotate the rotary body by hand to adapt the gland packing to itself.

Supply shaft sealing water to check the leak status.

For adjustment, refer to 4.3 Pump Operation and Stop

4.2 Mechanical seal inspection

4)

a)

b)

☆ c)

d)

5)

a)

b)

c)

5.

! WARNING When a strainer is provided in the flushing pipe, clean the strainer.

If the strainer is clogged, the flushing flow rate will be lowered so that the sliding

portion will be damaged, leading to a leak.

•


- -


19


Routine inspection

Check if any leak does not occur.

If a leak is found, make the following checks.

Leak from the slide surface.

Wear or damage on the floating seat slide surface

Wear or damage on the seal ring slide surface

Inclination of the slide surface and spindle

Inclusion of foreign materials on the slide surface

Swing or vibration of the spindle

Strain or one-side touch of the slide surface due to installation, etc.

Leak from any portion other than the slide surface

This leak may be attributable to a defect or installation defect of packing such as O- ring.

The cause can be found by careful observation of the leak status.

In the case of a leak, disassemble and replace the corresponding parts.

Check if flushing is normally performed.

If a strainer is provided in the flushing pipe, clean the strainer periodically. In the early stage of operation (after

disassembly and inspection), clean it at intervals of 1 or 2 days.

After that, determine the cleaning time according to the clogging status.

Handling of mechanical seal

Generally, take the following points into consideration.

Check if any dust or foreign material is stuck on each part of the mechanical seal and each part of the pump

side. Don't touch the slide surface with a bare hand.

Check that any defective part is not included in packing.

Check that any burr does not exist on the pump parts on which the packing is installed.

Installation of mechanical seal

Perform installation work with special care for precision equipment in accordance with the mechanical seal

drawing or the instruction manual.

The DF-S type pump is classified into the grease lubrication type and the oil lubrication type.

Perform replacement or refilling referring to the LUBRICANT OIL LIST.

In the case of the oil lubrication type, replace oil once every 6 months to every year depending

on the operating condition and enviroment as a matter of replacement intervals.In the early stage (after delivery

or after disassembly and inspection),replace the oil once every 2 to 3 months.

In the case of the grease lubrication type, if too much grease is refilled, heat generation will occur. Refill

grease to 1/3 to 1/2 of the bearing case. Perform refilling once every 2 or 3 months.

Usually, for a roller bearing, replace oil when the total time reaches 20000 to 40000 hours. If any abnormal

noise or vibration or any abnormal heat generation is found during operation, replace it regardless of the

operating duration.

1.

a)

*

-

-

-

-

-

-

*

b)

2.

a)

b)

c)

3.

1)

2)

3)

5.5 Bearing Maintenance


- -


20

Chapter 6 Storage and Curing

When the pump must be stopped over 2 months, inform us of it.

Special rust prevention is required depending on the storage period.

Generally, execute the following points.

Bleed the liquid in the pump completely. (*1)

Take a proper rust preventive measure for portions where rust tends to occur.

When the machine work surface such as flange surface is exposed, take a rust preventive measure using a

rust preventive agent. (*2)

Rotate the rotary body by hand once a week to change the contact portion of the bearing.

Check the rust generation status, too.

When operating the pump after a long-time stop, check the direct coupling status (centering check) between

the pump and the motor, then start with the check items before starting.

During the stop period, perform disassembly and inspection. Check each section and make

a schedule for part replacement or spare part procurement as required.

1)

2)

•

3)

4)

5)

(*1) The drain port is shown in the outline drawing of the pump or the piping diagram of small pipes.

(*2) Our recommended agent:

Rust Bete 342

E.F.Houghton & Co.

- -



21

Chapter 7 Counter-measures for Non-conformance

When a failure has occurred, perform troubleshooting referring to the following items to find its probable

cause, then take a proper corrective measure. The following items are general failures and corrective

measures for them. In some cases, however, several causes may be combined. Please inform us of its

detailed contents when necessary.

C a u se Em e r g e nc y m ea s ure P er m a n en t m ea s ure T he s t ar t c o n d i t i o n s ca n n o t b e s a t i sf i ed .

C h e ck eac h c o n d i t i o n . If t h i s i s d u e t o a n a p para t u s fa i l u re, s h o r t a n d s t ar t t h e p um p t em p o rari l y . C h e ck i f t h e p um p ca n b e s t ar t ed i n d e pe n de n t l y .

C h e ck eac h a p para t u s a n d c i rcu i t . R e p ai r .

T he s t ar t c o n d i t i o n s ca n n o t b e s a t i sf i ed .

C h e ck i f a rec o ver y h a s b e en m a d e fr om t h e fa i l u re.

C h e ck t h e c i rcu i t .

T he m o t o r fa i l e d . R e p air t h e m o t o r .

F or e i g n m a t eria l s are ca u g h t i n t h e r o tar y s e ct i o n , e t c.

S t o p t h e e q u i p m e n t , t h e n re s tar t i t. R e p air t h e m o t o r .

T he b e ari n g i s s e ize d . R e p lace t h e b e ari n g .

T he i mp e l ler i s c l o g ge d w it h f o rei g n m a t eria l s .

S t o p t h e p um p , t h e n re s tar t i t. D is a ss em b l e a n d c l ean .

T he s u c t i o n h e i g h t w as i n crea s ed b y w ater l e ve l l o w e ri n g .

W a i t i n t h e c u rren t s t a t us u n t i l t h e s u c t i o n w ater l e ve l r i se s .

C h e ck i f l a n d s u b s i d en c e h a s o c curre d .

T he rea l l i f t a n d l o s s o f h e ad are h i g h er t h a n t h e p l a n n e d o n e s .

C h e ck t h e rea l l i f t a n d rea l p i p i n g l o s s a g ai n .

T he ca s i n g w eari n g r i n g i s w or n a w a y .

R e p lace t h e ca s i n g w eari n g r i n g .

A ir i s i n h a le d fr om t h e g l a n d . T i g h t e n t h e g l a n d p a ck i n g f u rt h e r . R e p lace t h e g l a n d p a ck i n g . P erf o r m p r i mi n g a g ai n . C h e ck t h e a s p i rat i n g s y s t e m f o r

a i r l e aka g e. I mp erfect f u l l w ater s t a t u s.

C h e ck i f a n y a i r l e ak o c cur s fr om t h e g l a n d .

T i g h t e n t h e g l a n d p a ck i n g f u rt h e r .

Start failure Lift failure or lift am

ount reduction

- -



22

CHAPTER 7 Counter-measures for Non-conformance

C a u se Em e r g e nc y m ea s ure P er m a n en t m ea s ure E xce s s i ve r o ta t i o n s p ee d . A dj u s t t h e p ow er s u p p l y . E xce s s i ve w ater v o l um e . A dj u s t t h e d i s c ha r g e v a l v e

o p e n i n g . O pera t i o n o u t o f t h e s p ec i fica t i o n . A dj u s t t h e d i s c ha r g e v a l v e

o p e n i n g . R e v ie w t h e s p ec i fica t i o n p o i n t .

I n cl u s i o n o f m u d o r f o rei g n m a t eria l s .

S t o p t h e p um p , t h e n re s tar t i t . C l e an t h e s u c t i o n w ater t a n k a n d t a ke a p r eve n t i ve m ea s ure a g ai n s t f o rei g n m a t eria l s .

E xce s s i ve t i g h t e n i n g o f g l a n d p a ck i n g .

L o o se n t h e g l a n d p a ck i n g .

F reez i n g o f p um p . P erf o r m t h a w i n g . A xi a l o f f s et . P erf o r m ce n ter i n g . B ear i n g d am age . R e p lace t h e b e ari n g . C o n t a ct o f r o tar y s e ct i o n . D is a ss em b l e a n d c o rrect . R e p lace t h e c o n t acte d p a rt . T he u s e d l i q u i d t em pera t ure i s t o o h i g h.

L o w er t h e l i q u i d t em pera t ure .

I n s uf f i cie n t w ater v o l um e . A dj u s t the discharge valve opening.

C u t -o f f c o n t i n u o u s o p era t i o n . O pe n t h e d i s c ha r g e v a l v e.

I n s uf f i cie n t m i n i mum f l o w . C h a n g e t h e m i n i mum f l o w .

C o n t a ct o f t h e r o tar y s e ct i o n . D is a ss em b l e a n d c o rrect . R e p lace t h e c o n t acte d p a rt .

I n s uf f i cie n t b o l t t i g h t e n i n g S t o p t h e p um p a n d t i g h t e n b o l t s e q ua l l y f u rt h e r .

P ac k i n g d e gra d at i o n A dj u s t the discharge valve opening. R e p lace t h e p a ck i n g .

T he f u l l w ater s t a t us o f t h e p um p a n d s u c t i o n p i p e i s i n s uf f i cie n t .

P erf o r m p r i mi n g a g ai n .

A ir s t a y s i n t h e s u c t i o n p i p e . M o d if y t h e s u c t i o n p i p e .

T i g h t e n t h e s u c t i o n p i p e b o l t s f u rt h e r .

R e p lace t h e p i p e p a ck i n g . A ir i s i n c l u d ed .

T i g h t e n t h e g l a n d f u rt h e r . R e p lace g l a n d p a ck i n g .

Overload

Main body overheating

Leakage W

ater feed disabled

- -



23

CHAPTER 7 Counter-measures for Non-conformance

C a u se Em e r g e nc y m ea s ure P er m a n en t m ea s ure T he p a ck i n g i s e x ces s i v el y t i g h t e ne d .

L o o se n t h e p a ck i n g g l a n d , t h e n t i g h t e n i t g r ad u al l y .

T i g h t e n p a ck i n g g l a n d caref u l l y a n d e q ua l l y .

P ac k i n g s e lec t i o n i s n o t p r o p e r . C h a n g e t h e p a ck i n g m o d e l .

P ac k i n g i n s e rt i o n i s fa u l t y . R e- s et t h e p a ck i n g . T he s l ee v e i s w or n a w a y . R e p lace t h e s l ee v e. T he l a n t ern r i n g p o s i t i o n i s n o t p r o p e r .

A dj u s t t h e p o s i t i o n.

T he s e al i n g w ater v o l um e i s n o t p r o p e r .

A dj u s t i t b y t h e s e al i n g w ater v a l v e.

A dj u s t t h e w ater v o l um e t o t h e s p ec i fie d v a l u e.

L u b rica t i n g o i l i s u s e d u p. T he l u b r ica t i n g o i l v o l um e i s e x ces s i v e.

A dj u s t t h e l u b r ica t i n g o i l v o l um e t o t h e p r o p er l e ve l .

L u b rica t i n g o i l i s d e gra d ed . R e p lace t h e l u b r ica t i n g o i l . L u b rica t i n g o i l i s n o t p r o p e r . R e p lace t h e l u b r ica t i n g o i l w it h

t h e re g u l ar o n e . I n cl u s i o n o f f o rei g n m a t eria l s . C l e an . R e p lace t h e l u b r ica t i n g o i l . B ear i n g d e fect s u c h a s p l a y . B ear i n g d am age .

R e p lace t h e b e ari n g .

A xi a l o f f s et . P erf o r m ce n ter i n g . T he s p i n d l e i s b e n t . C or r ect o r re p lace t h e s p i n d l e .

S ha f t c o u p l i n g d e fect . R e p lace t h e r u b b er r i n g . R e p lace t h e r u b b er r i n g o f t h e s h af t c o u p l i n g b o l t.

C e n ter i n g d e fect . P erf o r m ce n ter i n g a g ai n . B ear i n g d am age . R e p lace t h e b e ari n g . C l o g g i n g w it h f o rei g n m a t eria l s . R e mo ve f o rei g n m a t eria l s .

C o n t a ct w it h t h e r o tar y b o d y . D is a ss em b l e a n d c o rrect . R e p lace t h e c o n t acte d p a rt . T he p i p e v i b r ate s . S u p p o rt i t.

R a i se t h e s u c t i o n w ater l e ve l . R a i se t h e s u c t i o n w ater l e ve l . A ir i s i n h a le d fr om t h e s u c t i o n p i p e .

P re v en t a c o n v o l u t i o n fr om o c curr i n g .

I n st a l l a c o n v o l u t i o n p r eve n t i ve w al l .

T he f o u n da t i o n i s i mp erfec t . I n crease t h e f o u n da t i o n s t re n g t h .

Gland tem

perature riseBearing heat generation

Vibrations and noise

- -



24

Chapter 8 Maintenance and Inspection

! CAUTION Entrust us or a specialist company with parts replacement, repairs, etc.

Incorrect work may result in a failure or accident.

•

8.1 Precautions on Pump Disassembly and Assembly

! WARNING Before starting disassembly work, make sure that the motor power supply is

shut off.

When lifting, pay attention to the weight, lifting angle, work place.

The pump is heavy. If it drops, it will invite danger.

•

•

! CAUTION Have a good understanding of the pump structure and don't mistake about the

work sequence.

•

Prepare replacement parts beforehand.

As a rule, all the packings will be replaced. Prepare them beforehand. Use the packings of the specified

materials and dimensions.

For contact sections and fitting sections, clean them and apply necessary machine oil or liquid packing (*1),

then perform the work with proper tools without strain.

Tighten each bolt avoiding one-side tightening.

If there is a lock plate, bend it and be sure to put a detent.

The match surfaces of necessary portions are provided with a match mark. Pay attention to it.

If the match mark is unclear at disassembly put a match mark anew.

After disassembly, keep parts with care. At assembly, perform assembly at specified positions pay attention

to the match marks.

Measure the dimensions of each slide section and record the measurement results.

Arrange additional parts as required.

1)

2)

3)

4)

5)

6)

7)

8)


- -



CHAPTER 8 Maintenance and Inspection

8.2 Disassembly Procedure

8.3 Assembly Procedure

Pull out the shaft coupling bolt and disconnect the pump from the motor.

Discharge the bearing oil and bleed the lift liquid in the casing.

Remove each small pipe to separate it from the pump.

Remove the packing gland.

Remove the casing match surface bolts and detach the upper casing.

In the case of the grease lubrication bearing, separate the bearing housing and the lower casing, and lift the

rotary body in the status where the bearing housing is built in the rotary body. (*2)

Unless it is required, don't remove the rotary bodies such as impeller and shaft coupling from the spindle for

disassembly. (Except when the shaft sleeve is replaced)

For assembly, reverse the disassembly procedure. Take the following items into consideration.

Clean the junction surface and the fitting surface enough and remove any scratch or burr thoroughly.

To the junction surface and the fitting surface, apply seizure preventive material or liquid packing (*3).

Clean the residual lubricating oil in the bearing housing completely.

Perform repair painting (*4) as required.

Be careful not to neglect assembling packings and small parts.

1)

2)

3)

4)

5)

6)

7)

1)

2)

3)

4)

5)

(*2) Lift the wear ring and lantern ring in the status where they are built in the rotary body.


Refer to DIVISION OF SEALANT for matching surface of casings.

(*4) Use the same painting material as that used in the early stage of the delivery. For the painting material,

refer to the painting specification and pump data sheet.

25


- -



8.4 Disassembly and Inspection

8.5 Spare Parts

4.1 5-year inspection

Pump disassembly and inspection are greatly different depending on water quality, material, and operating

frequency. However, we recommend you to execute them at intervals of 2 or 3 years after the first use.

Inspection items

Clearance between the impeller and the casing wearing ring (wear amount)

Wear amount of the shaft sleeve

Internal inspection about corrosion of the liquid contact section

For the replacement standard, refer to 4.6 Parts Replacement.

Recommended replacement parts

Ball bearing, shaft sleeve, etc.

The seal materials including seat packing and O-ring must be totally replaced.

Regarding painting, all-surface painting is required for the liquid contact section and repair painting is

required for the liquid non-contact section.

Preparations for the next disassembly and inspection

According to inspection results, make a procurement schedule for parts that are considered to be replaced

at the next disassembly and inspection.

4.2 10-year inspection

We recommend you to perform disassembly and inspection at our factory. The bearing and shaft sleeve will

be replaced and the whole pump including the impeller, casing and spindle will be precisely inspected.

5.1 Recommended spare parts

Arrange spare parts beforehand so that the pump may not be stopped for a long time if any abnormality is

found at pump inspection.

Usually, we recommend you to keep the following parts as reserves.

Casing wearing ring

Shaft sleeve

Gland packing (mechanical seal)

Ball bearing

O-ring and gasket

Lubricating oil

Rubber bushing (flange type flexible shaft coupling)

8.

1)

1.

2.

3.

2)

1.

2.

3.

3)

8.

8.

1)

2)

3)

4)

5)

6)

7)

26


- -


27


8.6 Parts Replacement After the pump is operated for a long time, each slide section will be worn away. Consequently, the clearance

will become large, resulting in performance lowering or vibration generation. The replacement standard must

be examined from different aspects and cannot be easily determined. Fig. 8-1 shows a reference standard

P ar t n am e S ta n d a rd v a l u e E x p la n at i o n

I mp el l er a n d ca s i n g w eari n g r i n g

T he C v a l u e b e ca m e 2 o r 3 t im e s a s l ar g e a s t h e i n i t i a l v a l u e

S ha f t s l ee v e

B ear in g ( b a ll b ear i n g ) T o t a l o p era t i n g t im e : 2 0 0 0 0 t o 4 0 0 0 0 h o u r s

W he n a b n o r m al h e at g e n era t i o n o r v i b r at i o n s o c curre d , m a k e a c h eck a n d re p lace i t w it h a n e w o n e i f a n y a b n o r m al i t y i s f o u n d re g ard l es s o f t h e o p era t i n g t im e s h o w n a t l e ft .

　　　　　　　 F i g. 8 - 1 G enera l R e p lace m e n t S ta n d a rd f o r S l i de S ec t i o n ( W ear L i mi t)

I f t h e c l ea r ance s h o wn a t l ef t d oe s n o t m a t te r p rac ti ca ll y , y o u m a y u se t h e se p ar ts .

W he n t h e d i am eter o f t h e w ear o n t h e s l ee v e s u rface e x ceede d 0.1mm ：M ec h an i cal s e al

exceeded the size shown at left, replace this part.

O ne- s i d e c l earance : C

φＢ

S le e ve

φＢ S le e ve

when a convexworn section inthe part in contact with the packing was found and the maximum convexity

When the wear amount of the sleevesurface exceeded B × (0.025 to 0.03).


- -


28

Chapter 9 Warranty and ServicePlease entrust the distributor or us with repair or inspection of the pump that you purchased. If any fault is

found in the motor or pump while you use it, stop the operation at once and investigate its condition.

(Refer to 8. Causes of Failures and Corrective Measures.)

In the case of a failure, inform the distributor of the nameplate items (specially, our serial number and model)

and the failure (fault) condition immediately.

If you have any comment, please give us it.

The warranty period depends on the purchase conditions when you place an order.

When you handle the equipment properly in the warranty period and yet any defect is found because of our

design or manufacturing fault, the corresponding section will be warrantable.

Failures attributable to improper handling, use, storage on the user side

Failures occurring after the expiration of the warranty period

Failures attributable to repairs or modification by others than our related service agents

Failures resulting from use other than that contracted with us

Failures attributable to use of parts other than those specified by us

Failures by a fire, disaster, natural calamity or other force majeure

Consumables: Packing (*1), seal parts (*2), slide section parts (*3), etc.

Our responsible indemnity range on this warranty condition shall be limited to modification, repair and

replacement of defective parts or dispatch of replacement parts, excluding indemnity of any loss that may

occur secondarily.

(*1) O-ring, seat packing, etc.

(*2) Oil seal, mechanical seal, etc.

(*3) Bearing, casing wearing ring, sleeve, etc.

9.1 Warranty Period

9.2 Warranty Range

9.3 Repairs at the User's Own Charge

9.4 Responsible Indemnity Range

•

•

•

•

•

•

•

Date post:	05-Aug-2020
Category:	Documents
Upload:	others
View:	10 times
Download:	0 times

Installation,Operation and Maintenance Manual MODEL DF€¦ · MODEL DF AXIALLY SPLIT CASING...

Documents