20 pump manual desmi

INSTRUCTION MANUAL & PARTS LIST

BOMBAS

: pumpvip 7

engineering pte ltd

Ruby Warehouse Complex. 8 Ka!=i Buldt Road 2, g01-23 Singapore 417841 Tel : 65-7483888 (5 Lines) Fax: 65-7488858 (2 Lines)

GST Ree No.: M2-0056147-3

Page l

PUMP SPECIFICATIONS

1 CUSTOMER LABROY SHlPBUILDING & ENGRG PTE LTD d HULL NO. @I ~ 1 8 3 / T184 1

ELEC. SUPPLY : 440V/3PH / 60HZ

B JOB NO. 26545fBL DATE 14 October 08

I - S/N SERVICE PUMP TYPE M3IHRxM OTY

1) Fuel Oil Itur RC-2 Horizontal gear 10 X 20 1 Transfer Pump pump with RNalve

Cast Iron Casiog

1 Teco 2.2 kw @ 1764 rpm Coupling CL-130

I 2) . Clean FO Ihu RCJR Horizontal gear 30 X 20 Transfer Pump pump with RNalve

I Cast Iron Casing Teco 11 kw@ 1184 rprn Coupling CL-180

3) Sludge Oij 'Pump ITUR RC-1 Horizontal gear . 2.6 X 30 pump with RNalve Cast Iron Casing Teco 1.1 kw @ 1160 rpm Coupling CL-100

I 4) Bilge 1 Ballast Desmi S70-50-175ND09-1 45. X 30 pump Horizontal self priming pump (ABS Class) Bronze Casing Impeller = 165mm Teco 11 kw @ 3500 rpm

Coupling CL-160

5) Bilge Eductor Bilge Eductor - Bronze Body

Pump pip enaineerina ote i td

3 Rubv Warehouse Com~lex. 8 Kaki Bukit Road 2, h1-23 Sinpanore 417841

SERVICE

GS 1 Fire Extinguishing Pump (ABS Class) Impeller = 235mm

F.W. Hydrophore Plump

S.W. Hydrophore Plump

. .

Liquid Mud pump

Fuel Oil Cargo Pump

Page 2

PUMP TYPE M3/HRxM OTY

Desmi S80-70-275ND09-2 80 X 75 1 Horizontal self priming Bronze casing Tew, 45 kw @ 3500 rpm Coupling CL-200

IturMZ312 Horiz. Cast Iron Casing Teco 3 kw @ 1720 rpm Coupling CL-112

300 litres diaphragm tank

Itur MZ 312 Horiz. 3.5 x 35 Cast Iron Casing Teco 3 kw @ 1720 rpm Coupling CL-112

300 litres diaphragm tank

Mission Magnum 4~3x13 100 x 80 Teco 132 kc @ 3500 & 17 kw @ 1750 rpm Coupling CL-250

Dami Rotan HD201 gear 125 X 75 Cast Iron Casing Pump Teco 50 kw @ 375 rpm Coupling CL-235

PurnpTip engineering pte itd

S/N SERVICE -

11) Drill Water

12) Fresh Water Cargo Pump

13) Raw Watter

(ABS Class)

Emergency Fire pump Impeller = 2 10mm

Cement Compressor. Cooling Pump Impeller = 135mm

Ruby Warehouse Complex. 8 Kald Bukit Road 2, #01-23 Sineanore 417841

PUMP TYPE M31HR x M

Dami NSL100-215D14 125 X 75 Vertifical self priming Brome casing pump Teco 45 kw @ 3500 rprn

Desmi NSL100-215lA14 125X 75 Vatifcal self priming Cast iron casing pump Teco 45 kw @ 3500 rpm

Desmi NSL100-330D02 Monobloc bearing type Verticial non-self priming Bronze casing Teco 15 kw @ 1750 rpm

Dami S70-50-220ND09-1 25 x 68 Horizonal self priming Brom casing Teco 15 kw @ 3500 rpm Coupling CL-160

Desmi S50-32-135/D09 Horizontal self priming Bronze casing Teco 4.6 kw @ 3500 rpm Coupling CL-130

Page 3

m'

1

SERVICE

Hydraulic Power Pack S.W Cooling Pump

K a m Fork I Tow Pin 1 Thruster Cooling Pump

Air-Cond S.W. Cooling Pump Impeller = 275mm

Page 4

PUMP TYPE M31HRxM OTY

DesmiNSL125-265BD16 170 x 28 4: Vertical non self priming Bronze casing Tea ' 25 kw @ 1750 rpm

Itur MZ412 Horizontal self priming Bronze casing Teco 5.5 kw @ 1720 rpm Coupling CL-140

Desmi S125-80-275D09 80 x 30 Horizontal self priming Bronze casing Teco 15 kw @ 1750 rpm Coupling CL-180

INSTRUCTION MANUAL

&

PART LIST

HORIZONTAL GEAR

PumpQuip Singapom Tel : 65-6748 3888 Fax : 65-6748 8858 . -. .

E-mail : [email protected]. sg

INSTRUCTION MANUAL 7

RC, RCV, RCA Series

- Gear Displacement Pumps

I

MIF-2300101-I CONTENTS 3-05-00

1.- GENERAL INFORMATION

1.1. Manual Scope 1.2. Manufacturer's Detalls 1.3. Technical and Post-Sales Servlce

1.3.1. Requesting Assistance 1.3.2. Obtalnlng Replacement Parts

2.- SAFETY

2.1. IdentMcatlon of Safety lnsl?uctlons 22. Quallflcstlons and Tralnlng of Personnel 2.3. Rlsks incurred by fallure to follow the

safely Instructions. Valldlty of Guarantees.

2.4. Compllance with regulations concerning safety at work

2.5. Operational Hazards 2.6. Safety Instructions for maintenance,

inspection and assembly. 2.7. ~rdhlblt lon of unauthorlied modMcations 2.8. Safety Instructions for users and Installers.

3.-TRANSPORTATION AND STORAGE

3.1. Packaging and protection 3.2. Storage l n ~ u c t l o n s 3.3. Transport and Handling

4.- EQUIPMENT DESCRIPTION

4.1. Shaft seal 42. Surge or Bypass valve

5.- INSTALLATION

5.1. Mountlng 5.1.1. Anchoring bolts 51.2. Levelling up

5.2. Alignment 5.2.1 Flexlble coupling 5.2.2 Rlgld coupllng

5.3. Plpework unlons 5.4. Auxlllaryflttlngs

6.- BEFORE STARTING

6.1. Pump testing 62. Elecklc motor tesUng 6.3. Petrol or diesel engine testlng

7.- STARTING AND OPERATING

7.1. Starting the unit 73. Checklng

8.- PREVENTATNE MAINTENANCE

8.1. Monitoring the pumpmotor assembly 8.2. Troubleshooting

9.- RULES FOR ASSEMBLY AND DISASSEMBLY

9.1. Driver 91.1. Rlgld coupling 9.1.2. Flexlble coupllng

9.2. Mechanical seal 9.3. Retainers 9.4. Packlng gland 9.5. Pump

10.- LUBRICATION

10.1. Grease Lubrlcatlon 10.1.1. Changlng Grease 10.12. Grease Type

8 GENERAL INFORMATION

1.1.- Manual Scope The information given in this manual is applicable to the all the pumpscomprising theseries listed in section 4. In the case of doubt the Spanish language version of the manual will be considered authoritative. The manufacturer reserves the right to modify technical details of the equipment.

1.2.- Manufacturer's Details This pump is a product of BOMBAS iTUR, S.A., Co Urteta - Zarautz (Guiprizcoa) Spain.

1.3.- Technical and post-sales service The identification number of the pump must &!i3Y~ be quoted in all orders for replacement parts and when calling for Technical Assistance or Post-Sales Assistance. This number may be found on the pump name plate. 1.3.1 .- Requesting Assistance

When assistanceisrequiredtheusershouldcontac either the nearest Technical Support Departmen or the Client Services ~ e ~ a r t m e n i at Head-Office

1.3.2.- Obtaining Replacement Parts WARNING: Only replacement parts which havt been supplled directly by -BOMBAS ITURn wll have been checked and approved by tht manufacturer.Theinstallation or useof unauthorise~ parts may, under certain circumstances, adverse13 affect the normal running and the safety of thl equipment.The manufacturertakesno responsibilit fo; damage resulting from or as a consequence c the use of non-original parts and accessories. When ordering spare parts please indicate th' following: - PUMP MODEL - IDENTIFICATION NUMBER - TYPE AND REFERENCE NUMBER OF PAR

AS GIVEN IN THE CROSS-SECTIONAL DIE GRAM (PLEASE INDICATE DIAGRAM NUhr BER)

- NUMBER OF PARTS REQUIRED

-SAFETY This instruction manual indicates the basic instru~ tions to be observed during the installation, Nnnir and maintenance of the equipment. It is theref01 essentialthatthe personnel inchargeof the pump re6 the manual before assembling or starting the pum The manual must then always be kept available nei the pump installation.

2.1 .- Identification of Safety Instructions

e

T C I-

2-

19 re id P. ar

In this manual special safety instructions are marked with the following symbols:

Failuretoobservesafetyinst~ctions marked a i t h this symbol may affect personal and installation safety. Failuretoobservesafetyinstructions marked

kith this symbol may entail the riskof electric shock

lwARNlNol -Failureto observesafety instructionsmarked with this symbol may affect the pump mechanism and its normal running.

Markings will be found on the equipment itself in order 1 to:

- Indicate the direction of rotation (arrows) - Permit the identification of auxiliary connections.

These markings must always be respected and must be kept fully legible.

2.2.- Qualifications and Training of Personnel The personnel responsible for the running, maintenance, inspection and assembly of this equipment must be authorised and adequately qualified. The scope of the responsibility and the supervision of personnel must be determined by the plant operator. The plant operator must ensure to his satisfaction ;hat the instruction manual has been understood by all personnel.

2.3.- Risks incurred by failure to follow the safety instructions. Validity of guarantees.

'Bombas ITUR, S.A.' will not accept responsibility for the consequences of any failure to comply with the current health and safety regulations, during the handling, installation or operating of equipment manufactured by it. The operating condiions of the pump may not be altered from those stated at the time of ordering without notifying the manufacturer. The inappropriate use of the pump, its use outside its normal operating conditions and its assembly or disassembly by unqualified personnel can jeopardise the following:

Human life The pump mechanism and its accessories The normal functioning of the pump equipment.

During its period of validity the guarantee offered by 'Bombas ITUR' will be honoured only if the following conditions are met:

-The instructions given in this manual have been followed correctly. -The equipment has not been taken apalt excepl by personnel either authorised by our Technical Support Department or sent directly from oul factory.

2.4.- Compliance with regulations concerning safety at work. National Safety legislation must be observed.

Failure t 0 0 b s e ~ e these rules may place people, tht environment andlor the equipment, at risk It will alsc invalidate any claims for compensation arising.

All safety regulations must be observed. This include! manufacturer's instructions concerning the use o electrical material to be used in conjunction with higl voltage power-supplies.

2.5.- Operational Hazards. Thenormal running ofthe pumpmay entail operation6 risks arising from the following:

-Pumped liquid; its nature, pressure, temperature. - Rotating parts -Type of drive - Inappropriate installation - Overload

2.6.- Safety Instructions for maintenance, inspection and assembly.

It is the responsibility of the plant operator to ensure thatmymaintenance,inspectionorassembIybecarried out by authorised and adequately qualified personnel who must be familiar with theworkto be done and have read this manual thoroughly.

No work may be carried out on the equipment except when it has been withdrawn from service and fully stopped.

If the installation deals with dangerous liquids it mLst be decontaminated prior to any work on the pump.

The individual manuals should be referred to fordetaiis of the maintenance of specific parts of the equipmenl such as the motor.

Once any work on the pump is finished all protection and safety measures must be replaced and put back into operation.

All auxiliary connections must be reconnected anc made ready for operation before the pump is se running.

When the pump is being stalted for the first time thc appropriate instructions should be followed.

The use of gloves is recommended during handling a this eouioment as it contains many small pieces sucl ~ -

as nu&, bolts etc. which could cause minor cuts an1 abrasions to the hands.

The following instructions are intended to avoid opera tional hazards in the use of this equipment:

. . n e oumoed w v cause bums. 0 0 i s ~ t h u s W r h ~ e s W w .

. . It is therefore essent id%

- Tighten all threaded connections fully, both on th pump unit itself and on all the auxiliary connection! using a tightening toque.

-Ensure that the gaskets and seals are correctly fm and are in good condition.

- Control the temperature and flow of any leaks fro1 around the area of the mechanical seal or packir gland. Drain away any such leaks and discharg them in a safe place.

- Take the necessary precautions to avoid dire contact with the pumped liquid wheneverthe pump filled or primed.

- Before taking the pump apart clean out the inside I pouring cleaning fluid in through the inlet pipe al emptying it through the drain outlet.

-Take the necessary precautions to avoid contact wil the pump when it is being used to pump liquids : temperatures higher than N°C.

- Take the necessary precautions to avoid the risk I

explosion if pumping liquids with a high vapol pressure. Do not allow the liquid to become trappc in the pump when it is stopped. Open the suction 1

delivery vaivesorfdavent connection tothe inlet sic of the pump which discharges thefluidinasafe plac

- Ensure that there are no rotating parts which are n protected by the comsponding covers (eg. tl coupling guard)

7 - To avoid the danger of serious accidents do not allow loose clothing to come near the machine and tie back long hair.

- Do not try to free jammed rotating parts manually if the machine is connected to power.

A ~ I safetv rules for the oumD rnotorldrive must be followed,

Incorrect installation could give rise to cracking or fracture of the pump casing and be a hazard to both personnel and the environment. It is therefore essential to:

- Ensure proper venting of the pump before it is pul into operation.

- Check that all the necessary auxiliary circuits are working correctly before starting the pump.

Check that the suction valves are fully opened.

Overload conditions

- Do not exceed the maximum pemlitted values (o temperature, outputpressure, intakepressure, r.p.m. stated in the offer of sale and in the technica specification.

- Do not exceed the maximum load on the inlet o outlet lines.

nn -1 ewi~ment. The customer should therefore take thl -

necessarv stem to avoid this risk.

2.7.- Prohibition of unauthorised modifications

The manufacturer. <<BOMBAS ITURn, must b consulted if the customer wishes to make an modificationstothe pump unit. Forsafety reasons on1 spares and accessories authorised by 4OMBA ITURm may be used. The manufacturerwill accept n responsibility for loss or damage if unauthorised pa0 are used.

2.8.- Safety Instructions for users and installers. The installer must give notice of any safety risi

& e m and not operate the pump until such problen have been resolved. The operator must give notic immediately of any change in, or modification to, tt equipment that may pose a safety risk. Unsa equipment mustbe dismantledandtaken out of senrice.

I.- TRANSPORTATION AND STORAGE

3.1.- Packaging and protection After painting .BOMBAS ITUR>h carries out the following protective measures:

- All openings are plugged with plastic or adhesive stoppers.

, - With the exception of those in stainless steel, all the visible mechanical surfaces are coated with atempo- rary layer of peel off varnish.

-To avoid movement during handling and transportation the equipment is securely packaged. Depending on the customer's requirements the pump may be packed in an open woodencrate, In aclosed wooden box or on a wooden pallet and covered in thermally bonded plastic.

This protection is intended for use during transportation and short-tenn store6 only. The following storage ~ ~

instructions mustbe obterved at all times.

lo 3.2.- Storage Instructions

These instructions are for storage of less than 12 months from date of despatch. In the case of storage for longer periods please request manufacturer's long-term storage instructions.

Before storaoe; -This equipment must be stored in a dry enclosure,

rotected from impacts, sunlight, dust and flooding. WARNING 3- Pumps should not be stacked even when the'

typs of packing allows it. I - Both close coupled and bearing stool pumps A must be stored on the original factory supplied

pallets or in any other way that is stable. -The pump and its auxiliary conduits must be empty

of pumped liquid. - It is advisable to cover unpainted areas with a

protective film (such as vaseline). -Apply oil or liquid rust-proof to the wear ring faces

via the suction flange to avoid them seizing up. - Pumps supplied on a movable base plate (trolley etc) should be secured by use of the brakes or locking mechanism fined - The electric motor and the cables must be disconnected and the terminal box lid closed.

- Electrical panels must be disconnected and placed vertically.

After storaoe: - Remove the temporary protection (part 3.1) and

check the state of all components visually. - If the pump has been stored and out of use for a prolonged period (more than 6 months) it is necessary to:

Change the gland packing (i model uses it). Renew the bearing lubricant. Check the state of the couplings. Check that the installation is level. Check all the auxiliary connections.

- Following a short storage period it will suffice to turn the pump shaft manually to free up the impeller mechanism.

- For the motor and all the other related elements. carry out the steps described in the 'after storage' section of the respective manuals.

3 llowthe steps given in 'startingthe pump' section. If the equipment is going to be left unused for a long period and there is a possiblw of freezing il shouldbe drained mmpletely to avoid any risk oi damage being caused by freezing of the liquid inside.

3.3.- Transport and Handling

The,transport and handling of this equipment must be csrned out using means capable of supporting the load. The weight is usually indicated on the invoice or on the name plate. If it is not and there is a doubt concerning the suitability of the handling equipment, please contact the manufacturer, 'Bombas ITUR'. In order to ease handling, eye-bolts are fitted where necessary to the base plate upon which the pump equipment stands. However, the whole unit should never be lifted by the eyebolts intended for lifting one ol its parts, such as the motor or pump. Do not use the necks and flanges on the pump and plpework nor the

mgs or futings to lift the pump unit. 2 WARNIN If the pump is to be lifted uslng e sling thls must pass under the body of the pump and motor in the case ofunitsmountedon a movable base-plateanc under the houslng in the case of vertical pumps.

M

- EQUIPMENT DESCRIPTION.

RC pumps, RCVpumps (vertical version of RC) and RCA pumps are gear displacement pumps with axial in-line suction and delivery. RC-OOand RC-01 sizes aresupplied in close coupled configuration and are not available in vertical versions.

CLOSE COUPLED

RC (Bare shaR)

RCV (VERTICAL)

RCA series pumps include an internal thermal isolation chamber.

This manual outlines installation In a fixed location.

According to the size and type of pump ordered a number of pieces may be deliberately omitted such that certain parts of this manual will not be applicable to all pumps. These parts may be, for example:

- Retainers, mechanical seal or packing gland. - Roller bearing or friction bearing.

-Type of motor

(7 The pump only has one or other of these systems

/1\ These pumps are only suitable for clean, solid-free liquids.

The sound pressure of these pumps is less than 96 dB(A) at any moment of operation (given that the flow is above the minimum required for each model). The sound power is less than 110 dB(A).

4.1. Shafl seal

Models RC-00 and RC-01 use retainers and all other models use mechanical seals or packing-gland.

4.2. Surge or by-pass valve.

All pumps in this family have an internal surge valve which recirculates the liquid if the delivery pressure exceeds rated pressure. This protects the pump anc installation from excess pressure.

As a rule of thumb this valve should be set to 2 kgtcm' above the pressure stated in the order and should nu be changed by the user. The valve is always locater: next to the pump delivery flange.

A Unauthorised changes to this valve run the risk o excess pressure (which may damage pipework o, pump) andlor destruction of the motor on acwun of the excess load.

A The sefefy valve shouldnot be usedto regulate thc flow or the discharge pressure as this may caust dangerous heating of the liquid.

- INSTALLATION

The design of the pipework, anchoring and other parts of the installation is not the res~onsibilitv of the manufacturer. rrUR offers information&dsuggestionsby way ofguidelines only and cannot assume responsibility for the design, assembly and running of an installation. We recommendthe customerwnsulta specialist in mountings, pipework, wells etc. to complement the information supplied by us and thereby ensure correct running.

5.1.- Mounting

The unit can be mountedon a large foundation. This foundation mustprovide a flat, level surface.

The unit is to be attached to this platform by anchoring bolts designed to avoid vibration caused by operation of the pump.

5.1 .I.- Anchoring bolts

'Bombas ITUR' can supply the anchoring bolts. They are fitted as follows:

Mode of use: - Place the equipment over its base. - Drill holes in the base in the points corresponding

to the anchoring points into which to fn them. - Level up the unit. - Once the equipment is located on its foundation

and the bol tsaref id into the holes, pourcement (do not use quick setting cement) into the holes and allow 48 hours for it to dry.

- Level up again and tighten the bolts.

5.1.2.- Levelling up

A conventional spirit-level may be used to level up the unit. The unit must be levelled UD both lenuthwavs and - crossways.

If it is necessary to level the base plate by using wedges small pieces of cut sheet metal should be used. Bond them with askin of cement to prevent them from deforming when the bolts are tightened.

Once levelling has been completed it is wise to fn a lock-nutto each of the boltssothatthey do not become loose during operation.

Equipment suppliedmounted on a movable base plate must besecured by use of the brakes or the fixing mechanism fitted prior to start up.

In the standard version all RC, RCV and RCA pumps include a flexible coupling except RC-00 and RC-01 sizes (closecoupled) which have a rigid, coupling.

Equipment supplled in the form of a complete motor-pump unit will already have been aligned in the factoty. However, owing to movements that may be caused during transpoltation and mounting tt must be realigned before use.

MI1

I I'

The unit must always be aligned once all parts are assembled and i t is ready for start up.

The correct alignment of the standard ITUR drive coupling consist of ensuring that it is both parallel and concentric by chocking up the motor as necessary.

- Measure the distance between thecoupling endsin four posm'ons 90' apart between the faces of the coupling using a micrometer. All four measurements should be the same (-3mm). The male and female coupling should never be butted up together.

-Take the following measurements:

The maximum recommended tolerances for ITUR couplings, with and without a spacer between the motorand the pump, am a ~ e n inthefollowina table . . . - - (all measurements in mm):

NB Refer to the manual provided if other types ol drive couplings are used.

5.2.2.- Rigid Coupling All units are factory aligned and this alignment is not lost unless the unit is dismantled. If this is the case the following steps should be taken once re- assembled: -Check that all the flange supporting surfaces

betweenthemotorand pumparecleanandsmooth. - Insert the motor shafl into the pump without

forcing it so as to avoid damage to the bearings. - Checkalignment between both shafts turning the

assembly by hand and measure possible misalignment with a comparator.

5.3.- Plpework unlons

Strain on the pump collar can cause misalignment ol the flanges. To reduce strain the flanges must be parallel and concentric. The bolts or studs used to fix the flanges must pass freely through the holes drilled in them. Do notforgetto placeasealorgasket between

rts of the joint. Do notuse thepumpitselfasastrucfuralmembei of the installafion~ The inlet and outlet pipe: should not place anv strain on the pump necks above the 'maxlmum Ilmits. Use indebendenl braces to hold the welght and the strein of the plpework. Pay attention to the direction of flow lnbicated In the diagrams.

) I 4

Diameters of pipes, valves and fittings must be calculated on the basis of friction losses foreseen in the installation design and such that liquid velocity matches its viscosity.

JN It is advisableto use acoarsefilter in the inlet pipe to avoid the pump drawing in lumps of dirt and debris larger than the permitted size. Elbows andsharp cuwes in the pipeworkshould be avoided, as should fittings that produceabruptnarrowingorwidening of the pipe (such as cones, valves etc)

THE OUTLET PIPE should generally be of a greater diameter than the mouth of the pump. A gate-valve should also be fitted to regulate the flow and avoid overloading the motor. This valve can also be used to isolate the pump for maintenance. I if hoses are used in either the inlet or outlet they A must be able to withstand pump pressures and

adequately restrained to prevent their movemenl causing damage or injury.

IF OPERATED AS A FLOODED PUMP the inlet line must be airiight and normally of adiameter greaterthan that of the mouth of the pump. The diffuser cone may be either eccentric or concentric. Fit a gate valve for isolation during maintenance.

theinlet linemust becompletely airtight and rise upward: towards the pump at all points. The diameter of the pipt should no&ly be greater than that of the mouth of the pump. The d i i se r cone used for this configuratior needs to be eccentric with the upper part horizontal Check that under normal working conditions the NPSt (Net Positive Suction Head) is at least 0.5m less thar that provided by the installation. In order to avoid tht pump emptying when stopped (and thus needing to bl re-primed) it is necessary to fh afootvalve at the end o the inlet line or include two elbows in the pipes to forn a siphon making the pump self priming.

IMPORTANTNOTE: It isrewrnmendedthatthelengthof diisor wnes be 7 times the difference between the internal diameten at the cone enlrance and exit

5.4.- Auxlllary flttlngs Except forthe external electrical and pipework connec tionsthe unit is normallvsu~~lied assembled and reap . .. for immediate use. The cooling of the mechanical seal or packing gland Derformed bv the external recirculation of the pumps . . iiquid (Plan PI-1 1). Follow the detailed instructions i the annex to this manual whenever it is necessary I attach the auxiliary fttings used by these devices.

1

/!\~ote that any auxiliary pipework fined is only de- sianed to wiihstand the internal forces aenerated bv

prohibited.

RCA pumps also have an inlet and outlet for heating liquid in the upper part of the casing. The heating chamber includesdrain connections on the underside.

l N LET OUTLET heating

fluid heating

fluid

rain age p lugs

i.- BEFORE STARTING

The pump may bestarted only when allthe mechanical hydraulic and electrical connections listed in Chapter; ! 'INSTALLATION' have been made. To start the puml proceed as follows.

6.1 .-Testing the pump

When starting the pump for the first time or after i

lengthy period of inactivity it is essential to prime it a! follows:

- Disconnect the power from the motor or remove t h ~ batteries.

-Open a vent in the deli~ery pipe before the st01 valve and fit a vent valve.

- Pour liquid into the outlet pipe until it overflows fror the vent.

-Whilst priming the pump turn the pump shaft mar ualiy to free it.

- Close the vent-valve.

Befom,statting the pump allparts of the drive-sha protecbon, such as the drive-shaftguard, mustbe,

hed (screws t&&m@. 6.2.- Testing the electric motor

-When connecting electrical power checkcarefully thi the voltage and current supplied by the mains netwol are the same as the nominal voltage and curre indicated on the motor's name plate.

- Follow the instructions given in the motor manual.

-1 -~tartthemotormomentarilylocheckthedim~k of rotation. This must be the same as that india ed by the arrow marked on the pump casing bracket. I f the direction of rotation is not wrre two phases in the motor terminal box must 1 changed over (if i t is three phase).

6.3.- Testing the diesel or petrol engine Follow the manufacturer's instructions supplied with the motor.

.-STARTING AND RUNNING

7.1.- Starting the pump unit

- Before starting the pump unit go through all the sections of Chapter 6: 'BEFORE START UP'.

- All the valves on the inlet side must be fully opened and the outlet valve partially closed before starting the pump. Once the pump has reached operating speed and all air has been eliminated from the inlet, the pump may be regulated by adjusting the outlet valve.

- If the motor protector cuts out on start up the outlet should be closed a little, thereby further restricting flow, until the motor starts normally.

/i\ ThepumpmustNEVER beoperated with a reduced or zero flow as the recirculating liquid contained in the pump will rapidly overheat leading to the risk of explosion owing to the high pressures that can build up within the casing.

A- Do not operate the pump with the suction or delive~y valves closed.

8.- PREVENTITWE MAINTENANCE. 8.1.-Pump-motor monitoring.

13 7.2.- Checking during running

Durina the first few M e s of oweration:

Pump wsh mechanical seal:

- Check that there is no leakage whatsoever through the mechanical seal. If there is the seal must be checked andlor replaced immediately.

Pump sealed with gland packing:

- If there is no leakage whatsoever immediately loosen the packing gland until it drips slowly.

- If there is excessive leakage leave it to settle for 10 minutes then tighten the gland 116 of a tum and leave to settle for another 5 minutes. Repeat this process until a drip rate of between 20 to 60 drips a minute is obtained.

After several hours omration:

- Check the bearing temperature by placing E thermocouple on the nearest housing. The norma temperature can reach 40° above ambient tempera. ture but must nwex exceed 90%

No Operationdescrlptlon Procedure Frequency Follow up 1 COMPIEIE PUMP OVDI~L~UL Perform checks and 2.3,4. 5, 6, 7. 8

dismantle pump Annually 9.10, 11.12 See manual pt. 9

2 Check for leaks through mechanical seal Vlsual Inspection Weekly 13 3 Check for leaks from retainers Vlsual Inspection Weekly 14 4 Check for leaks from packing gland Vlsual Inspection Weekly 15.16 5 Check for leaks between flanges Vlsual Inspection Monthly 12

6 Check for leaks between Ranges and unions Visual inspection Monthly 12 7 Check bearlng temperature With thermocouple Threemonthly 8. 10

Dismantle housing 8 Check for loss of normal operating characteristics Instrument reading Aaxrrdlng to use Check

installation, 1 9 Check tightness of bolts -anchor bob, motor to base- Manually Six-monthly 18

plate, pump to base-plate, covers to case, housing shlm to houslng, flanges to casing

10 Check gear wear Dismantle caslng Annually Vlsual lnspection

1 I Check wear to shaft and bearlngs Dismantle cover Annually Vlsual lnspection

12 Replace gaskets Manually Each tlme dlsmantled

13 Replace mechanical seal See manual pt. 9.2 On detection of leaks

14 Replace retalneffi See manual p t 9.3 Every 4000 hours 15 Tighten packlng gland Manually When leaks

excessive 16 Replace gland packlng See manual pt 9.4 Every 4000 hours

1 7 Replace rubber pads In coupling See manual pt. 9.1 Annually 18 Check and align wupllng See manual p t 5.2 Slx-monthly

and every time dlsmantled

19 Check surge valve sprlng Manually Blennlally

PROBLEMS I CAUSES REMEDIES I I

2.- lnsufflclent flow

c) Plpework, filter or impeller obstructed d)&r enters via suction pipe. e) Surge valve Incorrectly adjusted.

I a) Suction or dellvery valves badly adjusted.

a)Open hem. b)Change motor connections.

I.- Pump d o w not move liquid.

c) Dismantle and unblock. d)Check pipe is alfflght e) Adjust valve (Technical Senice).

I b) Incorrect rotational speed

a)Valves (suctiorddellvery) closed. b) Incorrect rotational direction.

( c) Pump badly primed.

d) Alr enters via seal system. e) Pipes blocked. f) Gears wom.

a) Open ihe suction valve fully and look for operating polnt using dellvery valve.

b) Measure speed, check voltage of motor power supply.

I ~~ ~

c) Refill pump and plpes, evacuate alr carefully. I

d) Dismantle and check seal. e) Clean out plpes. f) Dlsmantle and replace gears.

I e) Excessive friction In rotating parts (bearings, wear rings).

3.: Excessive absorbed power

I e)~ismantle pump and check assembly andlor wear of all components. I

a) Liquid denslty or viscosity too higher man normal.

b) Motor and pump badly aligned. c) Obstnrction Inside pump or Installation. d) Bearings (.) worn or badly assembled.

a) Reduce design point or change motor.

b)Allgn coupling. c) Dlsmantle and clean. d) Replace or check assembly.

I I

i.- Bearing temperature too high.

a) Replace bearings(.) and retit beatings. Grease if necessary.

4.- Excesshre nolse and vlbratlon

i.- Leakage through mechanical seal or retainer

a)Bearings (.) worn, badly assembled or under-lubricated.

b) Shalt bent or off-centre. c) Gears wom or badly assembled. d) Pipes straining against pump. e) Foundations lack rigldlty or anchor bolts

1wse. f ) Pump motor misalignment g) Pump cavitabng. h) Plpe diameters lnsufiiclent

a) Bearings(.) badly Wed. b)Coupllng badly Wed, wlthoutadequate

spacing between two parts. c) Motor pump mlsallgnment d) Beatings under-lubricated. e) Plpes stralning against pump. f) Pump cavitating.

7.- Bearings or gears wear out rapidly

b)DlsmenUe and replace. c) Replace or re-assembly. d)Check Installation. e) Remake foundation or tighten bolts.

f) Check and clean pumpmotor union.

g) Improve sucuon. Consult manufacturer. h ) M larger plpes if possible.

a) Adjust them In housings. b) Check coupllng.

c) Align ihe mupllng. d)Clean Internal condub. e)Brace plpework an level up unit f) Improve suction. Consult manufacturer.

a) Contact surfaces very worn. b) Mechanical seal spring broken

or has lost eldclty. c) Mechanical seal 0-rings broken, misshapen

or have lost eldclty. d)Seal or retainer Incorrectly flned.

a) Dismantle and replace seal. b) Dlsmanbe and replace seal.

c) Dlsmantle and replace sleebing.

d)Dlsmantle, check and replace If damaged.

(*) Roller or friction beatings

e)Retdner broken or worn.

a)Shan off-centre or bent b) Gears wom. c) Mlsallgnment of pump and motor. d) Plpes strelnlng agalnst pump. e)Presence of solids In llquld.

e) Dismantle and replace retainer.

a) Dlsmantle and replace. b) Replace them. c)Allgn wupllng. d) Brace pipes and level up unit. e) Fit an adequate fllter.


Before beginning to dismantle the pump ensure that:

A- The pump cannot be accidentally started during mamtenance. The motor must be disconnected from power either by removing fuses, unplugging, opening the circuit breaker etc. or by removing the battery power supply.

/j\ - The pump is drained of all liquid and cleaned ovt with an appropriate cleaner if the pumped liquid is hazardous (hot, toxic, inflammable etc).

9.1 .- Drive Coupling

DISMANTLING:

1.- Remove the coupling guard.

2.- Uncouple the pump from the motor (see diagram) Release the motor fixing bolts and remove it along with the male part of the coupling.

3.- If it is necessary to repair the pump release the nuts joining the casing to the cover and the rear foot.

4.- If it is necessary to remove the coupling use a puller. Do not hiithecoupling to remove itasthis may seriously damage the bearings or ball races.

ASSEMBLY:

1 .- Assemble the pump (if it has been dismantled) and tighten the cover fixing bolts.

2.- Coupleup the motortothe pump. Putthe motor in place inserting the male part of the coupling. Put in the bolts but DO NOT tighten them until alignment has been completed.

3.- Align the coupling (see Manual section 5.2.1).

4.- Replace the coupling guard or protection.

9.1.2.- Rlgld coupling.

DISMANTLING:

1 .- Free the pump unit (see section 9.5) leaving onl' the pump and shaft.

2.- Undo the clamp screw.

3.- Remove the motor.

ASSEMBLY:

Follow the same steps as for dismantling but in th reverse order, then align as described In pt. 5.2.2.

- 9.2.- Mechanical seal

ASSEMBLY: -Assemble the fixed Dart of the mechanical seal. -Fit the rotating part of the seal over the bushing 01 shaft taking care not to damage the o-ring.

-Fit the cover tightly. -Tighten the cover holding nuts. -Complete assembly of the pump. DISASSEMBLY: - To dismanUe the pump follow the same steps as for

assembly, but in the reverse order.

The following stepsmustbe observedif the seal is to function correctly: - Extreme care mustbe taken to avoidintroduc.

ingdirtinto thesealduringhandling, especiallj on the contacting surfaces. Do not use an) kind of lubrkan~except clean water. ~ l e & using a cloth of the type used by opticians.

- Take care not to damage the rings during assembly.

- Do not turn the mechanical seal whilst dry. 9.3.- Retainers.

DISMANTLING: The pump must be completely dismantled to extra( them (See pt. 9.5, subsection RCOO and RGO1 clos coupled pumps). Remove the circlip holding the retainers to the cash( Do not use a sharp edged tool to remove them fror their housing as this may damage them. ASSEMBLY: Always f i the retainers with the lip towards the insid of the pump.

1.4.- Packing gland

DISASSEMBLY:

1.- Release the gland. 2.- Remove thegland packing. If the lantem ring is alsc removed note its order in the assembly.

ASSEMBLY

1.-Cut the new gland packing to make as many ring: as are necessary. Viewed from above the cuts ma! be straight or at an angle of 45' (see diagram).

2.-It is agood idea to leave a little free play (around O.! mm) in the when cutting the packing.

3.-Fit the rings one at a time, pushing them dowl gently as far as they will go. The rings should b~ introduced wlth the cut placed 90°from that of t h ~ preceding ring.

4.-Take care to replace the lantern ring in its origina place.

)I-!

5.- Once the new packing has been inserted check that the shaft tums freely without any stiff spots.

6.- It should not be possible to screw the gland infully, insert more rings if necessary to prevent this.

7.- Gently tighten the gland nut. 8.- Todeterminethenecessarypacl6ngtightnessfollow

the instructions given in section 7.2 of this Manual.

I UPPER VIEW I

5.- Pump It is necessary to dismantle the pump almost completely in order to take out the shaft, bearings, bushes (shaft bushing) etc. Make use of the necessary diagrams, parts lists and the list of recommended spares. The following steps give a general guide to dismantling the pump: close-cou~led~.wnps (RGOO and RC-01);

- Undo and remove the pump cover along with th safety valve.

- Remove the gears. -Undo and removethe pump Casing along with th

retainers. (See manual pt. 9.3 for details). - Remove rigid coupling (See pt. 9.1.2).

R C a n d R C V ~ u m u ~ l e d vcx&tx - For RCV pumps, undo the motor and remove

with its part of thecoupling. Undo and remove th pump lantern housing. Take off the coupling ant the auxiliary pipes.

- For RC pumps remove the coupling guard and the1 the coupling and auxiliary pipes as described in pl 9.1.1

-Remove the cover on the motor side to reveal t h ~ mechanical seal. See pt. 9.2. for details of sef dismantling.

- Remove the cover on the opposite side to th shaft. The roller bearings (in RC-1. R C l M an RC2models)orfriction bearingsinothermodel! will be visible . Then:

- In smaller models remove the ball bearing: - In order to remove the roller bearings it is fir!

necessary to undo and remove the linesha bearings they contain.

16 - Remove the gears. -Take off the pump casing.

RCA Dumos;

- Remove the coupling guard and then the coupling itself as described in pt. 9.1.1 .Also remove all auxiliary pipes.

- Undo and remove the packing gland. See pt. 9.3.

- Remove the covers starting on the far side from the shaft..

- Undo the prisoners andthe protective deflectors or washers on both sides.

Undo the bearing holding screws on the driver side along with the bearing cir clips on the other - side.

- Strike theshafts gently with aplastic hammer on the far side from the coupling.

- Remove the lineshaft bearings thereby freeing the pump case and gears.

ASSEMBLY.

To assemble the pump follow the above instructions in the reverse order.

Be sure to put eaccof the parts back in the right place, especially the seal and impeller components. 7ighten the impeller nuts fully.

0.- LUBRICATION

RC and RCV series pumps are Vied with either friction or roller bearings which are lubricated by the liquid itself making it unnecessary to take any additional steps unless problems arise.

The models which are fitted with friction bearings are:

RGOO. RC-01, RC-1, RC-1%. RG2

RCV-1. RCV-1% RCV-2

The models using roller bearings are:

RCPR, RC2RD, RC9R, RC-4R

The models comprising the RCA series use external grease lubrication.

Before lubricating the pump ensure that

- The pump is stopped and there is no risk of its accidentally starting.

- The bearing housing temperature is less than 40°C so that there is no risk of bums to the hands. Uses thermowuple to measure tlts temperature.

10.1.- Greasing (RCA only)

The pump leaves the factory with the bearings ready greased for the first 1000 hours (approx.) operation.

For lubrication purposes a table has been included. Quantities shown are grams of grease to be applied to the greasing points approximately every 4000 hours of operation for pumps of the given shaft diameters (measured on the coupling side). 1 ; 1 GREASE I

QUANTITY (gr)

10.1.1.- Changing the grease. When changing the grease the bearings must first be stripped down and their seats in the base thoroughly cleaned to remove all traces of the old grease.

10.1 2.- Grease type. Use consistency2 lithium grease with anti-oxidising additives. DIN-51 502 class K2K.

I1 .- APPENDIX.

- Pump.cross-section

- Special instructions for electric, diesel and petrol moton

- Special instructions for coupling

- Supplementary diagram of mechanical seal

- Supplementarydiagrarn of pumpcooling/therrnal isolating system

Types R G I , RC-1 M and R G 2 Sect.No MIF-2300/00/01

- Ref. - 101 210.1 210.2 320 322 360.' 383 400: 412 420 422 433 452' 461 484 504 507 545 562 636 730 750 751 752 753 755 756 757 670.1 870.: 900 901 902 903 91 1 920 921 932 940 (.= 1

R = S (1) pi

Part name Pump casing Drlve shaft Lay shaft Bearing Roller bearing Cover Lineshaft bearing Gaskets O-ring Retainer Fell ring Mechanical seal Packlng gland Gland pacldng Washer Bearing retainer flange Deflector Friction bearing Guide pin Greaser Connector Protecting cap Valve body Valve seat (1) Valve seal Valve tightening sleeve Spring Valve tensor Driving gear Following gear Eyebolt screw Screw Threaded stud Threaded plug Filler plug Valve holding nut Bearing holding nut Cir-clio Key : 3. ... ) . . , res r m m e n d e d for2 years 3 RG1 112 does not have.

Types RCOO and RCOl Sect.No MIF-2300/00/02

nuvy wamuuube Lomplex. 8 Kala Bukit Road 2, #01-23 Singapore 417841

7 Tel : 654748 3888 Fax : 656748 8858 E-mall pddp?~. : lee@purn~q~ip.W

IS GST Reg No.: M2-0056147-3

SPARE PARTS LIST FOR ITUR RC - 2 / RCV-2

POSITION NO. REFERS TO SPARE PARTS DRAWlNG NO. C - 722

Singapore 417841 Tel : 856748 3888 F a : 656748 8858 Lm-mail: [email protected]

19 GST Reg No.: M2-0056147-3

SPARE PARTS LIST FOR ITUR RC-2 / RCV-2

POSITIDN NO. REFERS TO SPARE PARTS DRAWlNG NO. C - 722

'OS, NC

1 2 3 5 6

6 A 7 8 9 10

11 12

12 A 13 15

16 18 19 20 21

22 23

' 24 25 26 27

:over for bearing bush ShafI , driven 3et screw Sear casing Sear, driven

Sear, driving Sunk key Sasket 3earing bush :over, mech seal side

Mechanical seal Vlechanical seal cover Sasket set screw ShafI, driving

sunk key llalve seat ilahre spring fake stem 3asket

3egulator Zap Uut h i d e pin Nasher 3earing bush

QTY

1 1 8 1 1

1 2 2 3 1

1 1 1 2 1

1 1. 1 1 1

1 1 4 4 1 1

8 Kaki Buldt Road 2, $01-23 Singapore 417841 Tel : 656748 3888

. . Fax : 6567488858 E-mail: [email protected] W GST Reg No.: M7.4056147-3

L I ~ SPARE PARTS LIST FOR ITUR RC-3 R

POSITION NO. REFERS TO SPARE PARTS DRAWING NO. C - 753

' I I l l I I'l I 8 n 4 6 A S 16 9 a I0

8 Kaki Bukit Road 2, h l -23 Singapore 417841 Tel : 65-6748 3888 ' -

. . Fk: 656748 8858, . . . Email: [email protected]

GST Reg No.: M2-0056147-3

SPARE PARTS LIST FOR lTUR RC-3 R

POSITION NO. REFERS TO SPARE PARTS DRAWING NO. C - 753

Sunk key Shaff , driving Hook Gasket Mechanical seal ~ o c k nut

Washer Nut Bolt Gasket, cover Plug Washer.

Cap Valve spring Regulating screw ear , driving Gear, driven Bypass valve

Gear driving key Bolt Nut Pipe C/W ming End cover Washer

Ball bearing Bearing housing . mech seal side Bearing housing. end side Pump casing Gasket, main Sealing gland

shaft, driven Mechanical seal cover Male connector

QTY

1 1 1 1 1 1

16 16 16 2 1 1

1 1 1 1 1 1

2 8 8 1 1 4

4 1 1 1 2 4

1 1 1

D RLU~~ noaa L, x u - ~ j Singapore 417841 Tel : 65-6748 3888 - . Fax : 85-6748 8858,

%= E-mail: pumpquip@singnetcomsg GST Reg No.: M2-0056147-3

.-.-,I 5TUR SPARE PARTS LIST-. ITUR RC- I ( MECHANICAL SEAL ) INTRODUCED WORLD WIDE

r? Item Nos. refer to spare parts drawing No. C-747 in

RC-1 / R C V - 1

~ - --. . . . . - B Kaid Bukit Road 2. MI-23 Singapore 417841 Tel : 656748 3888 ? F a : 65-6748 8858 Brnail: [email protected]

23 GST Reg No.: M2-0056147-3

- --. . . . . - B Kaid Bukit Road 2. MI-23 Singapore 417841 Tel : 656748 3888 F a : 65-6748 8858 &mail: [email protected]

23 GST Reg No.: M2-0056147-3

SPARE PARTS LIST FOR ITUR R C - 1 / RCV-1

PosITION'NO. REFERS TO SPARE PARTS DRAWING NO. - . . C - 747

CODE DESCRIPTION

Gasket Valve spring Retum valve Gasket Sunk key

Shaft, driving Mechanical seal Pump casing- Guide pin Gasket

Bearing bush Bearing bush Cover for bearing bush Plug Gasket

Gear, driven Gear, driving Shaff , driven

Plug

Set screw Suide pin set screw 'resure regulator

:ap Vlechanical seal cover

Page 1

QTY

1 1 1 1 1

1 1 1 2 1

3 1 1 1 1

1 1 1

1

4 2 4 1

1 1

4 X 016 HOLES --- 20

- 350 -

Date 13 OCT 08 Dm By NYAN Dim Unit MM Scale 1 : 6

Drg No R 200124

Motor 2.2 KW/ 1764 RPM Power/Supply 440V/ 30/ 60Hz Full Load Current Frome Size D lOOL hsulation Item NO

IP 55 1

Rient LABROY SHlPBUllDlNG & ENGR PTE LTD lull 182/183/184/185 ; e ~ c e FUEL OIL TRANSFER PUMP

PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2, #01-23 Slngapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump ITUR RC-2 Horizontal Gear Pump c/w Relief Valve Capacity l o M3/HR Total Head 20 M Matl CI Casing. HT St h r , C St Shofl. Mech Seal C0uphg CL - 130 I NPSH(Reg) Weiqht 100 KG I

SUCTION 8 DISCHARGE


D, .~ NO R 3001 13

Motor 11 KW / 1184 RPM Power/Supply 440V/ 3 0 1 60Hz Full Load Current Frorne Size 0 160 L Insulation Class F / IP 55 Item No 2

Client LABROY SHlPBUllDlNG dr ENGR PTE LTD Hull 182/183/1 8411 85 Senice CLEAN FO TRANSFER PUMP

PumpQuip Engineering Pte Ltd 8 ~ a k i ~ u k i t ~ o a d 2. #01-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump ITUR RC-3R HORlZ GEAR PUMP Capacity 30 MJ/HR Head 20 M Motl CI Casinq, HT St Gears, C St Shaft, Mech Seal Cou~lins CL - 160 I NPSH(Req) Weight 300 KG

I 3"X 1 4 2 " C CHANNEL I

I ! I I I1

Client LABROY SHIPBUILDING & ENGR PTE LTD Hull . 182/183/184/185 Service SLUGE OIL PUMP . .

PumpQuip Engineering Pte Ltd 8 Kaki Buklt Rood 2. #01-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump ITUR RC-1 Horizontal Gear Pump Capacity 2.6 M3/HR Total Head 30 M Matl a Casing, HT St Gaar, C St Shaft Mech Seal Couplinq CL - 100 I NPSH(Req) Weiqht 45 KG

Motor 1.1 KW / 1160 RPM Power/Supply 440V/ 3 6 1 60Hz Full Load Current Frame Size D SOL Insulation Item No 3.

'lass 1 IP 55

Date 13 OCT 08 Drn By NYAN Dim Unit MM. Scale 1 : 6

Drg No R 100136

1. lntroduction 2. Design 3. lnstalllng

.-. ............... 4. Piping _ 5. Starting 6. Linlng-up 7. Fault-flndlng

@

I Ruby Warehouw Complex. : 8 Kakl Bukn Road 2. W1-23 Slngapom417841

Te l658748388~Fu 6587488858

%DeSmithsk I Desmi Modular S TAGHOLM I D K W NBRRESUNDBY TELEXBBB~O DENMARK ELEFAX PHONE ~ ~ 8 1 7 8 1 1 1 ~ 4 5 8 1 7 5 4 ~ lNSTALWTlON lNSTRUCTlONS

r R

c 4 Desmi Modular S PHONE + 6 8 l 7 8 i 11

n m B g 8 2 0 TELEFPJ(+6817H8I

INSTALLATION INSTRUCTIONS

For security reasons the pump is only allowed to operate against a closed discharge valve for a short time (ma. 5-10 minutes and at a max. temperature of 1300 C). Otherwise there is a risk of damage to the pump and at worst, of asteam explosion. If the pump room is unmanned, the installation of a safety device is highly recommended.

1. Introduction It Is vltally Important to Install the pump correctly in order to achleve the ultimate performance and long Ilfe. Correct lnstallatlon deoends on comoivino wlth . , - the following points:-

2. Design DESMl MODULAR S is a single-stage self-prlmlng, centrifugal pump wlth stainless steel shaft and mechanlcal shafl seal. The small pumps, sizes 532.25 110, 550-32-135, and S50-32-220, have open Impellers, all other sizes have closed impellers.

The pump Is sultable for clean or polluted liqulds wlth temperatures ranging from O0 to 60°C.

The pump has horizontal Inlet on the centre llne and vertical outlet at the top.

The back of the Impeller Is equipped wlth relief blades In order to reduce the axlal load on the bearlngs at . high revolutlons and pressure.

Relief holes in the Impeller ensure circulation of lip uids for the shafl sealand prevent, under normal cori. dltlons, overheatlng of the shaft seal.

The Dumos are oartlcuiarlv suitable for the oumolno of water in connection wlth coollng systems; cool in^ of dlesel englnes. Irrlgatlon, water lowering, and flre protection, as baliast and biige pumps, and-as pumps for fish farms, water works, salvage contractors, ar; mles, and navles.

The pump should be Installed on a base plate with a fiat surface to avold dlstortlon. The centre llne of the shaft Is to be horlzontal.

Bore H7 Is recommended If the pump is to be fltted wlth a V-belt pulley, to facilitate the fitting, the hub can be heatedto~aboutlOOO~;..~ . . ~ ~ ~~- ~~ . ~. .. .

The V-belt oullev can then easllv be slid onto the shaft towards the shoulder. ~lternatfvely, a belt pulley wlth a taper lock bush can be fltted.

When selecting the V-belt pulley, It is lmportant to observe the lnstructlons glven in the DESMl nomograms for the pump size In questlon. If In doubt, ask DESMl to advise.

If the pump Is to be drlven by a motor through a fiexl- ble coupling, pump and motor should be mounted on a common base piate. Please note the followlng:

1. Avold dlstortlon In the base plate. 2; Avold dlstortlon In the piping. 3. Make sure that pump and motor are correctly

allgned.

I "mm I

I I n o . r ahows dllonmsnt by use of steel rvlsr and Ullckness pauge. no. 2 show8 dllgnment uslno a dlnl oau~e. me dl8tancs between the coupllq halves should be 2 l o 4 mm.

no. 2

4. Plplng The suctlon hose should be fltted very carefully as -) even thy leaks may lmpalr the self-prlmlng. Water- tightness may be checked by a pressure test.

The suctlon hose should be as short as posslble. When selectlng make sure that the veloclty of the water does not exceed 2 mhec. Use a stralner when PumDlno oolluted Iloulds. The stralner must be fltted with asieve wlth a'sectlonal area of flow of 3 x the area of the stralner. Mesh slze - see data sheet for pump In questlon.

The pressure hose should be sized for a velocity of water not exceeding 5 to 6 mlsec. In order to ensure bleeding of the pump durlng prlmlng It is essential that the pressure h e Is made so that traps in the pipework'are avolded. During prlmlng the pump cannot produce enough pressure to overcome traps.

The plplng should be arranged so that posslble stresses resuitlng from~fluctuatlons In temperature are not applied to the pump.

Tools for Dismantling and Assembllng of Pump

5. Startlng

5.1 Llquld Filllng

A self-prlmlng pump must flrst be fllled with llquid. Llquld fllllng takes place at the top of the pump caslng. Remove the plug, flll the pump, replace the plug, and the pump Is ready for use.

The liquid also serves as coolant for the shaft seal.

5.2 Start-up Before start-up do the following:

1. Check that the shaft can rotate freely. 2. Check that the pump caslng Is fllled with water. 3. Start the pump for a moment to check the direc-

tlon of rotation. If the dlrectlon Is correct (clockwise when viewed from shaft end) the pump may be started.

6. Lining-up It i s often dlfflcult to calculate the manometrlc dellvery head In advance. It Is, however, declslvely lmportant for the quantlty of llquld dellvered.

3 I A considerably smaller dellvery head than expected .will increase the quantlty of llquld dellvered, causlng Increased power consumption, motor overload, and perhaps cavltatlon In the pump and the piping. The Impeller may show slgns of heavy eroslon caused by cavltatlon (corroslon), whlch may at tlmes render an impeller unfit for use In a very short tlme. Not unusually do slrnllar eroslons occur in pipe bends and valves elsewhere In the plplng system.

Therefore, it Is necessary to check either the quantlty of llquld dellvered or the Dower consum~tion of the pump, e.g. by measuring v'oltage and curient level on the motor. Together wlth a readlng of the counter pressure a determinatlon of the ouantltv of water de- ilvered can be compared agalnsi the characterlstlcs of the pump.

Should the pump not functlon as Intended, please proceed accordlng to the followlng fault-flndlng list. Bear In mind. thouoh. that the ourno was carefullv checked and testedit'our factoG and that the malo;- Ity of faults stem from the plplng system.

I . . . . . . .

2 Wrong dlrectlon of rotatlon Dlreotlon of rotallon Is changed to clockwlss when vlewed from shall end

7. Pump andlor plpework wmngly as 8 . . I dlmenaloned . . 1 - . . . '

3. ~lpework choked 4. Pump choked 5. Suctlm llne-IeakslPump takes

slrlstralner not submerged 8. Suct l~n llll too hlgh

m e pump uses too much Power

Ie cleaned or replaced me pump le cleaned Leakage Is found! fault repalred

Check data shad WH CUNB and NPSH or contact DESMl

me pump does not prlme Is not Illled wlth Flll pump caslng wlth llquld I

1. R.p.m. too hlgh

2 Countergre&ure too low

3. me llquld Is heavier than water

4. Forelgn body In pump

5. Pump and eleotrlc motor not llned up

8. EIwcBIc motor larunnlng on 2 phase8

.Leaking non.retum llsp in pump

Wrong dlmctlon of rotstlon

Blgger Vdelt pulley on pumplChenge r.p.m. of electrlc mobr Insen non-retum or check valvelCDntact DESMl Contact DESMl

me pump is dlemantled, the forelpn body Is removed Pump and motor are llned up. DESMl coupllng max radlal thmw 02 mm Check fuses, cable connectlone, and cable

. AIr 11) drawn In becauae of too llnle llquld or lesklng suction line

Forelgn body In non.retum flap la remmedlAny cdatlng on matlng lacas la removed Dlmalon of mtetlon Is changed to ClOCkW188 when vlewed fmm shall end

I 7. All cannot e8cape on preseure Ventilate the Bystem I .Ids

me pump capaclty Is unetable

me pump makes nolse

2 Pocket8 Of d r In auctlon llne

3. me pump takes alr

Normally, they dlaappear In a short t h e Uquld rssawolr emphl/Sustlon llns not lvfflclently submerged. (check)

Ruby Warehouse Complex.

m 8 Kaki Bukit Road 2. m1-23 Singapore 417841 Tel : 656748 3888 Fax : 656748 8858 Ernail: [email protected] GST Reg No.: h12-00.56147-3

N E W VERSION . . SPARE PART LIST- I I

Item Nos. refer to spare parts drawing No. : 41 96 70

. * 33 Ruby Warehouse Complex. 8 Kald Bulat Road 2. MI-23 Singapore 417841 Tel : 656748 3888 Fax: 556748 8858

7 E - d : [email protected] GST Reg No.: M2-0056147-3 . h

SPARE PART LIST - ' S ' MODULAR SERIES

Item Nos. refer to spare parts drawing No. 40 1761 A

SPARE PART LIST - S70 - 50 - [tern Nos. refer to spare parts drawing No.- 41 96 70

- tern No. - 1 2 3 4 5= 5

6 7 8 9 10 10 11 12

13 14 15 16 17 18

19 20 21 22 23 24

25 27 28 29

75 76

Part No. Description

'ump casing, RG5 :rew Plug 114" BSP :rew Plug 112" BSP Near ring v mpeller . 165

\lut M I 6 Spring lock M 16 Joint M 16 Sunk key 6 x 6 x 32 Wech shaft seal Wech shaft seal Nater deflector Lock washer

Ball bearing Shhoo"Ia~i~rina ~ss.; Ball bearing- Sunk key 8 x 7 ~ 3 2 Shaft Bearing housing

Allen screw MC 8 x 20 Cover, RG5 Gasket Allen screw MC 8 x 20 Inlet DN 70, RG5 Screw MC 8 x 18, AIS1316

Non return flap Sealing washer Sealing washer 0-Ring

Plug, 112" F. Safely valve Safely valve 114". 10 Bar

JAN 2mB

UK%4BA?FmndZ~?e,

shI.@%AGK*q ww--- -nllmBI1 'r.I:-(B m

PUhPQUIE' ENGRG FTE LTD ax OWRW sss :-Plow

SPARE PART LIST - S80-70-2751 DO9

kern Nos. refer to spare parts drawing No. 40 17 61 A - tern No. - 1 2 3 4 5= 5- 5

6 7 8 9 10 10 11 12

13 14 15 16 17 18

19 20 21 22 23 24

25 27 28


Pump casing, RG5 Screw plug 114" BSP Screw plug 314" BSP Wear ring

Impeller, 235

Nut M 16 Spring lock M 16 Joint M I6 Sunk key 6 x 6 x 32 Mech shaft seal Mech shaft seal Water deflector Lock washer

Ball bearing Shoulder ring SS - 30 Ball bearing Sunk key 8 x 7 x 25 Shaft Bearing housing

Allen screw MC 8 x 20 Cover, RG5 Gasket Allen screw MC 8 x 20 Suction piece, RG5 Allen screw MC 10 x 25

Non return flap .Sealing washer Sealing washer

Ruby Warehouse Complex. '' 8 K d 5 ByldtRoad 2. MI-23 Singapore 'a7841 .Tel : 65-7483888 (5 Lines) Fax: 65-7488858 (2 Lines) E-M@,+dw : [email protected] GST Reg No.: MUX)56147-3

SPARE PART LIST - S7O-50-220 DO9

item Nos. refer to spare parts drawing No. 40 17 61 A pa?

tern - No. - 1 2 3 4 5

6 7 8 9 10 11 12

13 14 15 16 17 18

19 20 21 22 23 24

25 27 28


Pump casing Screw plug 114" BSP Screw plug 112" BSP Wear ring Impeller, 220

Nut M I 6 Spring lock M 16 Joint M 16 Sunk key 6 x 6 ~ 32 Mech shaft seal Water deflector Lock washer

Ball bearing Shwlder ring SS - 30 Ball. bearing -

Sunk key 8 x 7 ~ 2 5 Shaft Bearing housing

Allen screw MC 8 x 20 Cover Gasket Allen screw 8 x 20 Suction piece Allen screw MC 10 x 25

Non. return flap Sealing washer Sealing washer

Pump casing , complete Bearing housing, complete

Ruby Warehouse Complw: . . ~ 3iL 8 Kaki Bukit Road 2.. # 02-16 Singap'ore 417841 ' ' - '

Tel : 656743 3888, . . Faa : 656748 88%~

e n g i n e e r i n g p t e itd E-man address: ~e=@~ur&~~p.wm.sg _ ^ -.-. . _ , ,, . . . . . L.- .... .-;. . . . .ST P?cLN!!!Q-O0561473.. .,

SPARE PART LIST - 8125-80-275NI D O 9 A ~ ~ , &

Item Nos. refer to spare parts drawing No. 41 96 70 - Item No.

1 2 3 4 5 -5- J-

6 7 8 9 10

11 12

13 14 15 16 17 18

19 20 21 22 23 24

25 27 28 29 29 75 76

28A 9999

Part No. I Qty Description

Pump casing Screw plug 114" ESP Screw plug 314" BSP Wear ring . Impeller, 275

Nut M 20 Spring lock M 20 Joint M 20 Sunk key l o x 8 x 56 Mech shaft seal. Crane

Water deflector, U 40 Lock washer

Ball bearing Shoulder ring 40150 x 2.5 Ball bearing Sunk key l o x 8 x 56 Shaft Bearing housing

Allen screw MC 12 x 25 Cover Gasket Allen screw MC 12 x 25 Suction piece DN 125 Allen screw MC 10 x 25

Non return flap Sealing washer Sealing washer ' 0 ' Ring, 228mm ' 0' Ring, 355 mm Plug 112" for safety vlv Safety v/v , 18 bar 112" Sealing ring Plug , RG112"

page 13A

Ruby Warehouse Complex. 3 5 8 Kaki Bukit Road 2. #01-23

Singapore 417841 Tel :656748 3888 ' . Fa: 656748 8856 Email: [email protected] GST Reg No.: M2-0056147-3

. .-

SPARE PART LIST - S50-32-135- D O 9

Item Nos. refer to spare parts drawing No. 41 08 22 A

3 9 Ruby Warehouse Complex. 8 Kaki Bukit Road 2. #01-23

SPARE PART LIST - S50-32-135 D O 9

Item Nos. refer to spare parts drawing No. 41 08 22 A - Item - No. - 1 3 5 10 11

14 15 16 17 18

21 22 23 24 25

28 30 31


Pump casing Screw plug 112" BSP Impeller Mechanical seal Water deflector

Shoulder ring 25 135 x 2 Ball bearing Sunk key 6 x 6 x20 Shalt Bearing housing

Gasket Allen screw MC 6 x 16 Suction piece Allen screw MC 6 x 16 Non return flap

S.6i~ii"g~waShei ~.

Lock washer 1-62 Oil seal

Pump casing , complete Bearing housing , complete

Page 1

L 4 " X 2' C CHANNEL I

125 4

4 X 018 HOLES 4 X 018 HOLES

DELIVERY SUCTION

SCALE 1:10

4 X 016 HOLES - 450

Xent LABROY SHIPBUILDING & ENGR PTE LTD Pump OESMI S70-50-175N / D09-1 Motor 11 KW/ 3500 RPM Date 21 AUG 08 lull 182/183/184/185 Capacity 45 M3/HR Power/Supply 440V/ 301 60Hz Dm By NYAN iervice BILGE/BALLEST PUMP Head 30 M Full Load Current Dim Unit MM

PurnpQuip Engineering Pte Ltd Matl 8R Cashg, A h Br Imp, St St Shaft, Mech Seal Frame Size 0 160 M Scale 1 : 8 8 Kaki Buklt Road 2, #01-23 Singopore 417841 Couplinq CL-160 I NPSH(Req) Insulation Tel : (65) 6748 3888 Fax : (65) 6748 8858 Weight 2101KG I Impeller Dia MM Item No

'lass / IP Drg No D 0221 17 4.

I CCHANNEL I I I

470 I

- - 470 I 1 150

4 1240

SUCTION 080 DIN -

8x018

DELIVERY 07ODIN SCALE 1:10

4 X 018

DIN FLANGE PN 16

DIN FLANGE PN 16


Drg No D 032138

Motor 45KW/ 3500 RPM Power/Supply 440V/ 30/ 60Hz Full Load Current Frame Size D 225 MA Insulation Item No

/ IP 55 6

:lid LABROY SHIPBUILDkG dr ENGR PTE LTD lull 182/183/184/185 Service G.S/FIRE MTlNWSHlNG PUMP

PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2, #01-23 Singapore 417841 Tel : (65) 6748 3888 FOX : (65) 6748 8858

Pump DESMl S 80-70-275 / D09-2 Capacity 80 MJ/HR Head 75 M Matl Br Casinq, Al Br Imp, St St Shaft, Mech Seal Cou~lina CL-200 I NPSH(Rea) Weiaht 443 KG lmaeller Dia MM

q I, 4" X 2' C CHENNEL I 1 I I I

4 X 018 HOLES 7 4 X 018 HOLES

Date 22 AUG 08 Dm By NYAN Dim Unit MM Scale 1 : 10

Drg No D 021 044

Motor 15KW/ 3500 RPM Power/Supply 440V/ 301 60Hz Full Load Current Frame Size D 160M Insulation Item No

Class I IP 14

I ient LABROY SHIPBUILDING & ENGR PTE LTD iul l 182/183/184/185 jervice EMERGENCY RRE PUMP

PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2, #01-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump DESMl S 70-50-220N / 009 Capacity 25 M3/HR Head 68 M Matl Br Casing, Al Br Imp, St St Shaft, Mech Seal Coupling CL-160 I NPSH(Req) Weiqht 230 KG I Impeller Dia MM

Date 25 AUG 08 Drn By NYAN Dim Unit mm Scale 1 : 5

Drg No D 022111

Motor 4.6 KW/ 3500 RPM Power/Supply 440V/30/60 Hz Full Load Current Frame Size D 112M Insulation Class F / IP 55 Item No 1.

l i ed LABROY SHIPBUILDING & ENGR PTE LlD lull 182/183/184/185 enice CEMENT COMPRESSOR COWNG PUMP 'umpQuip Engineering Pte Ltd

Kakl aukit Road 2, #01-23 Singapore 417841 el : (65) 6748 3888 Fax : (65) 6748 8858

P u m ~ DESMl S 50-32-135 / DO9 Capacity 15 M3/HR Head 30 M Matl Br Cusinq, Al Br Imp, St St Shaft, Mech Seal Couplinq CL-130 I NPSH(Req) Weiaht Aporox. 80 ka I

I I I L 4"XZ"

C CHANNEL 12W -

SUCTION DELNERY

8 018 HOLES 8x018 HOLES

DIN FLANGE DIN FLANGE

PN 16 PN 16

lient LABROY SHIPBLD & ENGR PTE LTD. uII 182/183/184/185 e ~ c e AIR COND C W N G PUMP umpQuip Engineering Pte Ltd Kaki Bukit Road 2, @I-23 Singapore 417841

31 : (65) 6748 3888 Fax : (65) 6748 8858

lient LABROY SHIPBLD & ENGR PTE LTD. uII 182/183/184/185 m,ipn AIR m n rnrr IN^: PIMP ", .."" ,.,,. ..",.., , "",,

umpQuip Engineering Pte Ltd Kaki Bukit Road 2, @I-23 Singapore 417841

31 : (65) 6748 3888 Fax : (65) 6748 8858

Pump DESMl S 125-80-275N/ DO9 Capacity 80 M3/H Total Head 30 M Matl Br Casing, Al Br Imp, St St Shaft, Mech Seal Couplinq CL - 180 I NPSH (Red Weiaht 317 ka

I Pump DESMl S 125-80-275N/ DO9 I Capacity 80 M3/H i T-LA U--A ,A , .

IYLU! ncuu 3U M

Matl Br Casing, Al Br Imp, St St Shaft, Mech Seal Couplinq CL - 180 I NPSH (Red 1 Weiaht 317 ka I

Motor 15 KW/1750 RPM Powef/Supplv 440 V/30/60 Hz Full Load Current Frame Size D 160 L Insulation Class F / IP 55 Item No 4

Date 13 OCT 08 D m By NYAN Dim Unit mm Scale 1 : 13

Drg No D 032172

I Motor 15 KW/1750 RPM I Powef/Supplv 440 V/30/60 Hz 1 L,II I A-A rllrran4

1 Date 13 OCT 08 I D m By NYAN I n I I ,,

I Frame Size D 160 L I Insulation Class F / IP 55 I&-- LI- 1

- Scale 1 : 13

Drg No D 032172

Pumqip onmlnmarinn pta Itd

ELLEHAMMERS

BRONZE EJECTOR

PUMPQUIP ENGINEERING SINGAPORE Tel : 65-6748 3888 Fax: 65-6748 8858

DELIVERY __b

WEIGHT1 3.1 KGS

--

ELtElHAMMERS WORATORIVM A/S Eibp .Indmkm . I r k - _ - DK-2600 Glostrup

Ihrp. N.

T-10-147T

FROM BILGE

F R O M PUMP DISCHARGE 447

2" BSP

-+ ISCHARGE

Date 04 SEP 08 Drn By NYAN Dim Unit MM Scale 1 : 3

~ r g NO 2550501231 1.5

Orhg Woter Consumption 15 MShR O h k g Water Prermre 4 BAR Speed NA Frame Size N A Insulation N A Item 5

Client LABROY SHIPBUILDING & ENGR PTE LTO Hull 182/183/184/185 Service BILGE EJECTOR - .

PumpQuip Engineering Pte Ltd 8 Kaki Bukit Rood.2, #Ol-23 Singapore 417841 Tel : (65) 6748 3888 Fox : (65) 6748 8858

Pump UHAMMERS WE 25-50-50 F / 2311.5 Capacity 5 MS/HR Head 15 M Mat1 ALL BRONZE Discharge Head M Suction Head 5 M

INSTRUCTTONS MANUAL & PARTLIST

FOR

ITUR FRESH / SEA WATER

HII)ROPHORE SYSTEM

Mu& : MZ 311 /lM2 312 M Z 512

HORIZONTAL SELF PRIMING

CENTRIFUGAL

PUMP

P~mPENGINEERlNGSINGAPORE TEL : 65-67483888 FAX : 65-67488858

E-mail : enquirv@pumpquipwrnsg

INSTRUCTION MANUAL

N-EZ, MZ, MA Series

Multistage liquid ring pumps


1.1. Manual Smpe 1 2 Manufacturer% Detalls 1.3. Technical and Post-Sales Servlce

1.3.1. Requesting k k t a n c e 1.32 Obtalnlng Replacement Parts

2- SAFETY

21. ldentlficstlon of Safely Instrudons 22 Quallficatlons and Training of Personnel 23. R k k Incurred by faflure to follow (he - .. .. . . . .- - . . . . . -. - - - , - sareq~~na~am.vamIly~fouaranties:--' 24. Compliance wlth regulations mncernlng -

safety at work 25. Operational Hazards 26. Safely InstruMlons for maintenance,

lnspedlon end assembly. 27. PmhlblUon of unauthorlsed modlficatfons 28. Safely lnstrucilons for users and Installers.

3.- TRANSPORTATION AND STORAGE

3.1. Packaging and protection 3 2 Storage lnstructlons 3.3. Transport and Handling

4.- EQUIPMENT DESCRlPTlON

5.- INSTALLATION

5.1. MounUng 5.1.1. Anchoring bolk 5.12 Levelling up

5 2 Allgnmant 521. Rlgld Coupllng 5.22 Flexible mupllng 5.23. Drlve vla pulleys

5.3. Pipework unlons 5.4. Auxlllery fittfngs

6.- BEFORE STARTING

6.1. Pump testlng 6 2 Eledrlc motor tm lng 6.3. Pebol or dlesel englne testlng

7.- STARTING AND OPERATING

7.1. Starling 73. Self-prlmlng opwratlon

0.- PREVENTATIVE MAINTENANCE


9.1. Drlver ' 9.1.1. Flexlble mupllng

9.12 Rlgld mupling 9 2 Mechanlcal seal 9.3. Packlng gland 9.4. Pump

10.- LUBRICATION

10.1. Grease Lubrlcatlon 10.1.1.. Chenglng Grease 10.12 Grease Type

11.- APPENDIX

12- CROSS-SECTIONAL DIAGRAMS

1 .- GENERAL INFORMATION 1.1.- Manualscope

The information given in this manual is applicable to the all the pumps comprising the series listed in section 4. In the case of doubtthe Spanish language version of the manual will be considered authoritative. The manufacturer reserves the right to modiiy technical details of the equipment.

1.2.- Manufacturer's Details . . . *. ..

This pump is a product of ' .' .. . . . . . ,, S.A:&OMBAS iTUR-, C.*Urteta-Zarautz(Guip0zcoa) Spain.

1.3.- Technical and post-sales service The identification number o f t h e p u m p m u s t ~ b e quoted in all orders for replacement parts and when calling for Technical Assistance or Post-Sales Assistance. This number may be found on the pump name plate. 1.3.1.- Requesting Assistance

When assistance is required the user should contact either the nearest Technical Support Depart- ment or the Client Services Department at Head- Office.

. 1.3.2.- Obtainlng Replacement Parts WARNING: Only replacement parts which have been supplied directly by *BOMBAS ITUR- will have been checked and approved by the manufacturer. The lnstallation:or useofunauthorisedparts may, under certain circumstances, adversely affect the normal running and the safety of the equipment. The manufacturer takes no responsi. bilay for damageresuiting from or as a.conse. quence ofthe use of non-original parts and acces. sories.

When-orderingSpar~pa~pleas~.indicate-th~ following: - PUMP MODEL - IDENTIFICATION NUMBER - TYPE ANDREFERENCE NUMBER OF PAR]

AS GIVENIN THE CROSSSECTIONAL DIA, GRAM (PLEASE INDICATE DIAGRAM NUM BER)

- NUMBER OF PARTS REQUIRED

!.- SAFETY

This instructlon manual Indicates the basic lnstruc tions to be observed during the installation, runnin; and maintenance of the equipment. It is therefor1 essentialthatthe personnel in chargeofthe pumpreal the manual before assembling or starting the pump The manual must then always be kept avallabie nea the pump installation.

2.1.- ldentiflcatlon of Safety lnstructions In this manual special safety instructions are markel with the following symbols:

~ai lure to observe safety instructlon

al and instaliation safety.

-Failure to observe safety instructlon . marked wi th thksym~rnay,enWSh~ 0s of electric shock.

-1 -Failure to observe safety instructlon marked with this symbol may affect th pump rnechanlsm and its normal runnln~

9 Markings will be found onthe equipment itself in order to: - Indicate the direction of rotation (arrows) - Permit the identitication of auxiliary connections. These markings must always be respected and must be kept fully legible.

2.2.- Qualifications and Tralning of Personnel

The personnel responsible for the running, maintenance, inspection and assembly of this equipment must be authorised and adequately qualified. The scope of the responsibility and the supervision of personnel must be determined by the plant operator. The plant operatormustensureto hissatisfactionthat the instruction manual has been understood by all personnel.

2.3.- Rlsks incurred by failure to follow the safety Instructions. Validity of guarantees. 'Bombas ITUR - . . S.A.' will not accept responsibility for the consequences of any failure to comply with the current health and safety regulations, duringthehandling, installation oroperating of equipment manufactured by it. The operating conditions of the pump may not be aitered from those stated at the time of ordering without notifying the manufacturer. The inappropriate use of the pump, its use outside Its normal operating conditions and its assembly or disassembly by unqualiiied personnel canjeopardise the following:

Human life The pump mechanism and its accessories The normal functioning of the pump equipment.

-during.itsperio~of-~alid'rty~thg9uarantee~off~rd.by 'Bombas ITUR'will be honoured only if the following conditions aremet:

i-:-The.4nstructions:give.n inthi'smmal:have beer followed correctly.

. The equipment has not been taken apart excepl by personnel either authorised by ourTechnica Support Department or sent directly from ou! factory.

2.4.- Compliance wlth regulatlons concerning safetl at work. National Safety legislation must be observed. Failure to observe these rules may place people, tht environment andlorthe equipment, at rlsk. It will alsc invalidate any claims for compensation arising.

Ail safety regulations mustbe observed. This include! manufacturer's Instructions concerning the use o

, electrical material to beused In conjunction with hlgl vokage power-supplies.

2.5.- Operational Hazards. The norrnal runnlng ofthe pumpmay entail operation al rlsks arising from the foilowlng:

- Pumped liquid: Bs nature, pressure, tempera ture ...

- Rotating parts - . --Type of 'drive

- Inappropriate Installation . -- Overload

GI

2.6.- Safety Instructions for malntenance, inspection and assembly. It is the responsibiirty of the plant operator to ensure that any maintenance, inspection or assembly be carried out by authorised and adequately qualified personnel who must be familiar with the work to be done and have read this manual thoroughly. No workmay be carried out on the equipment eicept when it has been withdrawn from service and fully stopped. Once any work on the pump is finished all protection and safety measures must be replaced and put back into operation. Refer to individual manualsfor maintenance of palls of the unit, such as the motor. All manufacturer's safety instructions must be followed, All auxiliary connections must be reconnected and made ready for operation before the pump is set running. When the pump is being started for the first time the appropriate instructions should be followed. The use of gloves is recommendeddurlng handling ol this equipment as it contains many small pieces such as nuts, bolts etc. which could cause minor cuts and abrasions to the hands. The following instructions are intended to avoid operational hazards in the use of thls equipment: A l The oum0ed liouid mav cause burns, ooisonino 01 other tvoes of iniurv. It is therefore essential to;

-Tighten all threaded connections fully, both on the pump unit itself and on all the auxiliary connections, using a tightening torque.

- Ensurethatthe gaskets andsealsarecorrectlyfittec and are in good condition.

.- - ;Mon%orthe-temperatureandtiow of-any leaksfrorr around the area of the mechanical seal or packlng gland. Drain away any such leaks and discharge

em in a safe place. .-.&ke the necessary precautions to avold direc

antact with the pumped liquid whenever the puny is filled or primed.

- Beforetaking the pump apart clean outthe inside b) pouring cleaning fluid in through the Inlet pipe anc emptying it through the drain outlet The clean in^ fluidused must nut be capableof producing danger. ous conditions inside the pump. Consult manufac. turer.

- ~ a k e the necessary precautions to avoid contac with the pump when it is being used to pump liquid: at temperatures higher than 409C.

' - Take the necessary precautions to avoid the risk o explosion. if pumping liquids with a high vapou pressure. Do not allow the llquld to become lrappec In the pump when R Is stopped. Open the suction o dellvery valves or llt a vent connection to the lnle sideofthe pumpwhichdischargesthefluidin asaft place.

BI For rotatlno a - Ensurethatthere are no rotating parts which are no

protected by the corresponding covers (eg. thc coupllng guard)

-To avold the danger of serlous accldents do no allow loose clothing to come near the machine anc tie back long halr.

fl - Do nottry to free jammed rotating parts manually if the machine is connected to power.

C ) The pump may still be under pressure when stopped. Before dismantling release the pressure by opening the drains (or vents) leading to a safe place. If the pump is connected to lengthy pipes knocking may occur when the pump is stopped; fit appropriate measures to avoid this.

D) An inaoorooriate lnsrallation mav cause breakaae of the untandconseauent hazardsforoersonnelandl orthe environment. It is therefore necessarv to;

- Ensure proper venting of the pump before it is put into operation.

- Check that all the necessary auxiliary circuits are working correctly before starting the pump.

- Check that the suction valves are fully opened. El Overload conditions

- Do not exceed the maximum permitted values (of temperature, output pressure, intake pressure, r.p.m.)statedintheofferof saleandinthetechnical speciflcation.

- Do not exceed the maximum load on the Inlet or outlet lines.

-The pump should be used only in the specified conditions and with the specified liquid as stated in the offerlorder.

FI Unexoected Interruption of the drive can be hazardous on account of the soontaneous startina of D e Dumo eouioment. The customer shouldrherefore take the necessarv steos to avoid th:s risk.

G1 When the CONTROI SYSTFM is supplied by a manufacturer other than ITUR it is the customets responsibillytoensurethatthe mmpiete unit, including tk~ontrPL?ysYemsy~.mplik5~ith~af~~yYstan.da~ds..

2.7.- Prohlbltlon of unauthorlsed modifications

The manufacturer, -BOMBAS ITUR-, must be consulted if the customer wishes to make any modifications to the pump unit. For safety reasons only sparesandaccessorles authorisedby *BOMBAS ITUR" may be used.The manufacturer will accept no responsibilityfor loss ordamage if unauthorised parts are used.

2.8.- Safety lnstructlons for users and installers.

The installer must give notice of any safety risks presentandnot operate the pump unlilsuchproblems have been resolved. The operator must give notice immediately of any change in, or modiiication to, the equipmentthat may pose a safety risk. Unsafe equipment must be dismantled and taken out of service.

.- TRANSPORTATION AND STORAGE

3.1.- Packaging and protection

Aner painting -BOMBAS ITUR- carries out the following protective measures:

-A l l openings are plugged with plastic or adhesive stoppers.

- Wahthe exceptlon ofthose in stainlesssteel, allthe visible mechanical suriaces are coated with a tem- .pxary layerof peel olf varnlsh.

- To avoid movement durlng handllng and transpor- tatlon the equipment is securely packaged. Depending on the customer's requirements the pump may be packed in an open wooden crate, in

Mode of use:

- Place the equipment over its base.

- Drill holes inthe base inthepointscorresponding to the anchoring points into which to fit them.

- Level up the unit. ...-. _: . - Oncethe equipment is located on its foundation

and the bolts are Vied into the holes, pour cement (do not use quick setting cement) into the holes and allow 48 hours for fi to dry.

- Level up again and tighten the bolts.

.1.2.- Levelllng up

Aconventional spirit-level may be usedto level upthe unit. The unit must be levelled up both lengthways and . crossways.

If it is necessary to level the base plate by using wedges small shims of cut sheet metal should be used. Bond them with askin of cementto preventthem from deforming when the bolts are tightened.

Once levelling has been completed it iswiseto weldto each of the nuts to its corresponding bolt so that it cannot become loose during operation.

Units suppliedmountedon a movable baseplate mustbe securedby use of the brakes octhe fixing mechanism f&dprior to start up.

-

5.2.- ~ i l gnment

- ~,~~iii~aerivereedun'ri-co-~pn Tsz5- ac-om~-~tepumi.-

mQlor assembly itwill havealready been aligned inthe factory. However, it should berealiclnedbefore use as i t .mihave lost alignment during transit or mounting.

2:; , ., .. . ... WARNING. :;The unit must always bealignedafiermounting i

and preparation for startlng.

Correct alignment of the coupling consists of correct- ing any devlation from parallel or concentricity.

N-EZ pumps are fined with a rigid coupling made up of a sleeve joined to each of the shafts by means of cotters and stud boks. Unless it Is defective or the strain exerted by the pipes Is excessive there is no need to realign it.

5.2.2. ~ lex lb le coupllng

This type of coupiing is used for MZ and MA type pumps.

Proceed as follows to checkto alignment of the rubber pads tined in the ITUR standard coupllng.

- Use a calibre to measure the dlstance between tht .....- coupling faces at four pdints 909 dpait. Ttie-dlstanct should be the same at each measuring point (- : mm). The male part s h o u l d ~ b u t up egalnsttht female.

- Take the foilowlng measurements.

h

The maximum recommended tolerances for ITUR couplinss With and without spacer. are indicated in thc

NOTE: for other types ofcouplihgs refer to the manual suppliec

5.2.3. Drive vla pulleys

If the pump is driven by pulleystake care to ensure thatthe) do not place roo much strain on the shafts.

5.3.- Plpework unions

Strain onthe pumpcollarcancausemisalignmentofthe flanges. To reduce strain the flanges must be parallel andconcentrlc. p he bonsorstuds usedto fixthe flanges . . . - . - - . - -. . . -. - -. - -. - . - - . - - . . - .. . . - . - . . - - - must pass freely through the holes drilled in them. Do not foiget to a seal or gasket between the parts of the joint.

-1 DonotusethepumpitseMasastrudoralmembe~ of the installation. The inlet and outlet pipes should not place any strain on the pump necks above the maximum limits. Use independeni braces to hold the welght and the strain of th6 pipework Pay attention to the direction of flow indated In the diagrams.

The diameters of the pipes, valves and accessories must be calculated on the basis of the frictlon losses plannedforthe installation such that theflpw rates are:

-velocity in outlet pipe: 2 to 3 mlsec

-velocity in inlet pipe: 1 to 2 rnlsec.

IN It is advisable to use a large coarse filter in the inlet pipe to avoldthe pump drawing in dirt In new Installations, given that some impurities takeatimetodetach it isadvisable tofii arelativelyfine filter in the 1nlet.Thetransverse sectionofthisfilter musl be greater than or equal to three times the transverse .section of the Inlet pipe so that it does not produce excessive frictlon losses. Avoid sharp elbows orfHtlng$ that DrOdUce sudden narrowlno orwldenlno of the aloe$ . , (cones, valves etc.). When &e pump dyaws from E vacuumvessel His agood ldeatofkavacuumcompen. sation tube of 25 mm mlnirnurn diameter between the pump and the tank (at a point hlgher than the hlghes posslble liquid level).

THE DELIVERY PIPFshould generally be of a greater diameter than the mouth of the pump. A gate-valve should also be fitted to regulate the flow and avoid overloading the rnotor. The use of a check-valve is not recommended as it makes self-priming diiicuk. If one is used, it should have the lowest possible opening pressure.

1 If hoses are fined they must be firmly fastened A before the pump is started and during running so as to avoid the risk of whiplashes caused by the pressure generated by the pump.

ATFD AS A FLOODED PUMP the inlet line must be airtight and normally of adiametergreaterthan I IF OPFR that of the mouth of the pump. The diffuser cone may be either eccentric or concentric. Fit a gate valve for isolatlon during maintenance.

IFOPERATEDASANFGATIVFSUCTIONI IFTPUMP the inlet line musi be completely airtight and rise upwards towards the pump at all points. The diameter of the pipe should normally be greater than that of the mouth of the DumD. The diiuser cone used for this

I configuration need; to be eccentric with the upper part horizontal. Checkthat under nom~alworklng conditions I the NPSH (Net Pos~lve Suction Headl Is at least OSm less than ;hat provided by the instaliation. As these pumps are self-drawing there is no need to fa a foot valve in the inlet line.

I The pipe-used to fill the self-primer must be short A so that the time taken to prime the pump is not greater than 4 minutes with water at room temperature. Foriiquids at higher temperatures or with higher vapourpressure this time limit must be reduced. Consult manufacturer.

5.4.- Auxiliary fittings

for immediate use: . -..Thamollngiof themechanicalsealor.~acking:giand Is

perlormed by the recirculation of thepumped liquid. - Follow. the detailed instructlons~in the annex to-this

manual whenever it Is necessary to attach the auxiliary fittings used by these devices. A Note that any auxiliary pipework fmed is only

desgnedto wrthstandtheintemdforcesgenewted by the circulating liquid. Therefore subJecting it to additlonal forces, for example by leanlng on it. is pmhibited.

1 6.- BEFORE STARTING

The pumpmay be started only when allthe mechanlcal, hydraulic and electrical connections listed In Chapter; 5'1NSTALLATION'have been made. Tostartthe pump proceed as follows.

6.1.- Testlng the pump

When starting the pump for the first time or after a lengthy perlod of inactivity it Is essentlalto prlme it. The procedure depends on pump type: - Disconnectthepowerfromthe rnotor orremove the

batteries. - Remove the vent plugs in the inlet and outlet

connections. - Pourllqlild into the hole In the inlef pip6 i 3 i l - A

overflows from the other. - Whllst prlmlng the pump turn the pump shaft

manually to free k. - Replace the plugs.

6 MI

N Priming should be checked each time the pump is started.

Before staning the pump alparts of the drive- shaftprotection, such as the drive-shaff guard, must be in dace and firmlv attached /screws tlohtened).

6.2.- Testlng the electric motor

Whenconnecting electricalpowercheckcarefully that the voltageandcurrentsuppfledbythemainsnetwork are the same as the nominal voltage and current indicated on the motor's name plate.

-1 Start the motor momentarily to check the direction of rotation. This must be the same as that indicated by the arrow marked on the pump casing or bracket. If the direction of rotation is notconect two phases in the motor terminal box must be changed over (if it is three phase).

6.3.- Checking petrol or diesel englne

Follow the manufacturer's instructions supplied with the englne.

STARTING AND RUNNING

7.1.- Startlng the pump unit

- Before starting the pump unit go through all the sections of Chapter 6: 'BEFORE STARTING'.

-Allthevalvesonthe inletside mustbefully openedand the outlet valve partially closed before stalting the pump. Once the pump has reached its operating speed and all air has been eliminated fromthe inlet, the pump may be regulated by adjusting the outlet valve.

- Ifthe motor protector cuts out on start-u~the outlet -. . . . . .. -. - - - .- - - - - - - - -- . . should be-closed a little, thereby further restricting flow;until the motor starts normally.

I .'--The pump m & 2 'NEVER ..be aperated with a reduced , zero flow .as the reclrculathg liquid

. . ~. containedln theoum~wiiI~~idlrioverheatleadinq to the riskofex&o&n owlnfitoihe highpressor& that can build up within the casing.

7.2.- Checklng durlng running

Pump with mechanical seal:

-Checkthatthereis~oleakaoewhatsoeve~throughthe mechanical seal. Ifthere is the seal must be checked andlor replaced immediately.

Pump with packing gland:

-If there Is no leakage at all loosen the packing gland until it drips slowly.

-If leakage is excessive leave itto settle forten minutes thentlghtenthepacklng gland li6turn and leave itfor another 5 minutes. Repeat untilthe dr1p.rate isaround 20 to 60 drlps a minute.

After several hours o ~ e r w

- Check the bearing temperature by placing a l~enocouple on the. ne.arethouslng,T_he nor@ temperature can reach 40Q above ambient temperature but must I~~YBL exceed 9OQC.


8.1.- P u m p m o t o r unlt rnonitorlng 5 s -

No Operation Description Procedure Frequency Follow-up

1 PUMP ovERnnuL Perform check 2.3, 4.5.6.8. dismantle pump 9. 10. 11. 12. 13.14 See manual ot 9

7 1 Check for grease asks Usual lnspecoon Monmly 11. 16. 17

8 Check for loss of normal operating chaacteristics lnsbument reading Acmrding to use Check iwtallation. 1

9 Check tightness of holding bolts, flanges, pump to base. Manually WeekJy 19 mver to housing, base to mver, supplement to housing. flanges to casing.

10 Check wear oh impeller and rings Dismantle housing Annually Usual Inspedon

11 Check wear to shaft and bearings Dismantle housing Annually Usual inspection

12 Grease housing See manual p t 10 See manual p t 10

13 Changebeadng ,... grease See manual p t 10 Evely two years (a)

14 Replace gaskets b u a l t y Each time dismantled

15 Replace mechanical sed See manual p t 9.2 On detecting leaks

16 lighten packing gland Manually When leaks bemme exCe55ive

17 Replace gland packing See manual p t 9.3 Annually

18 ~~!ace~lubber.pads.in the muplmg lb). ~eemanual p t 9.1 .. ~ ~ Annually . .

19 check and align mupling (b) See manual p t 5.2. Weeldy and each time dismantled

...* <,, . L) Ifthe environment is dusfy, damp or hostile, shorten (he lime beween grease changes

8.2- Troubleshoollng.

I.- Pump does not a) Valves (inlet or outlet) dosed. move llquld bl lnmrrect rotational direction.

cj Air enters via Inlet line. d) Mar head generated is lers than required for me Installation.

!.- lnsunident flow a) Valves (suction or delivery) badly adjusled. or pressure

b) lnmrrect rotational speed.

C) Impeller dearanca excessbe

I d) a r enters seal. 13) Obsbuction In plpes. I O ImDeller obsbucled or worn.

g) G a r rings worn OUL

h) Ea& pressure loo hlgh.

REMEDIES

a) Open valves b) change motor mnnecdons c) Check Inlet line is airlight d) Increase the mtationalsoeed. linot possible ifl a larger impeller or a blgger pump. Consult manufacturer.

a) Open me suction valve mmpletely and find the operating point by regulating me odetvaive

b) Measure the speed, check the voltage on the motor supply.

c) Check mldvless of gasket and mounting

d) Dismantle seal and examine It e) clean out pipes; 0 Dkmantle Impeller and Inspect iL g) Dismantle and replaw. h) Increase rotational speed. If not poslble it is necsssary lo fit a larger Impellerlpump. Consult manufamrer.

OPERATING PROBLEM

emperalum excessive

.- Excessive absorbed lower

.- Excessive nolse and vibration

6.- Loss ot liquld lhrough rnechanlcal seal

CAUSE I Bearings badly assembled.

I Coupling badly assembled, insufficient >ace between the two parts.

I Misalignment of pump and motor.

) Under lubrication of bsarings.

) Pipes staining against the pump.

Excess lubricant in bearings.

) Liquid unusually dense or vismus.

) Misalignment between pump and motor.

) Obsbuction to mouths or impeller inside pump.

I) The head produced by the pump is less ian designed lor, hen& flow and Nressure are hlgher.

I) Exoessive speed

) Bearings worn or inmrredy assembled.

1) Excessive friction betweenmoving Pans.

i) Bearings worn, inmrrecw assembled 01

badly lubricated.

,)impellers rubbing

:) shan bent or off-mnp.

j) impellers imbalanmd or wom.

3) Pipes strainingaginst pump.

O'Base not rigidoranchoring bolls loose.

3) Pump and motor misaligned.

REMEDIES a) Adjust in situ.

b) Check mupiing

c) Align the coupling.

d) Lubricate bearings.

e) Bram the pipes and level up the unit.

f) Remove grease from the bearings. Clean the bearings with soivent and regrease iL

a) Modify design characteristics.

b) Align the coupling

c) Dismantle and dean out pump.

d) Partially dose the outlet W e .

e) Regulate speed

f) Change them or checkassembly.

g) Dismantle the pump and check the mrrectassembiy of all its mmponenk.

a) Change bearings, remount them, Lubricate if necessary.

b) Checkassembly.

c) Dismantle and replam. . . .. . . ...~. . .. ... .. . .. . . . .

d) Balanceor replamlmpellers.

e)-Bramlhepipes andlevelupthe unit

f)'Remakebase ar;tighm boiS.

g) Realign the mupiing.

a) DimanUe and replaceseal.

b) Dismantle and replam seal.

c) Dismantle and replam seal.

d) Dismantle and replam sleeve.

e) Dismantle, check seal and rephm it damages

a) Bad wear on seal mntact surfaces.

b) Mechanical seal spring has broken or lost elastidty.

c) Mechanical seal wings broken. misshapen or have lost elasticity.

d) Replamable bushing smred or worn.

e) Seal InmrrecUy assembled.

I.- RULES FOR ASSEMBLY AND DISASSEMBLY

Before dismantling the unit ensure that:

The yotorcannotbeac~identallystarted. Discon- nect lt from mains power (eg remove the fuses, unplug it, disconnect the circuit breaker etc.) or remove thebatterie~ordisconnecthydraulicpower (disconnect from driver).

1 Thepumpis empty 01pumpedliqu;dandhas been A thorouohly cleaned inside il the DUmDed liouid is hazardo& (hot, polluting, inflammable 8tc.j

9.1.- Driver.

9.1.1.- Flexlble coupling

DISMANTLING:

1 .-Wihdraw the coupling guard.

2.-Detach the pump from the motor as follows:

2.1.- COUPLING WITHOUT SPACER. Undo the bolts holding the pump and withdraw It with the male part of the coupling.

2.2.- COUPLING WlTH SPACER. Undo the coupling holding screws and remove the spacer.

3.-If the motor needs to be repaired undo the nuts holding itonto the base plate.

i(

4.- Use apulierifitis necessaryto undothecoupling. Never strike it to extract it as this may seriously damage the bearings.

ASSEMBLY:

1 .-Mount the motor (if it has been dismounted) anc tighten the holding screws.

2.-Couple up the pump as indicated: .,.

2 1.- Couplmg WITHOUTSPACER. Mountthe motor inserting the male d art ofthe couolina. Fdths bolts b a do not thhten until alignment has

t. been completed.

2.2.-COUPLING WlTH SPACER. FR the male oart ol the coupling insertingtheteeth between rub. ber pads in on the female Dart. Fitthe sciacel and~xituslngthescrews onthe plate aildths male part of the coupling.

3.- Align the coupling (see manual part 5.2.)

4.-Replace the coupling guard. 9.1.2. Rlgld coupllng

In order to dismantle the rigid cou~llnp undo ths captive stud andthe screws holding ihe componenl to be dismantled (motor or pump) to the base ant pull to remove it.

9.2.- Mechanical seal.

In orderto galn access to the mechanical seal it Is firs necessary to dismantle the coupling once the pump is separatedfromthe houslng or baseplate. The mechan. ical seal cover Is lmmedlatelv accessible In N-E2 pumps.Forothertypes (MZ, ~ ~ j t h e bearlng houslng(s: need to be dismantled.

In order1o.dismantlafhehousing onthe driver side (MZ MApumps) it lssutflclemto undo the screws ortles ant withdraw Ii, The houslng on the skle away from thc drlver (MA) may be dismantled by removlngthe bearlnc cover and releaslngtheshaitnut beforewhhdrawlngthc houslng.

Once the seal cover is accessible undo its screws anc remove it. The mechanical seal will now be visible. The flxed sullace is anached to the cover and the rnovini pan sits in its nousing, from which it may easily be removed.

To assemble it follow the above steps in reverse order

The following steps must befollowed iftheseal istoworl properly.

- Take extreme care to ensure cleanliness during thc handling of mechanical seal parts, especially thc contact surfaces. Do not use any lubricant excep cleanwater andcloths of thetype usedby opticians

- Takecare nottodamagethe o-ringsduring assembly

- Do not turn the mechanical seal when dry

9.3.- Packing gland

DISASSEMBLY:

- Release the gland.

- Remove the gland packing. If the lantern ring is also removed note its order in the assembly.

ASSEMBLY

- Cut the new gland packing to make as many rings as are necessary. Viewed from above the cuts may be straight or at an angle of 4 9 (see diagram).

- It is agood ideato leave a l i l e free play (around 0.5 mm) in the when cutting the packing.

- Fitthe rings oneatatime, pushing themdowngently as far asthev will ao. The rinas should be introduced withthe ~ut~~acedgo~frornthat ofthe preceding ring.

- Take care to replace the lantern ring in its original place.

- Once the new packing has been inserted check thal the shaft turns freely without any st i i spots.

- It should not be possible to screw the gland In fully, insert more rings if necessary to prevent this.

- Gently tighten the gland nut.

- Todetermine the necessary packing tightnessfollou the instructions given In section 7.2 of this Manual.

In order to dismantle the pump make use of the crosssectional diagram and parls lists attached.

The following steps aregive ageneralguidetodisman- tling the pump (pumps types to which the instructions refer are indicated):

1.- Remove the coupling guard (if fied)followed bythe coupling, as described in pt. 9 (N-EZ. MZ, MA).

2.- Separate the pump from its mountings and pipes. Once empty move itto where work isto becarriedout (N-EZ, MZ, MA).

3.- Write a number on each stage and mark, in the direction of turn of the shaft, the relative adjustment (N-EZ, MZ, MA).

4.- Undo the auxiliiary circuits. (N-EZ. MZ, MA).

5.- Undo the bearing cover on the side away from the motor and undo the shaft tightening nut (i fied). (MA).

6.- Removethenuts/hoklingscrewsonthepumpbearing housing(s) (MZ, MA).

7.- Remove the mechanical seai(s) or gland packing. (N-R, MZ, MA).

8.- Undo the nuts on the ties and remove them in the orderofthestages(wnhtheir respect:vebearlngsand impellers) starting on the suction side. (N-EZ. MZ,

To assemble, starl with the delivery casing and follow the above steps in reverse order taking the following precautions:

- Ffithestagesandcasings inthe same orderandlnthe same relative positlons as they had prior to dismantling.

- Clean the contact area underthe gasketsthoroughly.

- Checkthe adjustment between impellers and stages. Excessive clearancewill cause adrop in performance.

-1 During assembly take care to ensure that a1 parts are in the right place, especially the seals and Impellers.

D.- LUBRICATION.

Before lubricating the pump ensure that:

- The pump is fully stopped and may not bc started accidentally.

- The temperature ofthe bearlng housings is lest than 40QC. so as not to risk causing burns to thi hands. Check the temperature with ; thermocouple.

The elements upon which the shaft turns arediieren in each pump:

- N-EZ. Roller bearlng in pump and ball race In motor

- MZ. Roller bearing and a ball race in pump.

. - MARoller bearlng and two ball races In pump.

The roller bearings are lubricate by the pumped llqul~ and the ball races by grease, via their correspondln~ . . ball greasers.

10.1.- Grease Lubrlcatlon

The pump leaves tne factory wilh sufficient grease in the bearings for approximately 1000 hours running.

For oreasina Dumoses a table of grease cluantitles (grabs) to 69 applied at eacn greasing ~ o i n t every 2000 hours running (approx.)forpumps ofg:ven shaft diameter (on the coupling side), has been 'ncl~ded.

1 MODEL I 1 GREASE (grs)

. 5,s

10.1.1 .- Changing the grease

Before carrying out a complete grease cnange it is first necessary totake the bearingsapad andclean theseatstho~ouohlvto remove alltracesof the old " . grease.

10.1.2.- Grease type

We recommend the use of lnhium based grease with antioxidant addklves, of consistency 2 and matching DIN-51 502 class K2K.

1.- APPENDIX

- Pump cross-section

- Speclal Instructions for the electric motor

no.

- Special inslructlons forthe driver

-Supplementary diagram of the seal system

- Supplementary diagram of the cooling~heating system,

Ruby Warehouse Comple*. 8 Kaki Bukit Road 2. #01-a Singapore 417841 Tel : 656748 3888 Fm: 6567488858 E-mail: pumpqup@singnuwresg GST Reg No.: M2.6056147-3

B

a SPARE PARTS LIST FOR 1TU.R

lTUR MZ - 31 INTRODUCED WORLD W E

,li POSITION NO. REFERS TO SPARE PARTS DRAWING NO. C - 0156

: pumpvip 7'3 engineer ing p te l t d

Rubv Warehouse Carnalex

r l SPARE PARTS LIST FOR ITUR M 2- 31 12

i 6 POSITION NO. REFERS TO SPARE PARTS DRAWING NO. C - 0156

CODE POS. NO DESCRIPTION QTY

1 Tie bolt 4 Nvt Plug Sealing ring Flange gasket Companion flange

Bolt Nvt Delivery casing side stage Stage gasket

Suction casing bearing bush Impeller key Suction casing Suction casing stage wver Impeller IXMZID 18 Stage wver

Delivery casing bearing bush - . Dd~very casmg Bolt Nut Set screw

Bearing bracket Ball bearing Bearing end wver Bearing sleeve Coupling key

Pump shaft Lock nut Washer Coupling half, female Grease nipple

Middle bearing bush Intermediate stage Mechanical seal . td rnm Seal wver Gasket Water deflector

TO DIAPHRAGM TANK

RESSURE GUAGE

032 JIS 10K FLANGE

Date 21 AUG 08 Drn By NYAN Dim Unit MM Scale 1 : 7

Drg No ZF 31203

Motor 3 KW/ 1720 RPM Power/Supply 440V/ 3 0 1 60Hz Full Load Current Frame Size D 100 L Insulation Item No

F/ IP 55 7.

Client LABROY SHlPBUlLOlNG & ENGR PTE LTD . . .

Hull 182/183/1~4/485 Service F.W HVDROPHORE PLANT

PumpQuip Engineering FTe Ltd 8 Kaki ~ u k k Road 2. #IN-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump ITUR MZ 312/L CENTRIFUGAL PUMP Capacity 3.5 M3/HR Head 35 M Matl CI Casing, Br Imp. St St Shaft, Mech Seal Coupling CL - 130 I NPSH (Req) Weiqht 7 0 KG

TO DIAPHRAGM TANK

RESSURE GUAGE

032 JIS 10K FLANGE

Client LABROY SHlPBUllDlNG & ENGR PTE LTD Pump ITUR MZ 312/L CENlRlNGAL PUMP Motor 3 KW/ 1720 RPM Date 21 AUG 08 Hull 182/183/184/185 Capacity 3.5 M3/HR Power/Supply 440V/ 301 60Hz Dm By NYAN

35 M Full Load Current Service S.W HYDROPHORE PLANT Head Dim Unit MM PumpQuip Engineering Pte Ltd Matl Br Casing, Br Imp, St St Shaft, Mech Seal Frame Size D 100 L Scale 1 : 7 8 Kaki ~ u k i t Road 2. @I-23 Singapore 417841 Coupling CL - 130 I NPSH (Req) Insulation T ~ I : (65) 6748 3888 FOX : (65) 6748 8858 Item No

F/ IP 55 Drg No ZF 31203 Weiqht 70 KG 8

Client LABROY SHlPBUlLOlNG & ENGR PTE LTD Hull 182/183/184/185 Service STERN MRUSTER COOUNG PUMP - .

PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2, #01-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump ITUR MZ 312/L CENTRIFUGAL PUMP Capacity 3 M3/HR Head - 3 5 - M Matl Br Casing, Br Imp, St St Shaft. Mech Seal Coupling CL - 112 I NPSH (Req) Wei~ht 70 KG

Motor 2.5 KW/ 1720 RPM Power/Supply 440V/ 30/ 60Hz Full Load Current . .

Frame Size D 100 L Insulation Item NO 2

Class F/ IP 55

Date 25 AUG 08 Om By NYAN Dim Unit MM Scale 1 : 7

D r g No ZF 31202.5

680

BOTTOM VIEW

SUCTION & DELIVERY

EL PRIMING "

PUMP "

I I I

- BASEPLATE

Date 02 JAN 09 Dm By NYAN Dim Unit MM Scale 1 : 10

Drg No 122625-16D

Motor 25 KW/ 1750 RPM Power/Supply 4 4 0 ~ 1 301 60 Hz Full Load Curent Frame Size D 180 LC Insulation Item

Mass / IP 55 1

Mient LABROY SHlPBUllDlNG & ENGRG PTE LTD Hull T-182b 83/l84/185 Service HYDRAUUC POWER PACK S.W COOLING PUMP PumpQuip Engineering Pte Ltd 8 Kakl ~ u k ~ t Road 2, #OI-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump DESMl NSL 125-265B/D16 NON SLF PRIMING CENTRI Capacity 170 M3/HR .Total Head 28 M Matl Br Casing, Ni Al Br Imp, St St Shaft, Mech Seal Cauplinq N.A. I Imp Dia MM Weight 413 KG I NPSH Reg

INSTRUCTIONS MANUAL & PART LIST

FOR

M I S S I O N

MAGNUM

AND

PEDESTAL PUMP

P W Q U L P ENGliWERWG SmTWORE TEL : 65-67483888 FAX : 65-67488858

E-mail : [email protected]

Mission Centrifugal Pumps

Operation and Maintenance Instructions For Mission S and W Pumps Bulletin No. M201-2

' MISSION FLUID KING World Headquarters 1530 Sam Houston Pkwy. N. Houston, TX 77043 Phone 1713) 935-8000

Introduction . Pump Assembly Mounting The Mission Fluid King Oilfield Products Cenfifugal Pump is shipped completely assembledand ready for operation. The impeller has been mrefully lined up, and the shdt bearinss have been locked in olace to pmvide~proper clearance within the housing. The shat should be m- Wed by hand before installation to make sure the impeller cleamnce has not been dislurbed during shipment. Ifthe impeller scrapes, it must be reset The Pump may be mounted on a cast imn or steel plate and may or may not be connected to the driver. The base plate must be well supported on a solid foundation, levelled, and firmly placed. External piping should be supported independently to a l i ~ n with suction and discharge flanges ofthe pump, sias to ward t ranh t ing pipe strains to the pump. Complete dimensions are given in the installation plan furnished with each pump.

Installation and Startup of Pump Packages General Instructions Operate the pump only in the performance mnge for which it was designed. When operating In drllling mud, prevent pacldng drippage from clogglng the drip pan. The buiid-up can allow mud to go amund the slinger and front seal into the bearings.

Adjustthe pacldng so that a small amount of leakage remains for lubrication and cooling.

Installation The pump should be located near the liquid source so that the suction line may be short and direct The pump should be located below the level of the liquid to eliminate the necessity of priming.

Coupling Alignment Good service life of the pump and driver depends upon good alignment through the flexible coupling. I t h e elecbic motor was mounted by the manufacturer, the pump and motor were in alignment when shipped. The alignment between the driver and pump should be inspected affer installalion to ensure that~sportation or other handling has not caused mis-alignment of the u n t Poor alignment may cause failure of the coupling, pump, or motor bearings, or of either shaft

The recommended pmcedure for coupling alignment is by the use of a dial indicator, as illusbated in Figures 1 and 2. The dial indicator is attached to one coupling,-half with the indicator button resting on the O.D. of the other coupling, half to measure M e t misalignment To measure angular mis-alignment, the indicator is positioned so that the buttons rest on the face, near the O.D. of the other coupling half. Rotate the shaff and dial indicator one full revolution while the other shall remains Wonary and note the 1.R. Unless othenvise specified by the coupling manufacturer, offset misalignment should be limited to.005 inches TI.R Adjust alignment by loosening driver or pump mountlng bolts and retightening or Shimmlng as required;

Measuring Offset Misalignment

Figure 1

Measuring Angular Misalignment

In areaswhereadial indicatormgement is notamilable,anadeq& job of alignment can be donewith asbaight edge. This method is espe- c i a l ~ useful i f the coupling used contains an all rubber drive element, which can be used wilh up to 5 times the misalignment of metal drive couplings.

To check offset misalignment, lay the sbaight edge in line with the shafts on the' OD's of the coupling halves. There should be no gaps under the W ~ g h t edge. Check two locations 90 degrees apart Angular misalignment can be checked by measuring the gap between coupling half faces. There should be no more than a 1/64Qap under the sbaight edge or 1/64" variation in the gap between coupling halves.

See figures 1A and 2k

I t

Figure 1A

2

Bearing Discoloration A brownish or bluish discoloration of the races and balls indicates that the bearing operating temperature was excessively high, to the extent that the bearing lost its physical pmperties and was nolonger opemble.

Retainer ~ai lure The bean'ng part that first indicates distress in lubrication failures is usually the retainer, where the greatest amount of rubbing action takes place. .

Cause

Dirty Lubrication Contaminants found in lubricants offen act as an abrasive compound which will lap or polish ball andmce surfaces, increasing the pmbabil- ity of early failure. Always be sure you use good clean lubriwntfmm a tube and NOTfmm an open bucket

Too Much Lubricant A w r y wmmon mr In the maln$nance of machinery is the lendency t o d u b d & Hthe bean'ng reservoir is kept constantly full of grease, the friction heat developed within the lubricant can not get out and will cause its rapid deterioration.

Wrong Kind Of Lubricant After experimentation with many types of lubricants, the equipment manufacturer rmmmends those whlch he feels will pmvide ideal lubrication life under g ~ e n operating conditions. In as far as availabilii allows, you should use the same lubricant or its equiMlent MANY GREASES ARE INCOMPAIBLE AND, ALTHOUGH COMPLEW AD- EQUATE WHEN usm INDMDUALLY, MY PROM UNSA~SFACTORY 'WHEN MIXED.

Mis-Alignment Between Pump and Driver A MAJOR CAUSE OF B W N G FAILURES IS MISAUGNMEM AUGN- MENT BETWEEN M E PUMP AND MOTOR SHOULD ALWAYS BE CHECKED AFrm SHIPMENT AND PERIODICALLY RECHECKU).

Re-Packing The Stuffing Box MOST EARLY PACKING FAlUJRES ARE CAUSED BY OWmGMOVlNG OR POOR INSTALlAllON.

Packing Appearance If the pacldng being removed is hard and brittle, it has been run dry sometime during its life. This is often done In the first hour of service. The pacldng has more abilily to gmw with heat during its early life. Even if the Packing is adjusted just right before starting the pump, in the first few mlnutes the packing will gmw with heat and become over-tight It then will'run drop tight and bum the packing. ONCE PACKING IS

3

BURNED IT WILL NEVER SEALRIGHT AGAIN. On new packing let i t leak more in the first few hours. then adjust it to 10-12 dmps per minute.

Correct Installation Of Packing: Make sure the box is clean of all old packing and the plastic lantern ring. Bend a wire and pull it down the shaft or shaft sleeve to be sure it is smooth for good packing life.

Placethe firstthree ringsof packing in the fmnt of the boxwith thesplits alternated. The first split to be down, the second split up, and the third split down. Then ins& the lantern ring and compress this assembly f o m d wlth the gland halves. Then install the last two rings split up then split down.The object is to have the last split down so leakage will drip down, not run along the shaft and maybe into the bearings.

Merlhepacking has been installed, install the packing glandand tighten hard to compress the pacldng assembly. Back off the gland bolts and re-tighten only finger tight

Adjusting The Packing: Paddng must have wollng, therefore it must leak When adjusting the pad4ng always adjust only one flai on the nut at a time, waiting for the packing to heat before adjusting tighter. M E PACKING MUST LEAK 10-12 DROPS PER MINUTE TO REMAIN COOL

Lubrication And Cooling Of Packing With Water it is best to inject Wr into the lantern ring fmm an Edemal source on drilling mud. This will keep most of the solids out of the packing.

Grease Lubrication Of Packing H water can not be used, the next best addiUon to the packing would be grease fmm an automatic spring loaded grease cup. This wil l help keep the pacldng sot There isavisual indication when the cup no longer has any grease. The stored grease normally lasts a week or more i f the packing is adjusted correclly.

Installation Of Replaceable Parts The fluid end is so consbucted thatthose parts subject to wear may be readily replaced in the field. To replace the w ing , wear plate, and impeller, the following pmcedure should be followed:

I. Stop pump and drain all lines leading to the pump. 2 Loosen the bolts atthe suction and discharge flanges of the

pump and move pipe clear of pump casingid remove pump fmm system.

3. Separate the coupling, and loosen the coupling half mounted on the pump shaft

4. Remove the casing stud nuts, and take off the casing. 5. Loosen the packing gland nuts, and swing the pacldng gland

bolts clear of the packing gland. Remove the pad4ng gland halves.

6. Slide the water sllnger along the shidtawayfmm the bearing cap.

Loosen bearing cap bolts on both ends and slide the bexirig clearance is obtained by pushing the bean'ng In until it seats

caps along the shait This will q o s e the bearings, which are against the'shoulder, and then pulling it out 111 6'.

locked to the shall by an eccentric locking ring and set screw. 7.' The fmnt bearing is then locked tothe shaft in the same way

Loosen the bearing set screw and tap the bearing locking ring a as the rear bearing.

Dunch and a small hammer so that it turns in the direction opposite to the rofation of the shaft When the bearing locking ring has been turned 114 revolution, the bearing is freed fmrn the shaft Both bearings must be released. File off any upset caused by the collar set screw before attempting to slide shaft through bearings. Remove the impeller and shaft fmrn the pedestal by pulling the impeller away fmm the pedestal, thus freeing the lantern ring. &r slingeri bearing caps, bearings, and the couplings. -

. Remove the impeller nuts and washer. 11. Remove lantern ring and packing. 12. Remove wear plate by applying pressure on the hub of the wear

plate through the sh& hole. The wear plate is pressed into the pedestal and forms the bottom of the M n a box

13. The bearings may now be removed fmm thepedestal for inspection, by tapping lightly with a wooden or brass rod.

14. For 6x8 pump, press impeller oit the shaft

To R&mmble the Pump, the Above Procedure Is Reversed. New gasketsshould be usedthmughout Gasketsshould be lfl6'thick and made of a material suitable to the pump opemting eont i in.

In establishing properclearances on the impeller, the following precautions are necessary.

Wm impeller installed on shalt and rigidly keyed in place. ~~.

insert the shdtthmugh the shaft hole in the wear pl&. The water slinger, bearings caps, gaskets, bearings, and coupling must be threaded on the shaft in the pmper order. Put on the casing with the casing gasket and tighten the casing shd nuts uniformly. Push the shalt foMmrd until the impeller hi the casing, mark the shaft, then pull it back until the impeller h i i the wear plate and mark the shaft again. The shaft should b&et halfwdy between thesp two marks, so that the clearance between the impeller and the casing is approximately the same as that behveen the impeller and the wear plate. Make sure the rear bearing is seated againstthe housing shoulder. and then lock it tothe shaft rotating the bearing locking ring in the direction of pump rotation, and locking it with the set screw.

Operating Conditions Space is provided for three rings of 318" square packing atthe impeller side of the Lantern Ring. Packing should be of a gmde suited to the operating conditions of the pump; square braided pacbng is regularly furnished. Excessive tightening of the packing gland nuts causes shaft wear, is unnecessary, and should be avoided. SligM leakage, appmxi- rnately 10-12 drops each minute, is desirable toactasa packing lubricant tf a corrosive or abrasive material is pumped, gland water at a maximum pressure of 15 PSI should be piped to the Lantern Ring by way of the 114" pipe connection and allowed to leak thmugh the packing for lubrication. The drip pan under the shaft is provided with two I/? pipe connections to drain off this leakage.

A grease fitting may be put in the 114" tapped Lantern Ring connection if grease lubrication of the packing is desired. Water pump grease is usually satsfactory.

Lubrication The pump is shipped with sufficient lubricant packing in the bearing to assure tmuble-h ooemtion for normal sewice l i . Under n o d operating wndiions, no lubricant needs to be added to the bearings. If the ourno is disassembled, it is advisable to pack the bearings with greaie pimperly before misembly. Packthe bearing thmugh approximately one-half of its circumference. It is not necessary to put grease in the bearing cap or pedestal.

The bearings normally may run at temperatures up to 180 degrees F, without injury. A temperature of 180 degrees F is hotter than the hand can stand to touch for more than a second or two, but will not bum off the paint The ternpenlure may be determined by sticking a ihermorn- eter to the bearing cap wiLh heavy grease and leaving it for twenty (20) minutes.

Should the bearings run hot, immediate service is necessary. This abnormal condition indicates that (I) the bearings may not be properly installed. (2) pump and motorare out of alignment, (3) excessive grease has been forced into the bearing housing, (4) insufficient grease is present in the housina, or (5) improper grade or contaminated lubricant -- . . . . -

Note: is present in the bearing housing. To correct this condition, first check 6. The fmnt bearing does not seat against the housing shoulder. This rnotorand pump for misalignment Check for pmper amount of grease.

bearing should be free to float along with the shaft to compensate and return the pump to Service. In addition, a competent lubrication for expansion and conbaction mused by temperature chmges. engineer should be consulted to recommend the pmper lubricant for The outer race clearance is about 1/16; on each side. Thls- thi@cular operating condition.

Piping (General) Piping should be anchored independently of the pump and as near to it as possible. Pipe companion flangesshould line up naturally with pump flanges. Do not draw the pipe to the pump with flange bolts.

Piping (Suction) Pmperly selectedand installed suction piping is extremely important to eliminate vibration and cavitation in the pump. Vibration can cause packing pmblems, or undue bearing loads. The suction should be equal to,or larger Ulan the pump su.ction.

Apositive shut-offvalve of atype to cause minimum lutbulence should be installed in Me suGon line to permitthe closing ofthe line and remml of the pump for inspeclion and maintenance. H m , the capacRy of a mbif@ should never be adjlsted by UuuUIing the suction.

The suction line should have a straight section into the pump ofa length equivalentto at least two times the diameter of the suction line.

For tempomy hook-up, where flexible hose is used, a non-collapsing hose is essential since the suction line is often below ahnospheric pressure. A collapsing suction line will result in below designor complete loss of flow.

Piping (Discharge) A positive shut-off valve should be located in the discharge piping to permil inspection and maintenance of the pump.

All piping should be independently supported and accurately aligned. The pump must not support the weight of the pipe or compensate for misalignment

If operating conditions are not known with sufficient accuracy, it will be necessary to pmvide athrottle valve in the discharge piping to ensure that the pump operates at the design point

If the pump is connected to a pressurized system, it is important to install a check valve between the pump discharge and the thmttling valve. The checkvatve will prevent back flow thmugh the pump.

Preparation for Operation Check Rotation Most pumps purchased are clockwise when viewed from coupling end. The correct mtation can be found by an arrow on the casing.

' , > ..,, :. It is very importantthat the pump is not started up and !hen go &see if Me pump is turning the correct mtation. The packing or mechanical sealcan run dry and be destroyed.

The best way to check rotation is to disconnect the coupling. before testing rotation, but i t can be checked without disconnecting. the coupling. One person should be at the pump watching the shaft, while the second person pushes the start button on the starter and immediately pushes the stop button so the shaft barely tums over.

Pump Speed Limitations TYPE OIL GREASE

S 3500 2400 W 3500 2400

Grease Lubrication Most pump bearings are pre-lubricated with grease from the factory, and in moderate speed, low temperature application may not need lubrication throughout the life of the pump. Plugs are installed where the grease fittings are to go. In heavy loads and hot applications, the bearings should be re-lubricated at regular intervals-for maximum bearing life. The bearings are lubricated with Chevmn SRl-2 grease at the factory. When relubricating, the Chevmn grease would be the best choice since mixing greases sometimes causes incompatibility pmblems. The h e r premium bearing greases are &on Unirex N2, Chevmn Polyurea V 2, Tewco Marfak Multi-Purpose 2, Shell Mp2, and American Oil Company's Rycon Premium 2 p

When using the five premium bearing greases isted above or their equivalent five shots of grease with a standard sked hand operated grease gun, in each bearing every 2-3 MOErmS will be sufficient in a twenty-four hour openlion. Reduce for lesser operation. The pump bearingsshould be lubricatedabout on the same scheduleasthe motor bean'ngs.

NOTE. AUTOMATIC OILERS are set at the factory to the lowest position. This setiing will pkce the oil level just below the center of the bottom ball of the bearing when the housing is level. Higher levels may cause churning and overheating of the bearings; lower levels may p.mmvide insufficient lubrication and promote rapid wear. The correct oil level will be visible at the center of the sight oil gauge.

Standard pumps are shlpped with empty oil resarmlrs. Oil must be added before operating the pump. Attach the oiler to the bearing housing, fill the bottle wlth oil and place it in position. Refill the,boffle until oil remalns visible in the bottle. Oil should not be added to Qe reservoir except thmugh the oller bottle.

A good grade of SAE 10W30 oil may be used. Theair vent should be kept clean to prevent pressure build-up because of normal heatingthat occurs in operation. A Trico optomatic oiler No. EB-64 with a 4 o r capacity bottle is used. The correct bottle must be used with the corresponding oiler body.

Priming Be sure the pump has fluid in its casing before running. ii the pump is operated without fluid, the mechanical s&l or packing can be desboyed in one minute. Vent air fmm the suction line and fill with liuuid. Start pump with discharge valve cracked open. After discharge prekure sta- bilizes, gradually open discharge valve to required position. ii flow is lost, close discharge valve and wit a few seconds for discharge pressure to build. Do not run the pump with suction valve closed ANYTIME and with discharge valves closed only for short periods of the.ihe en- ergy going into the pump heats the fluid in the casing. If the pump needs to opemte shut in some of the time, be sure to have a small line (114Qr 1 P ) back to the suction tank between the discharge valve and pump for cooling.

Pump Records Maintain data cards or pump records whenever possible. This will pmvide ready access to information for ordering spare parts, and for evalu- ating pump and mechanical seal performance.

Information to be included on these records should be: Pump she Pump model number, impeller diameter, material of construction Mechanical seal manufacturer, type, code, and drawing number Motor horsepower and speed of operation %ME ~0fldifi0nS Frequency of opemtion Record of maintenance, including parts usage and general condition of pump Nomenclature and part number of replacement items

Loosen Packing On Startup The gland bait ruRshould be only ffn~w t i ~ h t N& packing will expand faster with heat than older packing. Therefore, new packing must be adjusted more slowly than old packing: Too tigM and it will not leak Wth no cooling l w i l l hum and be no good for sealing.

Trouble Shooting Procedures WHERE EXCESSME Pdcking Leakage and Rapid Packing Failure occurs. the shafl or shaft sleeve nay be worn out Remove the pacldng. Slide a wire, with a short section of the tip be6 90 degrees into the stuffing box Runthe stylus tip of the wirealong the shaft If deep gmoves are noted,theshaRor shafl sleeve must be replaced. Excessivetighten- ing o f the packing will cause tapid shaft failure.

6

PACKING BURNED; If the packing is bumed and hard when removed, it has been over-tightened at some time and the lack of leakage caused the packing to bum. Once packing has bumed and is no longerand sot and pliable, it will not seal pmperly. inib'al over-tightening and attempting to run pacldng without leakage will cause Me packing to bum.

Bearing Failures EXCEPT FOR CAVITATION PROBLEMS, BEARING FAlWRE IS THE GREATEST CAUSE OF INCREASED WMP OPERATING COST.

IF YOU CONTINUE TO RUN A PUMP WHEN BEARING FAILLIRES OC- CUR, THERE IS AN EXCELLENT CHANCE THE WHOLE WMP MAY BE DESTROYED. Therefore it isvery importantto change the bearings when failure STARTS. If you wait for complete failure, other fluid end parts will be damaged.

Bearing failure is more often caused by LUBRICATION FAILURE than by normal bearing wear.

Identification of Bearing Failure Abnormal Temperature Rise The first indication of lubricant and bearing failure is a rapid rise fmm normal operaling tempemre. You can not hold your hand very long on unsab'sfactory tbmpemtures. ti you can hold your hand on the bearing housing about 5.seconds, the temperature isabout 160 degrees F. (suitable for most pumps). IF YOU CAN NOT HOUI WUR HAND ON THE BEARlNG HOUSING FOR 5 SECONDS OR IFTHE BEARING HOUSING IS SO HOT YOU DO NOT WAN TO PUT YOUR HAND ON IT mu PROF AEW HAVE LUBRICANT AND BEARING FAILURE.

Grease Appearance t the grease is sMf or caked and changed in color, it indicates lubrication failure. The original color will usually turn a darkshade or jet black

The grease will have an odor of burnt petmleum oil. Lubrication will be lostasa resuitof lackof oil IN CASES OFUMlUM BASE GREASESTHE RESIDUE APPEARS UKE A GLOSSY BRl lTE VARNISH. WHICH WILL SHAllER WHEN PROBED Wml A SHARP INSTRUMW.

Grease is a m'kture of oil and usually soap. When a pump M othw equipment sits a long lime without rotating the oil separates and runs out of the bearing housing. It may look like grease isstill in the bearing, but it will not have any lubrication properties.

Noise Lack of lubrication is soon accompanied by awhistling noise, coupled with the rise in tempemture. If not comcted, the b@ng temperature will continue to rise and the intense heating will reduce the bearing hardness.

Long Term Pump and Motor Storage

1. Pump packages should be stored indoors in a clean, dry and protected environment

2. The storage area is to be free from any vibration and from exbemes in temperature.

3. Motorand pump shahareto be rotated manually every2 months. A record of the rotation should be made.

4. Grease in the motor and pump bearings is to be purged at the time of removal fmm storage, making sure that an ample supply of fresh grease is in each grease cavity.

5. Motor winding should be rnegged at the time equipment is put in storage. At the time of removal fmm storage, the resistance reading must not have dropped more than 50% from the initial reading. Any drop below this point necessitates eleckical or mechanical drying of the motor windings. Condensation fmm hot days and cool nights can fill the motor half full of water. This is a greater potenthiproblem in damp areas.

6. il the pumps are to be stored outside, the pump suction and discharge openings should be sealed to prevent any water fmm entering the pump housing, causing rust of the fluid end during storage.

Recommended Lubricants Although the correct grease to use depends on the specific pump application, the following list of lubricants represents some grease manufacturer's recommendations for general service. similar type greases fmm other reputable grease manufacturers are also suitable.

Chevron SRJ-2 Texaco Premium RE

Available In Pails Shell Dollurn-R (Preferred) Amoco Rywn Premium Grease

f Exxon Unlrex ti2 Chevron Polyurea Ep 2

In mdge Texaco Mafak Multi-Pupose 2 (Acceptable) - Shell M P IAvalina) 2

Mission Fluid King World Headquarters 1530 Sam Houston Pkwy. N. Houston, TX 77043 Phone (713) 935-8000

A complete serial number record of every pump is maintained at Mission Fluid King Oilfield Products. .

For any additional information on installation, operation or service, call or write our Houston Headquarters or contact the Mission Fluid King Oilfield Products representafie in your area.

Information requested can be more quickly and accurately furnished if the size and serial number of the pump are given with your request for information.

llam Ho.

I 1 A 1 B 1 C 2 2A

; 3 4 5 6

6 0 7 7A 7 B 7C B BA 9

10 10A 100 IOC IOD 10E IOF 1 OG I I 12 12A 128 12C 13 13A 138 13C 130 13E 14 14A 148

Figure 6

Part Humbar

10399.46.1 3932-61 3862-76

19110.72 20614-01-M 20622A

83701A

20612.02.33 20613.21G7A

23444-01-72 22210.IA

20618-12.01 20626-01.01

20625A Kil 20619-01

20620.01 21641.01 20615.1 -20624-0 1.01 7496.253 3861.138 3932-62 2061 7.01-01

7496.26 20619.02 3861.139 3936.19.10 20616.1 6 124.4 61 23.4

P l l l Nan.

Casing Gasket. Casing Nuts. Casing Stud Stud. Casing Impeller Seal. Impeller Cover. Stuffing Box Gland Set Packing Set Gland Bold Assembly

NUIS. Gland Bolt Shalt Sleeve. Shaft Key. Coupling Seal. Shalt Sleeve Delleclor Assembly Seal. Dellector Frame Cover, lnboard Bearing Plug. lnboard Brg. Cover Gasket. lnboard Brg. Cover Oil Seal, lnboard Brg. C O V ~ I

Bolt, lnboard Brp. Cover

Vegetable Fiber: Kit 10393.46.lA Steel - %.IOUNC - 20 He1 Nu! Steel - Jh - IOUNC - 2A All Thread. 2% Lg.

Elon: Use Kil 10393.46.lA M.Denotes Malerial Cast. lron

Stainless Steel

304 Stainless Steel % . I6UNC.28 Her Nut AISI.4140 Alloy Steel

4 16 Stainless Steel Buna N ("0" Ring]: Kit 10393.46.lA Bronze Buna N I " 0 Rind Cast Iron Casl lron Steel. b - 27 NPT VegetableFiber Kit 20625A Buna N Kil 20619A 36 - I6UNC . 2A Hex Head Bolt. 2" Long

Nut, Inboard Br;. Cover Steel. 36 - I6UNC - 2 0 Hex Nu1 Exclusion Seal. Inbd. Bg. Cover Buna N Kit 20619A G~ease Fitting. Inbd. Brg. Cover Alemile 1736 Bearing. lnboard ~ousing. Bearing. Outboard Seal. Bearing Housing Bolls. Bearing Housing Nuts. Bearing Housing Cover. Outboard Bearing Plug. Outboard Brg. Cover Seal. Outboard Brg. Cover Oil Seal. Outbd. Brg. Cover Bolts. Outboard Erg. Cover Washer. Outboard Brg. Cover Bearing. Outboard Lockwasher. Bearings Locknut. Bearings

Falnir 5313WBR. MAC 5313 Cas~ lron Buna N. I"0" Ring]: Kil 20625A Steel K . 13UNC.. 2A. IH" Long 304 S.S. . Y, . I3UNC . ZB lJam Nlrlsl Casl lron S~eel, b . 27 NPT Buna N ["Ow Ringl: Kil 20625A Buna N: Kit 20619A Steel . .36 . I6UNC . 2A. I" Long Sled . 36 SAE sw 73 SKF W l 1 (Sled]: Kil 6 1 2 3 4 SKF N l l (SleelJ: K i l 61234A

Lubncanon ol Packing by Clean W e w Oil. or Grease 7

Square Brdided

E r a ~ d e d Pack~ng Magnum I Pump Flgure 1

Lubricalion ol Pec!ing by Thn Amg Turned Clean Waler. Oil. or Grease 0111wa1d lo Prevenl Leakage o l h1 Inlo Pump

L Pecking Gland

King Type Packing Magnum I Pump Figure 8

i i

DWG. NO. 22451-1 n Figure 9 ; I

Recommended Spare Paw hems I. 4A 48. 4C. 5.

See Dwg. 17538 for Sub.Assembly Pans Nos.. and Stuffing Box Conversion Uni~.

Bellows

n Packino" I - ..

6 ( 1 1 Spring 70. I 1 I Slmve" . . . I '

9 I 1 - . !Spring Retainer 15 I 1 I Soring Pin

"These irems are not included with seal

2%" Mechanical SeaVPacking Arrangement for Magnum I Pumps in Severe Service

Dwg. No. 22451-1 Sht. 1 of 2

VII. Engineering Data, Suwion Piping

FlAl BAFFLE

Side V ~ e w

I

Top View

Vonex can be prevented by proper baffle arrangements.

SUCTION PIPE

\

H Suction Piping (Cont.)

Sucllon Plpe Slope Upwards From Source or SUP PI^.

n

n n WRONG

All Pockel Because Eccenhlc Reducer Is Not Used And k a u l e Sucllon Plpe Does -- NO1 Slope Gradually UDward from Su~ph

t""'! Air can be [rapped in suclion horn tanks.

60

Suction Piping (Cont.)

H-Submelgence In F e d (mln)

1 2 3 4 5 6 7 8 9 I 0 11 12 ?3 l d 15 16

Velocity In Feel Per See.

This can be used as a guide for minimum submergence and piping dnsign.

Velocity, fee per second = GPM x . 4 ,

D2 (inches)

RECOMMENDED

I I

LJ

I

T o minimize air entering mud, return should be away. from suction and aar liquid level.

Conversion Data GPM - .03 X ~ a m k par day Spanfic . might nuid in poundsl~al. Qfw. 8.34

SP, GR, - PounddScu. t 62.4

Feet Haad -

PSI - Fael Head X SP. GR. '

L.31 Bmke Honapowar - Cum Honepowsr X SP. GR Requirsd

Pounds Gallon per - .I33 X poundslcu. h

Theoretical Discharge of Nozzles in 'US Gallons Per Minute

Metric Conversions GPM - ,264 X h l r n i n . GPM - 15.9 X h n l s e c . GPM - 4.4 X maml/hr. GPM - 264 X melen'lrnin. lael - 3.28 X maws PSI - 142 X Kg/cm' SP. GR. - 1 X QmrnSfcu. cm.

6 X 022 HOLE

8"X3"C CHANNEL

SCALE I: 10

SUCTION 4lN 125# FF DELIVERY 31N125# FF

:lient LABROY SHIPBUILDING & ENGR PTE LTD I Pump MISSION MAGNUM 4 X 3 X 13 ( Motor 132117 KW@ 3500/1750 RPM I Date 21 AUG 08 lull ~ P I A Q Z A P A A P K I rnnn*itl. I Power/Supply 440V/ 301 60Hz I Dm By NYAN - . . ' n V 3 / H R . . I F~rll l ond Cmnnt I Dim Unit MM

I U L / IUdf IU7f IUd

iemce TWO SPEED UQUlD MUD PUMP PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2. #Ol-23 Slnaa~ore 417841

"Y,,U*'L, 1 "" Total Head 80 . M Mail Hard Cl Cadng 6: SS Shaft Impellsr, Mech Coupling CL - 250 1 NPSI

- - ~ ~ ~ S+d H (Red

T ~ I : (65) 6748 3888" Fax : (65j 6748 8858 I Weight 1560 KG I Impeller Oia

. - . . - - - - - -. . -. . . Frame Size D 315 SA Insulation Item No

IP 55 9

. . . . . . . . . . ....~.

Scale 1 : 15

Drg No 4313132

INSTRUCTIONS & PART LIST

FOR

DESMI ROTAN

HORRONTAL

GEAR

PUMP

Operation and Service Manual

DESMI

ROTAN PUMP

Type GP, HD,. PD, CD, ED, CC, and RT

DESMI AIS Tagholml, DK-9400 N011esundby Tell 45'96 32 81 11 Fax 445 96 32 81 49 -.

I I Manual I Language I Rev. , I

TABLE OF CONTENTS

2 . GENERAL INFORMATION ................................................................................................. 4

....................................................................................... 4 . PUMP TYPES AND VERSIONS 6 4.1 ROTAN IN GENERAL ...................................................................................................... 6

........................................................................................ 4.2 CONFIGURATIONS :. ............... 7

5 . TECHNICAL DATA ....................................................................................................... 9 ..... 5.1 SHAFT SEALS .................................................................................................................. 9 5.2 BEARINGS ........................................................................................................................ 9 5.3 HEATING ........................................................................................................................ 10

...................................................................................... 5.4 OPERATIONAL CONDITIONS 1 0 ................................................................................................ 5.5 PROTECTIVE DEVICES 12

5.6 SETTING DIMENSIONS . AXIAL (SLEARANCE ........................................................ 14 5.7 m A L LOADS ...................................................................................................... 14

.............................................. ......................................................... 5.8 NOISE LEVEL ....... 1 4

. 6 INSTALLATION ........................................................................................................... 15

. ..................................... 8 MATNTENANCE AND OPERATION ................................ 1 7 . . ............................................................................................................... 8.1 LTJBRICATION 17

.................................................................... 8.2 SOFT SEAL ................................................ 17 ......................................................... ............................... 8.3 SEALING LIQUID 1 ......... 1 7

............................................................................................. . 9 REPAR AND INSPECTCON 1 8 .................................................................................................. 9.1 DRAINING THE PUMP 18

9.2 PUMP PARTS ........................................................................... : 19 ...................................... ................................. 9.3 MECHANICAL SEAL ; ................................................................... 19

9.4 SOFT SEAL .................................................................................................................... 19 9.5 SLEEVe BEARINGS ............................................................................................ ......... 19 . . 9.6 FLEXIBLE COUPLING .................................................................................................. 19 9.7 LOCKING THE PUMP SHAFT ............................................................................ ; 19 ......... 9.8 A D J U S T M E N T O F A X I A L ~ C E ................................................................ 20

..................................................... ......... 9.9 ED PUMPS IN PARTICULAR : ....................... 20 9.10 GP PUMPS IN PARTICULAR ..................................................................................... 21 9.11 SPECIAL DESIGN ..... (SHD ................................................................................... 1 21 ........

...................................................................................................... 21 10 . TROUBLE-SHOOTING

22 11 . SPARE PARTS : ................................................................................................................... 11.1 ORDERWG SPARE PARTS ........................................................................................... 22

.................................................................. 11.2 SECTION DRAWINGS OF SPARE PARTS 22 ................................................................................................. 1 1.3 LIST OF SPARE PARTS 26

1. EC DECLARATION OF INCORPORATION

DESMI AIS, Tagholm 1, DK-9400 ~@rresundb~, hereby declare that ROTAN pumps of the types GP, HD, PD, CD, FD, CC, and RT have been manufactured in accordance with:

- THE COUNCIL DIRECI?VE 89/39Z/EEC on mutual approximation of the laws of the member states on macbines with' special reference to Annex 1 of the directive on essential safety and health requirements in relation to the construction and manufacture of machines.

- THE COUNCIL D l l W T F E 73123EFE on mutual appro&tion of the laws of the member states on eleca-ic equipment intended for the use within ceaain voltage limits.

Bare shaft pumps with delivered by DESMI ,US, must not be put into service unless all relevant provisions are fuh%ed,

JOS ~ i j & Division manage~

.2. GENERAL INFORMATION

On receipt, please check that the unit 'is complete and undamaged. In the event of shortage or damage, the carrier and the supplier must be advised immediately, for the purpose of submitting a claim.

In accordance with the product liability act it is our duty to draw yonr attention to the following risks if the pump is misused

It is imperative that the engineers involved in assembling and servicing are familiar with the current operating and maintenance manual before installing and starting-up the pump, they must be technically qualified,

The user is responsible for observing the safety instructions in this manual.

General safety insmctions including local safety and operating regulations do not form part of the pump manual. The user is fully responsible for complying with these regulations.

The erection and the service of ROTAN pumps must be cauied out in-strict accordance with existing regulations for mechanical and electrical engineering.

The pump must only be used in accordance with the operaring conditions specified on customer's order. Any deviation must be with the manufacturer's consent

The operating and maintenance manual covers standard designs only. Variants in construction, erection, operation and maintenance are not included.

The supplier must be contacted in the event of any necessary information not being found in the manual

The service life and the specified properties of the unit are limited by wear, comosion, andbreakdown dependent on the operating conditions. It is the user's duty to ensure that regular service is carried out and that parts are replaced as and when necessary. The pump should be stopped if it is operating abnormally or if there is any visible damage.

Installations which can cause personal injury or material damage in the event of breakdown must be provided with reliable and regularly tested alarm systems andlor spare units.

AU units which are in contact with foodstuffs must be thoroughly cleaned before use.

Non-observance of these. warnings and operakg instructions can lead to complete breakdown and possibly result in personal injury and material damage.

The manufacturer is absolved from all responsibility if the instructions in this operating and maintenance manual are not adhered to.

If the pump is sent on to a third party, it is absolutely essential that it is accompanied by this operating and maintenance manual plus operating conditions specified in the order.

A Do not put your fingers into the suction/discharge ports of the pump when handling the unit.

The pump must be handled carefully and not exposed to hocks and damage.

Lifting is canied out using stable suspension points so that the unit is in equhbrium. Lifting straps must not be placed over sharp edges.

Wbere long storage is envisaged steps must be taken to avoid corrosion and drying out This can cause seizure of the nkhanical seal seats, which in turn will cause damage to the seal, when &e pump is started up.

Base coat or top coat is applied on the extemal - not stainless - surfaces of the ROTAN pumps.

The pumps are usually lubricated with machine oil kom the factory; pumps for foodstuffs are heated with a food approved lubricant

4. PUMP TYPES AND VERSIONS

The ROTAN pump is a gear pump with an internal idler gear in mesh with a main rotor. B'

The operating principle is shown below:

The modular design of the ROTAN series allows a large number of pump configurations. It is therefore possible to adapt the ROTAN pump for a specific duty. fl p AU ROTAN pumps can be provided with a relief valve tb prevent the build-up of excess pressure. Most of the pumps can be fitted with a heatinglcooling jacket for the pump section and shaft seal

All standard pumps allow reversible pumping, the direction of flow is determined only by the direction of rotation of the motor.

The pumps are grouped into 5 main series: F HD: Heavy Duty.

Par$ in contact with the liquid are manufactured in cast iron and steel

CD: ChemicalDuty. Paas in contact with the liquid are manufactured in stainless steel.

PD: Petrochemical Duty. Paas which suround the liquid are mauufactured in steel. L

HD, CD, and PD are each bare shaft units coupled to a motor and mounted on a common base plate. Shaft sealing arrangements vary, i.e. stufting box, a single mechanical seal and double mechanical seals in tandem or back-to-back

i i

GP: General Purpose. L The pump end is identical to that of the HD punip, but is direct coupled to a m g e mounted motor. The motor must have the located b k h g at the drive end The GP can be fitted with a stuffing box or a single mechanical seal.

: Environmental Duty - magnetically coupled pump. Paas in contact with the liquid are manufactured in cast iron, stainless steel or steel. The pump has a bare shaft and is coupled to a motor and mounted on a common base plate.

4 2 CONFIGURATIONS

The configuration of the pump in question is shown on the nameplate (see 11.1):

5) Material codes for main parts/wetted parts my clglm~~~mnp.:

7 1

Cont3gnrations (supplement to item 3 of the page before)

TECHNICAL DATA

The ROTAN pumps have three types of shaft seals, viz.

- Soft shaft seal - Mechanical shaft seal - Magnetic coupling

The type of seal fitted in the pump is indicated on the nameplate (see 4.2).

5.1.1 SOFT SHMT SEAL

A packed box requires constant maintenance, a leakage of 10-100 drops per minute being allowable. If the stuEng box is tightened too much, there will be an increase in frictional heat, which can cause hardening and increase wear on the sh&

5.1.2 MECHANICAL SEAL

Mechanical seals are virtually leak-&ee and require no maintenance. Pumps with n&&cal - seals should only be run after bleeding and being med with liapid because if allowed to +dry

the seal faces of the mechanical seal will be damaged. Self-priming up to one minute's d d o n however is allowed.

5.1.3 MAGNETIC COUPLWG

The magnetic wupling is I&-6ee. The magnetic wupling separates the pump fiom the drive shaft

Magnetic couplings are designed specifically for each ROTAN pump so that its pedormance corresponds to the specifications called for in the order. The pumped liquid acts as the cooling agent Depending on the speed and viscosity the maximum temperature rise of the liquid passing through the coupling for cooling will be 30°C.

Steps must be taken to ensure that the motor cuts should the magnetic wupling slip because of overload.

5.2 BEARINGS

As a general rule the pumps are fitted with sleeve bearings, the exceptions being HD .. EM(see 4.2) and GP .. EM, which are fitted with "sealed for life" ball bearings. These bearings, items andNB (see 11.2) are factory lubricated and need no attention.

The sleeve bearings of the U configuration (see 4.2) are lubricated by the liquid pumped, whilst the M co&guration requires separate lubrication. See item 8.lregarding lnbrication.

5.3 HEATING

Where heating is required for the pump, a heating jacket can be provided for the *ant andlor rear cover, configuration D and K (see 4.2).

The heating jackets are designed for a maximum worldng pressure of 10 bar.

5.4 OPERATIONAL CONDITIONS

The limitations (RPM, pressure, temperature, and viscosity) stated in this section are to be considered as recommended maximum values as the individual ROTAN pump can have further Limitations, e.g. on account of the medium pumped, the shaft seal chosen and in particular tlie motor laid out

5.4.1 RPM

The maximum RF'M of the ROTAN pumps for viscosities below 400 cSt are as follows. In the event of higher viscosities the RF'M is reduced to avoid cavitation

P m size

5.4.2 D F E 3 E W U L PRESSURE

The total overpressure (inlet pressure + Werentid pressure) may not exceed.

- 16 barfor thetypes 26 - 81.

- 10 bar forthe types 101 - 201.

The nwes below illustrate maximum permissible differential pressure for ROTAN pumps used for pure, non-abrasive liquids. NOTE: the exceptions are:

- Configuration "MM and "MMP! with the main bearing placed between the shaft seals - maximum pressure 6 bar.

ED81EH - maximum pressure 8 bar.

P u m ~ size26-81:

B o r .

Bar 15 1 I I I I I I I I I

I I I I I I I I I I

Sienature Material of the bearin=

Bronzelsteel Cast irodsteel

Carbodsteel Ceramiclceramic Carbodceramic Carbodcarbide Carbidelcarbide Silicon carbidelsilicon carbide

5.4.3 SUCI'ION HEAD. NPSH

In order to ensure a cavitation-free pumping, the suction conditions should be such that the pressure on the inlet side is higher than the NPSH, of the pump at the specific operating conditions.

The limitation of the operating temperature is, among other things, dependent on the elastomers used in the pump.

NBR - Nitrile approx. + 30 / + 70°C FF'M - Viton approx. + 25 1 +17OoC (maximum 135" C in water) PTFE - Teflon approx. + 15 / +170°C

Pumps with standard clcamices are limited to a maximum temperature of 150 "C.

The HD, CD, and PD types provided with special, clearances (the codguration includes a "T" - see 4.2) can in certain cases be used up to 300°C.

The ED pumps must not be exposed to a temperature exceeding 25O0C, including the temperature rise in the magnetic coupling - see subsection 5.1.3; Viton is standard elastomer.

ROTAN pumps in standard wnfiguratiom can be used in the viscosity range 1-7.500 cSt In the event of special clearances (T forms part of the designation - see 4.2) the HD, CD and PD types can be used up to 75.000 cSt; the EO type is limited to 10.000 cSt

55 PROTECTIVE DEVICES

The unit should be provided with suitable protective measures so that pump and motor are not loaded beyond the h i t s stated in the order.

5.5.1 VALVE

As a result of the ROTAN pump operating against a closed discharge outlet an unlimited pressure build-up can occur. This means that the pump, piping, and valves etc. should be protected by a ROTAN relief valve as a minimwi safeguard.

The relief valve leads the pumped liquid from the discharge side back to the suction side when the set pressure is exceeded. The pump must not operate in "by-pass" mode for a long time, as it will cause heating of both liquid and pump.

The standard relief valve (confguration R) only protects in one pumphg direction. The adjusting screw of the relief valve should point to the kction side of the pump. In the case of a valve with a vertical adjusting screw, it shall point to the pressure side of the pump. N o d y the valves are provided with a "p" for pressure side and a "s" for suction side.

The opening pressure should be 1-3 bar over the normal operating pressure.

The adjustment of the safety valve from factory may appear from the order. If the valve is readjusted, the adjusting screw must be re-wrapped in thread tape.

Setting dimensions for the relief valves are shown in the following chart

I OPENING PRESSURE BAR -1 I .

VALVE NO. ) 2 1 4 ) 6 1 8 1 1 0 ) 1 2 ) 1 4 ) 1 6

5.6 SETTING DIMENSIONS. AXIAL CLEAE4NCE

The axial clearance is the distance between the rotor/idler and the front cover. See section 9.8 regarding adjustment Setting dimensions are seen from the table below.

*) Pumps made of stainless steel are adjusted with a clearance 0.10 mm bigger than stated.

**) The configuration of pumps with special clearances includes a " T or "CHD (see subsection 4.2).

5.7 EXTERNAL LOADS

Permissible force and torque loads on the pump flanges.

1261151

0,30 0.375

060 0,75

Pump size

N o d axial. tolerance *)

Pumps with spec. clearances **)

b m p I F m i N I Torauei Nm I

51/66

0,15

0.20 Oi3O

O N

If ROTAN pumps with free shaft end are required to be belt-driven, information on the permissible load allowed on the output shaft can be given on request.

152

0,35 0,45

0.70 0.90

811101

0.20 0,25

0,40 0,50

26/33

0,lO 0,125

,030 0.25

The A-weighted sound pressure level of the ROTAN pumps dependent on the pump size and the RPM is seen from the followjng graph. Other panmeters affecting .the sound pressure level are $e differential pressure, the viscosity as well as the manner of installation.

201

0,40 0,50 0.80

1.0

41

0,lO 0,15

0.20 0,30

The dB(A) nwes in question are basdon measurements made during the pumping of mineral oil with a viscosity of 75 cSt and at a differentialpresmte of 5 bar.

- - - PUMP SIZE

6. INSTALLATION

The following should be considered to avoid operating problems:

- The base must be such that the unit is solidly supported and is not pre-seessed when erected

- There should be sufficient space around the pump for service. Below is stated the minimum distance to a wall to enable dismmtling of the kont cover.

- The suction height of the pump (see 54.3) should be taken into consideration

- Normally the pump is mounted horizontally. If the pump is placed with the flanges upldovk, it will not self-prime. Normally the pump must be installed so that the shaft is horizontal.

Pipework

- All pipework must be free of any conramination.

- Plugs in the connecting branch of the pump must be removed.

- The pump must be installed in such a way that stresses in the pump casing caused by the pipework are kept to a miaimurn. Permissible loads on the pump flanges appear £rom subsection 5.7.

Mounting pump and motor:

- Alignment of pump and motor is to be checked after the installation Procedure is described in subsection 9.6.

- Check that the pump shaft rotates easily and regularly.

- The coupling between motor and pump is to be completely guarded.

Wiring:

- The wiring is to be carried out by an authorised electrician in accordance with local regulations.

- Check suitability of voltage available with that on the motor plate.

- The motor overload switch is to be set at the maximum rated current of the motor.

- Check direction of rotation of the motor. If the direction of rotation of the motor is clockwise then the flow direction is from right to left seen from the motor side.

Relief Valve:

- Check that the valve points in the correct direction (see 5.5.1).

Control:

- The control &quipment is to be adjusted and checked.

7. ' STARTINGUP

Because of the sleeve bearings and shaft seals, ROTAN pumps can only be permitted to rim without a flow of liquid for the short period of self-priming. The faces of the sleeve bearings and shaft seals must not be allowed to become dry during prolonged storage.

When starting-up, please check

- that shut-off valves on the inlet and outlet sides are open.

- that on f i s t start-up the pump casing is filled with a small quantity of liquid to ensure the self-priming ability.

- that coolinghbricating devices etc., if any, are operational.

- that the control equipment functions.

- that the direction of rotation is c o m t If the direction of rotation of the motor is clockwise, then the flow direction is from right to left seen £tom the motor side.

- that the pump is drawing the liquid.

- that the pump does not vibrate or is noisy.

- that the pump does not leak

- that a soft seal, if any, leaks 10-100 drops a minute - see section 8.2.

- that the relief valve opens at the required pressure.

- that stuffing box and beatings do not give overheat; lip seal rings will normally cause a heating of the shaft during the time of &g-in the ring (approx. 2 hours).

- that the operational pressure and power consumption are correct.

- tliat on the magnetic coupling pumps, slip does not occur (no flow), and that the temperature rise does not exceed 30°C.

8. MAJNTENANa AND OPERATION

O p d g conditions under section 7 should be checked regularly.

8.1 LUBRICATION

ROT& pumps in configoration M (e.g. HD41ER-IM22B) demand external lubrication of the slide bearings. The intervals of re-lubric+ion and the type of lubricant are dependent on the operating conditions; ask the mpplier for particulars.

Packing cord as shaft seal demands current adjustment to ensure correct leakage at the stuffing box.

Dependent on RPM and viscosity the stu£6ng box must leak 10-100 drops a minute to remove the friction heat genergted between shaft and packing cord In the event of insufficient leakage the heat generation will cause bardend packing rings and increased wear on the shaft.

Systems of sealing liquid in connection with double mechanical seals (configuration MM) must be checked regularly to ensure

- that the liquid level in the sealing liquid container is coned

- that the concentration of the pumped medium in the sealing liquid does not overstep the permissible quantity.

- that the circulation of the sealing liquid between container and s-g box is in order.

- that in the case of "back to back" (configuration h4MP) the pressure of the sealing liquid is higher than that of the pumped medium on the primary shaft seal.

8.4 DRY RUNNING

The slide bearings and the shaft seal of the ROTAN pump are usually lubricated by the pumped liquid, and that is why dry runuing must not occur.

The lubricating properties of the pumped liquid decide how long the pump may run without liquid during priming and draining of the system.

9. REPAIR AND INSPECTION

A Before attempting any work on the pump ensure that it cannot be started accidently or unintentionally.

A The system mast be completely de-pressurized and drained for liquid

The service engineer mast know which .liquid has been pnmped as well as which a precautions he must take when handling the liquid in qnestion.

In connection with the servicing of magnetically. coupled pumps it should be A. considered that the magnetic parts can cause damage to pacemakers, credit cards, floppy disks, compaters, and watches.

A All precautionary measures, such as coupling gnards, pressure relief devices, and insolation for wiring, mast be in place before the pump onit is restarted.

Pump construction appears in subsection 11.2 sectional drawings.

9.1 D W G THE PUMP

-. When the pipe work has been drained, some liquid will remain at the bottom of the pump and in . . themffhgbox.

The pump can usually be drained by dismantling the kont cover or by placing t h e p u p with the suction/discharge ports upside down and rotating the shaft.

However, it can be difficult for very viscous liquids to pass fiom the stu&g box and the chamber between rotor and rear cover on to the pump casing; in such cases the stn£6ng box and the rear cover are fitted with draining devices.

On ED pumps the liquid in the canister is removed through the plug (item MB).

Where toxic liqmds are pnmped, precautions should be taken before dismantling, e.g. circulating neutralising liquids in the pump or using safety clothes and a breathing mask.

9.2 PUMP PARTS

The rotor, idler, pump casing, front cover and idler bearing can be inspected merely by removing the front cover. There is no need to remove the pump from the installation.

Place the idler so that the smaller root diameter faces the front cover.

The front cover should be placed so that the crescent is at the bottom of the pump.

The replacement idler pin is secured by an adhesive to ensure tightness.

9 3 MECHANICAL SEAL

Before replacing the mechanical seal and prior to dismantling, the position of the rotating parts on the shaft should be measured and noted so that the new seal can be fitted correctly.

9.4 SOFT SEAL

To replace the above, the packing gland is dismantled, and the packing rings are removed with an e m o r . New packing rings can be obtained already formed or they can be produced in the following way: Packing cord of the corm3 size must be wound round the shaft a number of times appropriate to the number of packing rings and cut through along the shaft with a sharp M e . The packing rhgs must be placed in the stu£6ng box with the slits diametrically opposite and pressed together using the packing gland. See section 8.2 regarding adjustment

95 fxmm'E BEARINGS

The sleeve bearings must be lubricated when assembling, as they will not withstand dry operation The lubricating groove, if any, in the idler pin should face the crescent The lubricating groove in the main bearing should be turned upside down.

9.6 FLEXlBLE COUPLING

The HD, CD, PD, and ED pumps are coupled to the motor by means of a flexible coupling. The alignment between the pump and motor must be checked by means of a straight edge over the coupling halves at 2 or 3 points on the coupling. Any misalignment, will appear as a gap between the straight edge and the coupling flange. A feeler gauge must be used to check that the gap is constant all the way around the coupling. Permissible clearances for eccentricity q d parallelism appear h m the supplier's instructions. For correct aligoment of the motor and pamp suitable shims must be fitted between the base of the pump and motor amj the base plate. Inaccarate alignment of the pump and motor will result in increased wear on the coupling elements.

9.7 LOCKING THE PUMP SHAFT

On disassembly/assembly it may be necessary to block the pump shaft. This is done by means of a piece of wood or soft metal placed between the teeth of the rotor through one branch of the Pump.

9.8 ADJUS- OF AXIAL CTEARAANCE

The axial clearance is checked with a feeler gauge between rotorlidler and front cover. Access is gained through one of the connection branches of the pump. Setting dimensions are shown in sub-section 5.6.

I€ the pump is in sin& the following method of adjusting the axial clearance can be used, a feeler gauge is not necessary. Adjust the pump shaft so that the rotor touches the kont cover, and then adjust the clearance between the rotor/idler and kont cover using the adjusting screws in accordance with the following table:

Angle change in0 = Axial clearancex 360

pitch

.. . .~. -. Regarding types HD, CD, and PD the clearance is adjusted by means of the b-g covers, items . .. CS and CR. Ensure that the screws, item CT, are tightened crosssvise so that the bearing will be

ptished squarely into the hoGing.

IDLER

The axial clearance of the GP pump is adjusted by means of the sleeve coupling, iitem DB, between pump and motor shaft by means of the adjusting screws, items KX and W , which are adjusted crosswise.

For adjustment of the axial clearance 'of the ED pump the fimt cover is displaced axially by means of the screws, items E and NM. It is recommended that the clearance is checked at a m i n k m of 3 points to ensure that the fiont cover is parallel to the rotor.

After the adjustment is made, check that the pump shaft rotates easily and regularly.

9.9 ED PUMPS IN PARTICTIJAR

- Thread

Pitch

The separation of the pump end (the screw joint, item ME) should be done with great care as the magnets in the external magnetic rotor (item MM) are easily damaged by scratches.

M8

125

The pump is provided with two threaded holes and two clearance holes in the lower part of the rear cover (item BA) and the coupling housing (item CQ) respectively. By means of two threaded bars the pump and the coupling part can thus be pressed from each other, the foot of the pump. casing being fixed to the base, and the foot of the coupling housing sliding on the base, guided by the threaded bars. The coupling housing is pressed as far back'that the outer magnet (item IvlIvI) is completely free of the canister (item MJ). The same procedure is followed during assembly.

M5

0,8

Alternatively disassembly/assembly can be done by using a block and tackle. The pump must be mounted vertically on its end and the coupling part lifted using an eye bolt in the shaft end.

M10

115

M6

1,O

M12

L75

Never put y o u fingers between the coupling part and the pump part during the e m b l because, magnets will draw the parts together with mforce.

hitially the front cover is set to a distance of 2 mm fiom the pump casing to allow a clearance between rotor and front cover during the assembly.

The torque of tightening for the bolt, itemMP, fixing the shaft in the main bearing, is: - 10 Nm for coupling type A.

30 Nm for coupling types G, H, I; Check that the disc spring, item NG, is correctly turned.

Take care that the magnetic parts do not pick up metallic shavings.

9.10 GP PUMPS IN PARTICULAR

The flanges motor of the GP pump must be provided with a- locked bearing at the drive end to ensure that the axial clearance of the pump is kept within the permissible limit

The HD and CD pumps for pumping chocolate (re. s&g box see section 11.2) have been designed so that the main bearing (item BC) is removed from the shaft seal housing along with the pacldng gland (item BB). Then the packing gland is separated in two parts and'removed, whereupon the main beadng can be pulled back on the shaft. Now there is k e access to pulling out the packing rings by means of a packing extractor, and to fit new rings in the shaft seal housing.

10. TROUBLESHOOTING

The following list makes it possible to locate failure causes:

Possl%le cause

-The pump is not self-priming 1-348-9-13 -The pump is unable to maintain flow 1-5

-The capacity is too low 2-3-5-7-8-9-13 -Noisy pump operation 2-5 -Overloading of motor 4-10 -The pump becomes jammed 4-10 -The pump is subject to excessive wear 8-10-11

1. Toohighavacum 2. Cavitation 3. Too high a viscosity 4. Too high a temperature 5. ThePumpdrawsair 6. Too high a pressure 7. Valve defective 8. The pump is corroded 9. Thepumpis worn 10. Impurities in the pump 1 1. Stuffing box tightened

too much 12. Defects in motor 12. Pipe diameter too small

or pipes clogged up.

11. SPARE PARTS

11.1 ORDERING SPARE PARTS

When ordering spare parts, please state the following information: Enam~le

- Serialnumber - Item list number (SX-No.) - Type designation - Code of mech seal, if &y - Number of magnetic coupling, if any - Number of by-pass valve, if any - Item reference of spare part - Designation of spare part

252756 5310 HD81ERM-1U332 AD -

Item CJ Mech. seal

The serial number of the pump, SX No, type designation and code of mechanical seal, number of magnetic coupling and bypass valve, if any, appear from the nameplate. In addition, the serial number is stamped on the left hand connecting branch of the pump, seen from the coupling end The item reference and designation of the spare part are to be found in the section drawings (subsection 11.2) and the spare parts list (subsection 11.3).

.. -- . - -. . . .. I ROTAW PUMP 1

HOB1 ERU 111332

e.m =MI RolPN=

The example shows the information necessary for specifying a mechanical seal to be supplied for a given HD8 1 pump.

112 SECTION DRAWINGS OF SPARE PARTS

The following pages show a representative selection of ROTAN assembly drawings. Not aJl pnmp configuratiois -are represented, but the drawings show all item references and configuiations that generally apply.

Relief valve for HD, GP (CD, PD, ED).

Relief valve for CD, PD (ED) - 26/33/41

LLST OF SPARE PARTS

Designation

Pump casing

Joint ringlo-ring

Joint ring

Bolt

Bolt

Bolt

Pipe plug

Drive screw

Name plate

Blind cover

Pipe plug

Joint ring

Front cover

Idler

Idler pin

Idler bearing

Lub. nipplfipe plug

Joint ring

Heating jacket

Bolt

Pipe plug

0-ririg

Rear cover

Packing glandbearing cover

Main bearingball bearing

Stud boltmolt

Nut

Washer

Pipe plugflub. nipple

Boltlpipe plug

Bolt

Pin

Designation

Seal housing

Intermediate bearing

Gasket

Distance ring

O-ring

Rotor

Shaft

Ball bearing nut

Ball bearing l o c h g ring

Key

Key Fixing rinp/dist.nce ring

Threaded screw

Snap ring

Packing ringslmech. seal

Mech. seal

Lantern ring

V-ring

Bearing bracket

Bearing cover

Beadng cover

Bolt

Ball bearing

Stud bolt

Heating jacket

Nut

=we Motor bracket

Coupling

Threaded screw

Threaded screw

O-ring

Item Desiwtion - EG Sealring

EJ Bolt

GA Valve

GB Spring

GC Adjusting screw

GD Nut

GE Cap GF Joint ring

GG Pressure plate

GH Pressure plate

GJ Valve cover

GK Valvecasing

GM Pipeplug

GN Jointring

GQ Bolt

GR Washer

HD Shield

HE Bolt

JL Joint ring

EM Bolt

KY Bolt

LT Washer

MA O-ring

MB Pipeplug

MC O-ring

MD Rollpin

ME. Bolt

MF Bolt

MG Bolt

M3 Canister

MK Inneimagnet

ML Bolt

MM Outermagnet

MN Washer

&E

MP

MQ MR

MS

hfrr MU

MV

IVIw

MX

MY

MZ

NA

NB

NC

ND NE NF NG'

NJ

NK

NM NN NP

NQ NS

NT

N U NZ

Bolt

Bolt

Lock ring

Key Seal ring

Connecting h g e

Main bearing complete

Spacer ring

Bolt

Cylinder pin

O-ring

O-ring

Ball bearing

Temp. sensor

Bearing cover

Shaft

Cover

Disc spring

Bolt

O-ring

Set screw

O-ring

O-ring

Key Intermediate piece

Threaded fitting

O-ring

Draining plug

SUCTION 8 DELNERY

Delivery

I l l j l ljll I y CHANNEL I Holedrill

6XP120

950 /I 950 I

Date 22 AUG 08 Dm By NYAN Dim Unit mm Scale 1 : 15

Drg No T 201052

Motor TECO AEVB 50KW c/w Reducer CB9F Power/Supply 440V/30/60Hz Full Load Current Frame Size 0 225 MC hsulat i~n Class F / IP 55 Item No. 10

ient LABROY SHIPBUILDING & ENGR PTE LTD 111 1 82/1 8311 8411 85 :ME FUEL OIL CARGO PUMP umpQuip Engineering Pte Ltd Kaki Buklt Road 2, #01-23 Slngapore 417841

11 : (65) 6748 3888 Fax : (65) 6748 8858

Pump Desmi ROTAN HD2OI Gear Pump c/w Gear Reducer Capacity 125 M3/HR / 347 RPM (RATIO-4.68) Total Head 75 M Matl CI Casinq/CI Geor/St Shafthech Seal Coupling CL - 250 Weight 811 KG


FOR

DESMI - . NSL

VERTICAL IN LINE

PUMP

PuMPQmENGmERlNGSINGAPoRE lEL : 65-67483888 FAX : 65-67488858



FOR

DESMI VERTICAL - NSL

Compact Spacer : TYPE 13 / 14

TYPE 16

A 02 / D 02,

Pm4PQmmG2NEERmTGSmGAPoM TEL : 65-6748388d FAX : 65-67488851


1'4 TABLE OF CONTENTS: PAGE

. 1 .PRODUCT DESCRIPrrON . - .....-- -3

1.1 DELIWRY .................................................................................................................................................................... 3

2 . C C DATA . . . . . . . . . . . . . . . . . . . . . 3

2.1 EWLANATION OF THE TYPE NOMBW ............................................................................................................... 3 2 2 TECHNICAL DESCFWTION ..................................................................................................................................... 4

3 . INSTALLATION . . ....................... ...... 6

3.1 MOUNTING/FASTENING ........................................................................................................................................... 6 3.2 WIRING ......................................................................................................................................................................... 6

4 . TRANSPORT/SMRAGE - . 6

5 .DISMANTLING .... ...-.-. ................................................... 7

5.1 ACCESS TOJMPEUER .................................. ........................................................................................................... 7 5.2 DISMANTLING SHAPT SEAL .................................................................................................................................... 8 5.3 DISMANTLING SEAT ............................................................................................................................................... 8 5.4 DISMANTLING S m WlTH BEARINGS ........................................................................ : ............................. 8 5.5 INSPECTION ................................................................................................................................................................. 8

6 . ASSDIBLING- ..8

6.1 FITTING S M G RINGS ..................................................................................................................................... 8 6 2 FITTING SHAFT WITTI BEARINGS ...................................................................................................................... 8 6.3 FITTING WATER DEELEClDR ................................................................................................................................. 9 6.4 FITTING SHAFT SEAL ................................................................................................................................................ 9 65 Fl'ITlNG IMPELLER .................................................................................................................................................... 9 6.6 FITTING BEARING HOUSING AND SHAFT SEALCOVER 9 6.7 SHAIT ............................................................................................................................................................................ 9 6.8 FTITNG COUPLING ............................................................................................................ ............................... 10

7 .FROST PROTECTION 11

8 . DISMANTLING 11

9.1 STARTING .................................................................................................................................................................. 11

10 . SYSTEM BALANCING 11

1 1 .INSPECTION AND MAINTENANCE 13

11.1 DRAINING THE PUMP ........................................................................................................................................... 13 1 1.2 BEARINGS ................................................................................................................................................................ 13

12.1 ORDERWG SPARE PARTS .................................................................................................................................... 15

13 .OPERATING D A T A . - - - 1 5

..... 1 4 . EU DECLARATION OF CONFORMlTY . . . . . . . 16

15 .ASSEMBLY DRAWING AND SPARE PARTS LIST 02151265- .....I-....tll.....II....--....-.1.-.17.... 17

16 .ASSEMBLY DRAWING AND SPARE PARTS LIST 033014151525 .......... ....-... 18

17 .DIMENSIONAL SKETCH 0215/265 ............. ........ ...... -........19

......................... 18 .DIMENSIONAL SKETCH 0330/415/525 . . 20

1. PRODUCT DESCRIPTION

These operation and maintenance instructions apply to the DESMI NSL Spacer pump.

The pump is a single-stage vertical "in-line" centrifugal pump (i.e. horizontal inlet and outlet on the same line) equipped with stainless steel shaft, mechanical shaft seal, and closed impeller.

The pump is suitable for the of liquids with temperatures up to 80°C. W1th special shaft sealup to 120°C. M a working pressure and number of revolutions are indicated under Operating Data

The pump is particularly suitable for the pumping of water in connection with cooling systems, cooling of diesel engines, as bilge pumps, ballast pumps, f ie pumps, brine pumps, pumps for irrigation, iish farms, water works, district heating, salvage corps, army and navy, etc.

The descriptions in the operation and maintenance iustructions are divided into two parts covering the groups 02151265 and 033014151525, as the designs of these two groups are Merent. The nurnbersrefer to the standard impeller diameter of the pump. E.g.:

G2151265: Pumps with 0215 or 0265 impellers: The back of the impeller is equipped with relief blades to reduce the load on the bearings. The h e through inlet and outlet is flush with the centre line of the shaft.

#33014151525: Pumps with 0330, &15 or 0525 impellers: The back and the front of the impeller are equipped with sealing rings and relief holes to reduce theload on the bearings. The pump inlet and outlet are tangential ie. the line through inlet and outlet is offset m relation to the centre line of the shaft.

1.1 DELIVERY

- Check on delivery that the shipment is complete and undamaged - Defects and damages, if any, to be reported to the carrier and the Supplier immediately in order that a claim can be advanced

2. TECHNICAL DATA

The pumps are manufactured in various material combinations which appear from the type number on the name plate. See below.

2.1 EXPLANATION OF THE TYPE NUMBER

All the NSL pumps are provided with a name plate. The type number indicated on the name plate is built up as follows:

Pressure branch diameter, YYY: Standard impeller diameter M: The material combination of the pump. R: The assembly combilllittion of the pump. 2: Other variants

M may be the following: A: Casing and shaft seal cover : Cast iron + cast iron alloy. Impeller and sealing rings: Bronze B: Casing and shaft seal cover : Cast iron + cast iron alloy. Impeller and sealing rings: Stainless. C: All cast iron D: Casing and shaft seal cover: Bronze. Impeller and sealing rings: NiAlBz E: Special materials U: Nonmagnetic material

The pumps can be delivered in other material cornfinations according to agreement with the supplier.

R may be the following: 02: Monobloc, with bearing in the pump 12: Monobloc, without bearing in the pump 13: Spacer, light bearing housing 14: Spacer, heavy bearing housing 15: Spacer, heavy bearing housing and heavy motor bracket (special motor bracket)

Z may be the following: i : PN16 flanges j : PN25 flanges k : Special flange 1 : Other s e g b o x m : BSflanges n : ANSI flauges o : Shockproof design p : Other design q : ns flanges

Any use of the pump is to be evaluated on the basis of the materials usedin the pump. In case of doubt, contact the supplier.

Pumps in material combinations A and C are primarily used for fresh water. Pumps in material combination D are primarily used for seawater.

If the pumps are designed for special purposes the following is to be indicated:

PumpNo. : Pumptype : Application : Comment :

2.2 TECHNTCAL DESCRIPTION The noise level indicated is the airborne noise inchlding the motor. The noise depends on the motor type supplied, as the noise fiom the pump can be calculated as the noise level of the motor + 2dB(A). The noise level is for pumps with electric motors.

The capacity of the pump appears h m the name plate on the pump. If the pump has been'delivered without motor, the pump capacity is to be indicated on the plate when mounting the motor.

The permissible loads on the flanges appear from the following.table. The values apply to standard pumps in bronze @g5) and cast iron (GG20). As to pumps in SG iron (GGG40) the values are to be increased by factor 1.5.

In connection with the permissible loads on the flanges the following is to be observed:

where index "calc" are the values calculated by the user. At the same time none of the forces or moments may exceed the indicated figure multiplied by 1.4.

n . b 3. INSTALLATION

The pump should be mounted and fastened on a solid base plate with a flat and horizontal surface to avoid distortion.

The max. permissible loads on the flanges stated in paragraph 2.2 are to be observed.

At installations pumping hot or very cold liquids, the operator must be aware that it is dangerous t o touch the pump surface and, consequently, he must take the necessary safety measures.

3.2 WIRING

A' Wiring to be canied out by authorised skilled workmen according to the rules and regulations in force.

The weights of the pumps in A andD combimation (without motor) are stated in the following table, and the pumps are to be lifted as shown below.

I The pump is to be stored in a dry area.

Before shipment the pump is to be fastened securely on pallets or the like.

Pump

Weight in kg A 1 D-combination

incL base plate h

Weight m kg A / D-combination

incL base ~ h t e

The pump is to be lifted in the following way:

The lifting straps must not bear against sharp edges. and comers.

5. DISMANTLING

5.1 ACCESS TO IMPELLER

The numbers in brackets refer to the position numbers on the assembly drawing.

Dismantle guard (69).

02151265 Remove Allen screws (77) between coupling part motor (71) and spacer (72) and the screws (76), which hold the flexiile coupling (74) to the coupling part pump (70). It is not necessary to remove the screws (also 76) which hold the flexiile coupling to the spacer. After a vertical pull downwards take out the spacer (72). Loosen the pointed screw (73) and pull the coupling part pump (70) off the shaft. Dismantle the copper pipe (58). Remove Allen screws (22) which hold the shaft seal cover (20) to the pump casing. Remove the shaft seal cover from the pump casing by means of the pointed screws (86). The bearing housing with shaft and impeller can now be lifted up ftom the pump as a unit, and the impeller can be inspected.

033014151525 Remove Allen screws (76) at each end of the coupling, and remove the spacer (72). Loosen the pointed screw (73) and pull the coupling part pump (70) off the shaft. Dismantle the copper pipe (58). Remove set screws (22) with washers (23) which hold the shaft seal cover to the pump casing. Remove the shaft seal cover from the pump casing by means of the pointed screws (86) The shaft seal cover and the bearing housing with shaft and impeller can now be lifted up ftom the pump as a unk and the impeller can be inspected.

5.2 DISMANTLING SHAFlC SEAL

82151265 Remove nut (6). Pull off the impeller, and remove sunk key (9). Remove AUen screws (19), which hold the bearing housing to the shaft seal cover, pull shaft seal cover and bearing housing apart, by which the shaft seal (10) and water deflector (1 1) are pulled off the shaft.

0330/415/525 Remove set screw (6). Pull off the impeller, and remove sunk key (9). Remove set screws (19), which hold the bearing housing to the shaft seal cover, pull shaft seal cover and bearing housing apart, by which the shaft seal (10) is pulled off the shaft.

5 3 DISMANTLING SEAT

Press out the seat from behind the shaft seal cover.

5.4 DISMANTLING SHAFT WlTJ3 BEARINGS

Before dismantling the shaft with bearings, remove the sunk key (16). The shaft cannow bepuIled out of the bearing housing allowing inspection of the bearings.

5 5 INSPECTION

When the pump has been dismantled check the following parts for wear and damage:

- Sealing ringslimpeller: Max. clearance 0.4-0.5 ram measured in radius. - Shaft sedshaft seal cover.: Check the seat for flatness and cracks.

Check the rubber parts for elasticity. - Bearings: Replace in case of wear and noise.

6. ASSEMBLING

6.1 FTlTNG SEALING RINGS

When fitted, the sealing ring (4) in the pump casing (1) is to bear against the shoulder of the pump casing.

03301415/525 When fitted, the sealing ring (27) in the shaft seal cover (20) is to bear against the shoulder of the shaft seal cover.

6.2 ETJTJNG SHANT WITH BEARINGS

Lead shaft with bearings into the bearing housing. Fit sunk key (16).

0330/415/525 Fit cover under bearing (26).

6 3 FITTING WATER DEFLECTOR

6215/265 Assemble the bearing housing and the shaft seal cover. Lead the water deflector (1 1) over the shaft until it touches the shaft seal cover and then further 1-1.5 mm into the shaft seal cover.

Lead the water deflector (1 1) over the shaft until it touches the cover under bearing (26) andthenfmtk 1-1.5 mm towards the cover under bearing. Assemble the bearing housing and the shaft seal cover.

6.4 FITTING SHAFT SEAL

Before fitting the seat, clean the recess in the shaft seal cover. When fitting the seat, remove the coating without scratching the lapped surface. Dip the outer rubber ring of theseat into soapy

water. Now press the seat into place with the hgers and check that all parts are correctly imbedded.

If it is necessary to use tools for assembling, then protect the sliding surface of the seat to prevent it fiom beiig scratched or cut. Lubricate the inner diameter of the slide ring rubber bellows with soapy water and push it over the shaft. The use of a fitting bush as shown on the assembly drawing is recommended to avoid that the rubber bellows is cut.

Push the slide ring over the shaft with the hand. If the rubber bellows is tight, use a fitting tool and take care that the slide ring is not damaged. If the carbon ring is not &ed, it is important to check that it is fitted correctly, ie. the chamferedhpped side is to face the seat. The carbon ring can be held by a little grease.

When using soapy water on the shaft, the bellows wiU settle and seat in about 15 minutes, and until then tightness should not be expected. After start, check by viewing the leak hole at the bottomof t h e m - - housing that there are no leaks.

6.5 JTITTh'G IMPELLER

Fi the sunk key in the shaft and lead the impeller towards the shoulder of the shaft. Take care that the ring at the end of the shaft seal spring locates in the recess of the impeller. Secure the impeller with washers (7 and 8) and a nut (02151265) or a set screw (033014151525).

6.6 ETITJNG BEARING HOUSING AND SHAET SEAL COVER

Place the O-ring (21) between pump casing and shaft seal cover on the shaft seal cover where it can be held with a little grease. However, check the material of the O-ring fist. As standard the katerial is nitrile, but it might be EPDM which will be damaged by mineral grease. Use soft soap or silicone grease for EPDM. Fd and fasten bearing housing and shaft seal cover. Screw the pointed screw (86) back into the shaft seal cover before tightening. Insert the copper pipe (58).

When the pump has been assembled, check that the shaft rotates fieely.

6.8 FTIWNG COWLING

Fit the flexile coupling (74) to the spacer (72) by means of the Allen screws (76) which are tightened up with torque according to the table below. Check that the aluminum insert in the mbber part does not rotate during tighteniug as it may damage the coupling. To prevent this, apply a little grease to the bolts under the bolt head. The Allen screws (76) can be used again and up to 3 times before they are to be replaced by new on@ bolts to secure the locking function Do not use Loctite as it will damage the rubber element.

Fix the spacer with the flexible coupling to the coupling part motor (71) by means of the Allen screws (77) and lock nuts (79). also with torque according to the table below. In order to secure the bolt connection M a new lock nut or secure with a locking means.

Check that the distance, cf. the table below, between spacer and coupling par^ pump corresponds to the actual coupling size which appears &om the coupling element itself. Et the flexible coupling to the coupling part pump by means of the Allen screws (76) which are to be greased a little under the bolt head and tightened with the torque stated.

033014151525 Check Allen screws (76) and coupling bushes (74) for damage and clean these with a cloth. Replace themin case of damage.

Thread

M8 MI0 M12 M14

Remove grease ffam the screw threads by means of benzene, and clean the threaded holes in the coupling halves for pump and motor by means of pressure air. If new coupling halves are mounted, also remove grease ffom the threaded holes by means of benzene.

Torque

25 Nm

50 Nm

90 Nm

140 Nm

Place coupling bushes (74) in the top holes of the spacer (72), the chamfering on the bushes is to face downwards. Place the coupling bush in the bottom holes of the spacer, the chamfering on the bushes is to face upwards. Hold the handunder the spacer and the bottom coupling bushes and carefully push the spacer into place.

Apply Loctite type 242 on the Allen screws (Lnctite 242 is recommended as it will allow dismantling) and tighten all screws with the hand. It might be necessary to push the spacer a little until the screws have located in the thread and you feel that the spacer has found the right position.

Coupling element

V1700-0832 V1700-1042 V1700-1242 V1700-1442

Tighten the screws with a torque wrench at 55 Nm. As motor/pump shaft will rotate during this operation it is necessary to hold the spacer by wedging a pin bolt, a piece of Oat bar or the like between the two following screw heads in order to lock the system while the screws are tightened.

Fit guard (69).

Distance

4mm 4mm 6mm 6 mm

- . .

7. FROST PROTECTION

Pumps that are not in operation during fkost periods are to be drained to avoid kost damage. Remove the plug (3) at the bottom to empty the pump. Alternatively, it is possible to use anti-fieeze liquids in normal constructions.

8. DISMANTLING

A Before dismantling the pump make sure that it has stopped. Empty the pump of liquid before it is dismantled fkom the piping system. If the pump has been pumping dangerous liquids you are to be aware of this and take the necessary safety measures. If the pump has been pumping hot liquids, take great care that it is drained before it is removed from the piping system

9. START-UP

a A centrifugal pump will not function until it has been filled with liquid between the foot valve and somewhat above the impeller of the pump. The liquid also serves as coolant for the shaft seaL In order to protect the shaft seal the pump must not run dry.

A'ITENTION I For safety reasons the pump is only allowed to operate against closed suction and discharge valves for a short time (max. 5- 10 minutes and at a max. temperature of 130°C). Otherwise there is a risk of damage to the pump and, at worst, of a steam explosion. If the pump is not manually obsesved, the installationof a safety device is recommended. . .

9.1 STARTING

Before starting the pump check that:

- the shaft rotates keely without jarring sounds. - the pump casing and the suction line are filled with liquid.

Start the pump for a moment to check the direction of rotation. If the direction is correct (ie. in the direction of the arrow) the pump may be started.

10. SYSTEM BALANCING

It is often di£Ecult to calculate a manometric delivery head in advance. It is, however, decisively important to the quantityof liquid delivered.

A considerably smaller delivery head than expected will increase the quantity of liquid delivered, causing increased power consuraption and perhaps cavitation in pump and piping. In the pump the impeller may show signs of heavy erosion caused by cavitation (corrosion) which may at times render anirnpeller un6t for use in a very short time. Not unusually do similar erosions occur in pipe bends and valves elsewhere in the piping system.

Therefore, after start-up, it is necessary to check either the quantity of liquid delivered or the power

consumption of the pump e.g. by measuring the current intensity of the connected motor. Together with a reading of the differential pressure the quantity of water delivered can be determined against the characteristics of the pump.

Should the pump not function as intended, please proceed according to the fault-hdhg list. Bear in mind, though, that the pump was carefully checked and tested at the factory and that the majority of faults stem 6rom the piping system.

I FAULT

The pump has no or too low capacity

The pump uses too much power

The pump makes noise

CAUSE

1. Wrong direction of rotation

2. Piping system choked 3. The pump is choked 4. Suction line leaks

Pump takes air

5. Suction lift too high

6. Pump and piping system wrongly dimensioned

1. Counter-pressure too low

2. The liquid is heavier than water

3. Foreign body in pump

4. Electric motor is running on 2 phases

1. Cavitation in pump

REMEDY

Change direction of rotation to clockwise when viewed ftom shaft end (the direction of the arrow) Clean or replace Clean the pump Fmd the leakage, repair the fad5 non-return valve not submerged Check data sheet Q/H curve and NPSH or contact DESMI As5

Insert or& plate or check valvdContact DESMI Contact DESMI

Dismantle the pump, remove the cause Check fuses, cable connection, and cable

Suction lift too high1 Suction line wrongly dimeusioned/liquid temperature too high

ll. INSPECTION AND MAINTENANCE

Inspect the shaft seal for leaks at regular intervals.

- Before inspection of a pump without guard check that the pump cannot be started ' ' " any. - The system is to be without pressure and drained of liquid. - The repairman must be familiar with the type of liquid which has been pumped as well as the

safety measures he is to take when handling the liquid

11.1 DRAINING THE PUMP

When the piping systemhas been drained, note that there is st3l liquid in the pump. Remove the hquidby dismantling the pipe plug (3) at the bottom of the pump.

11.2 BEARINGS

02151265 The bearings are dimensioned for a nominal life of 25,000 working hours and are to be relubricated according to the below table.

Light bearing housing (combination 13): The bearings are lubricated for life and require no attention but are to be replaced m case of noise or bearing wear. In connection with replacement, the lower bearing is to be mounted with an RS - sealing faciug downwards, mthe bearing itselfwith grease and place a grease bead on the bearing towards the sbaftm a quantity corresponding to the table below. , .

Heavy bearing housing (combit ion 14): Only theupper bearing (15) is lubricated for life, whereas the lower is to be relubricated through the lubricator nipple (84) in accordance with the table below. The replacement of bearings to be made under the same conditions and according to the same procedure as for combination 13, however, the RS - sealing is not to be considered.

0330/415/525 The bearings are dimensioned for a nominal life of 100,000 working hours and are to be relubricated according to the below table;

Light bearing housing (combition l3): The bearings are relubricated through the lubricator nipples (84) at top and bottom of the bearing housing (18). In connection with replacement, the bearings are to be mounted with the RS - sealing facing downwards, the bearing itself with grease and place a grease bead on the bearing towards the shaft m a quantity corresponding to the table below.

Heavy bearing housing (combination 14): Both bearings are relubricated through lubricator nipples (84) at top and bottom of the bearing housing (18). See instructions for 02151265. The top bearing (15) is to be mounted with the RS - sealing facing downwards, fill the bearing itself with grease and place a grease bead on the bearing towards the shaft m a quantity corresponding to the table below.

Assenbly Interval

Light bearing I Lubricated for life housing

Heavy bearing 8000 hours housing

Heavy bearing 4500 horn housing

Heavy beaxing 4500 hours housing I

Heavybearing housing

Quantity Bottom bearing

(13)

' 4500 hours

Lubricated for life

Lubricated for life

If the pump liquid temperature is below 80°C the following types of grease are recommended::

ESSO

BP

Shell

Mobil

Castrol

Texaco

If the pump liquid temperature is above 80°C, high-temperature grease is recommended, e.g. SKF LGHP2.

Beacon 2

Energrease EP grease 2

Alvania grease 2

Mobil lux grease EP 2 eIler Mobil plex 47

Spherol AP 2

Multifak EP 2

48

stat02

Rembrandt EP 2 ellet Rubens

Statoil Uniway u2

12. REPAIRS

12.1 ORDERING SPARE PARTS

When ordering spare parts please always state pump type, serial No. (appears on the name plate of the pump), position No. on the assembly drawing and designation on the spare parts list.

13. OPERATING DATA

The following workkg pressures (pressure in piping incL the pressure increase caused by the pump) and number of revolutions are allowed in standard pumps. 0215 pumps with frame size 280 motors and 0265 pumps with frame size 315 motor are only available in combination 15 (& bracket).

The above-mentioned max. working pressure is NOT valid for pumps approved by a classification society. Pumps approved by classification societies have been pressure tested according to the

Pump NSL80-215

NSL80-265

requirkmentiof these societies, ie. a test presswe of 1.5 x theepermissible working he test pressure is stated in the test certificate and stamped into the discharge flange of the pump.

Max. working Press- Iba1

Bronze1 Castiron

16

145

Max. working Presswe [bar]

SG-iron

32

29

Max. RPM

Light 1 heavy bearing housing

1800 13600

1800 / 3600

Pump NSL150-265

NSL15C-330

Max. working pTessure

[bar] Bronze1 Castimn

7 7 I 13

Max. working P ~ S W

par] SG-iron

14

27

Max. RPM 1800

1800

PART LIST

FOR

1/2" AIR EJECTOR

PRIMING UNIT

PUMPQUIP ENGINEERING SINGAPORE TEL : 65- 7483886 FAX : 65 - 7488856

AIR EJECTOR PRIMING UNIT. 112"

PRESSED AIR INLET

X'BSP

TO PUMP DISCHARGE

FROM PUMP SUCTION

SPARE PART UST-

item NO. I ~ t y I Desulption

I I I I I I

1 1 Pn'mlng ejector, 112" mehammer

2 1 2 1 EI~OW. 112. I 3 1 Non-returnvalve

4 3 Nipple. 1 R"

5 2 Solenoid valve body, 136670D. Blakert

6 2 Coil. 15 watt 2 3 0 ~ 1 I ~hf50Hz-601-b

AIR EJECTOR PRIMING UNIT. 112'

4 FROM PUMP SUCTION

8 TO PUMP DISCHARGE

SPARE PART UST-

Item No. Qty DescripSon

I I 1

~ - ~~ . - 20. SPARE PARTS LIST 033014151525 OZcokm.

1 Pump casing 2 Pipe plug 3 Pipe plug 4 Sealing,hg 5 Impeller 6 ~et.screw 7 -SplingcoIlar' 8 Washer 9 Sunkkey 10. Me& shaft seal 11 Water deflector 12 Ring lock 13 Ballbeadng 14 Grease valve h g * 15 B w c o v e r 16 Setscrew 17 Shaft 18 Shaft seal cover 19 Coupling 20 Motor bracket 21 O-ring 22 Setscrew 23 Lxkwasher 26 Cover under bearjng 27 Skalingdng 2 28 Guard 58 Copper pipe 59 Hexagonnipple 61 Hexagonnipple 64 Setscrew 70 Allenscrew 71 Setscrew 72 r ' . - ". k flange 73 Pointedscrew 75 INSEX-screw 76 Sunkkey 81 Sealing washer 84 Lubdcar~rnipple 86 Pointed screw u 93 Setscrew 94 Base plate 95 ' Lock warha 96 Manometer 97 Nipple 98 S k v e 107 Pipe plug

*) Support disc in light . bearing honsing

15. ASSEMBLY DRAWING 02151265 OZCOMB.

See 033014151525 pump on the next pages 16. SPARE PARTS LIST 02151265 02-COMB.

1 pumpvip e n g l n e e r l n g p t w Itd

- 8 Kald BUM Road 2, Ruby Warehouse Complex MI-23 (malnkAes office) MI-22 (csnbal stores) Singapore 417841 Tel: 8547483888 (5 Llnes) Fax: 65674.38858 (2 Unes)

. E-mall:. [email protected]

1 Pumpcasing 2 Pipe plug 3 Pipe plug 4 Sealing ring 5 Impeller 6 Nut 7 Spring collar 8 Washer 9 Sunkkey 10 Shaftseal 11 W B ~ T defleCt01 12 Ring lock 13 Ball bearing 14 Suppondisc 15 Bearing cover 16 Allenscrew 17 Shaft 18 Shaft seal cover 19 Coupling 20 Motorbracket 21 0 - ~ g 22 AUenscrew 28 Gnard 58 Copper pipe 59 Hexagon nipple 70 Allenscrew 71 Setscrew 72 Intermediate flange 73 Pointed screw 75 INSEX-screw 76 S d k e y 81 Sealing washer 93 Setscrew 94 Base plate 95 Lockwasher 96 Manometer 97 Nipple 98 Sleeve 107 Pipe plug

PDMPQUIP SINGAPORE TEL : 65-6746 3888 F q : 65-6746 8858 IULL NO ERVICES AIR WECTOR PRIMING SYSTEM EM DESC. 112" AIR EJECTOR PRIMING UNIT CIW SOLENOID VALVE &

PRESSURE CONTROL SWITCH

L. SUPPLY 220 V 1 PH 50 HZ SCALE NTS RAWN BY M.L LEE DATE SFeb-92 IMENSIONS ' mm APPROX WT 10 KGS DRAWING NO. W 112-1017571

15. ASSEMBLY DRAWING 02151265 16. SPARE PARTS LIST 02151265 See a3301415 pumps on the next page

1 Pumpcasing 2 Pipe plug 3 P i g plug 4 SesLingring ' '

5 Impeller 6 Nut 7 Spring collar 8 W+er

' 9 Sunkkey 10 Mech.shaRsesl 11 Water deflector 12 Ring lock 13 Ballbearing 14 Support disc 15 Ballbearing 16 Sunkkey 17 Shaft 18 Bearihg houing 19 Allenscrew 20 Shaft seal cover 21 O-ring 22 AUensorew 58 Copper pipe 59 Hexagonnipple 60 Set- 63 Bracket 64 Setscrew 67 Setscrew 69 Guard 70 Couplinghalfpump 71 Couplinghalfmotor 72 Spaca 73 Pointe+aew 74 Elastomer 76 Allenscrew 77 AUenscrew 79 Nut 81 Sealing washa 84 Lubricatornipple *) 86 Pointed mew 93 Set screw 94 Base plate 9s Lockwasher 96 Manometer 97 Reduciugnipple 98 Haxagonnipple 99 T-piece 100 Bulkhead cormection 101 Screw cap 103 Copper pipe 106 Manometa cock 107 Pipe plug 109 Set screw 110 Manometp fitting

15. ASSEMBLY DRAWING a3301415 16. SPARE PARTS LIST a3301415

1 Pump casing 2 Pipe plug 3 Pipe plug 4 Sealing ring 5 Impeller 6 Set.screw 7 Springcollar 8 Wssha 9 sunkkey

10 Mech shafl seal 11 Water deflector 12 Ring lock 13 Ball bearing 14 Grease valve ring* 15 Ball bearing 16 Sunkkey 17 Shaft 18 Bearing housing 19 Setscrew 20 Shaft sealcover 21 O-ring 22 Set Screw 23 Lockwasher 26 Cover under bearing 27 Sealing ring 2 . 58 Copperpipe 59 Hexagonnipple 60 Setscrew 6 1 Hexagqn nipple 63 Bracket 64 Setscrew 67 Setscrew 69 Quad 70 Coupling halfpump 71 Coupling half motor 72 Spam 73 Pointed screw 74 Coupling bush 76 Menscrew 8 1 Sealing washer 84 Lubricator nipple 86 Pointed s m 93 setscrew 94 Base plate 95 Lockwasher 96 Manometet 97 Reducing nipple 98 ha tag^ nipple 99 T r p' lece 100 TMkhd connection 101 Screwcap 103 Copper pipe 106 Manometer cock 107 Pipe plug 109 Set screw 11oManometerfiting

15. ASSEMBLY DRAWING a215l265

See 83301415 pump on the next pages 16. SPARE PARTS LIST 02151265

j el:-65-67483888 (5 Unes) Far 8567488858 (2 Unes) ! . E-mall:' [email protected]

1 Pompcasing 2 Pqeplug 3 Pipe plug 4 S * ~ g 5 Impeller 6 Nut 7 springcollrn 8 Washa 9 sunkkey 10 SMsea l 11 Water deflmtor 12 Ring lock 13 Ball besdng 14 Sopport disc 15 BParingcova 16 Sunkkey 17 S M 18 Shaft seal cover 19 Wenscrew 21 @ring 22 Wenscrew 36 P o i n M m w 58 Copperpipe 59 Hwragonmpple 60 Sets- 63 Mokrbracket 64 Set- 65 hkmedhte flange *) 66 Alkn screw *) 67 Sets- 69 Gnard 70 C ~ u p l i n g F ~ u m p 71 c ~ u p l i n g ~ a ~ ~ ~ 72 S- 73 Pointedscrew 74 Coupling discs 76 Wenscrew 77 Alknsaew 78 Washer 79 Pinchnut 80 A h m 81 S~~ 86 Pointedscrew 93 Setscrew 94 Base plate 95 Lockwarha

98 sleeve 106 Pressure gauge cock 107 Pipe plug *) Only if malor is bigga k motor bracket

17. ASSEMBLY DRAWING 03301415 WrrH LIGHT BEARING HOUSING (W-330,100-330,125-330,100-415 and 125-415)

( N16 OR ~ 1 1 6

18. SPARE PARTS LIST 03301415 wnm LIGHT B E . G HOUSING

1 m* 2 Pieplug 3 Pipe plug 4 S&gIing 5 Impella 6 Nut 7 Spring& 8 warher 9 Smkkey 10 Shaft& 11 WataMector 12 Ring lock 13 Ballbeadng 14 s~pportrns~ 15 Bemingwver 16 Smkkey 17 Shafi 18 Shaft seal wva 19 Menscnw 21 Oriog 22 Allenmew 27 ShafiXal2 36 Poimedsuew 58 Coppapge 59 Hexagonnipple 60 Sdscrcw 63 Mombmcket 64 Sets- 65 r . "

-*I 66 AUenmew.) 67 Sdscrcw 69 had 70 C O T W P ~ P ~ 71 COUplingpwmtnr 72 Spacm 73 Pointedmew 74 Coupling discs 76 AnEnscrew 77 A l l m m 78 Warher 79 Pinchnut 80 AnEnsucw 81 Seaxngwssher 86 P o ~ m e w 93 Setmew 94 Baseplah, 95 Lockwaskr

98 ~A-ve 106 Ressore gauge cock 107 Pipe piug

Y2.I AIR EJECTOR PRIMING UNIT I- 458

-I SOLENOID VALVE 22ov110

I COMPRESSED AIR l N L E T 0 P ESP \ - 5-7 KGICM2 I

B O T O M VIEW \ TO PUMP DISCHARGE

PlPE 0114" ESP (VENDOR SUPPLY)

/ TO PUMP SUCTION

PlPE 0318" BSP (VENDOR SUPPLY)

8 X 018 BCD l s O

SUCTION & DELIVERY

Date 21 AUG 08 Drn By NYAN Dim Unit MM Scale 1 : 10

D rg No D102150-14A

Motor 45 KW/ 3500 RPM Power/Supply 440V/ 30/ 60Hz Full Load Curent Frame Size D 225 MA Insulation Item No 11&12

IP 55

lient LABROY SHIPBUILDING & ENGR PTE LTD lull 182/183/184/185 ervice DRILL WATER/ FRESH WATER CARGO PUMP

PumpQuip Engineering Pte Ltd 8 Kakl Buklt Road 2. #01-23 Singapore 417841 Tel : (65) 6748 3888 Fax : (65) 6748 8858

Pump D E M NSL 100-215/A14 COMPACT SPACER WE KRT Capacity 125 M3/HR ( With Air Priminq) Total Head 75 M Matl CI Wng. Ni A-Br Imp, St St Shaft Mech Seal Coupling SPACER Weiqht 505 KG

rBX0'? 8 X 018 HOLES

l ient LABROY SHIPBUILDING & ENGRG PTE LTD I Pump DESMl NSL 100-330 / DO2 MRT CENT I Motor 15 KW / 1750 RPM I Date 22 AUG 06 iull 182/183/184/185 I rnnnpitv r'inuz/HR 1 Power/Supply 440V/ 30/ 60Hz I Dm By NYAN ;emice RAW WATER PUMP I Total Head 25 M I Full Load Current I Dim Unit MM

PumpQuip Engineering Pte Ltd I Matl & k i n g , NI Alu Br Imp. St St Shofl, k c h Seal I Frame Size D 160 L I Scale 1 : 11 8 ~ a k i 6 k l i ~ o a d 2, #01-23 Singapore 417841 I Coupjing MONO BLOC with b e d IPSH(Req) I Insulation Tel : (65) 6748 3888- Fax : (65) 6748 8858

c'ass / IP 55 1 D rg No 103317-2D I Weiqht 407 KG I Imp Dia I Item No 13

B O T O M VIEW

SUCTION & DELIVERY

EL PRIMING Y

PUMP z

a PRESSURE

Date 02 JAN 09 Dm By NYAN Dim Unit MM Scale 1 : 10

Drg No 122625-16D

Motor 25 KW/ 1750 RPM Power/Supply 440V/ 301 60 Hz Full Load Curent Frame Size D 180 LC Insulation Item

Class / IP 55 1

lient LABROY SHlPBUllDlNG & ENGRG PTE LTD lull T-182/183/l84/185 iervice HYDRAULIC POWER PACK S.W COOLING PUMP PumpQuip Engineering Pte Ltd I ~ a k l ~ u k l t Road 2. #01-23 Slngapore 417841 re1 : (65) 6748 3888 Fax : (65) 6748 8858

Pump DESMl N 9 125-265B/D16 NON SELF PRIMING CENTRI Capacity 170 M3/HR Total Head 28 M Matl Br Casina, Ni Al Br Imp, St St Shaft, Mech Seal Couplinq N.A. I Imp Dia MM Weiaht 413 KG I NPSH Rea

INSTRUCTION MANUAL & PART LIST

FOR

ITUR

AU Series

PUMP

PUMPQULP ENGITVEEmG SmTGAPORE TEL : 65-67483888 FAX : 65-67488858


INSTRUCTION MANUAL AU Series

-

Single-stage self-priming centrifugal pumps CQbllIENLS

MIF-2100104-I -- - - . - 4o-oro5-


1.1. Manual Scope 1.2 Equlpment Descrlptlon 1.3. Technlcal ks l j tance and Post-sales Servlce

1.3.1. Reauestlna AEslstanca 1.32 Orderlng Kiplacement Parts

2- SAFETY

21. ldentlflcation of Safety lnstructlons 22 QualiRcatlons and Tralnlng of Personnel 23. R I sk Incurred by failure to follow the safety

lwtnrctlons. Valldlty of Guarantees. 2.4. Compllance with regulations concemlng safety at

work 2.5. Operational Hazards 2.6. Safety Instructions for malntenance, InspectJon and

assembly. 2.7. Prohlbltlon of unauthorlsed modiflcatlons 28. Safety lnstructlons for Users and Installers

3.- TdANSPORTATION AND STORAGE

3.1. PACKAGING AND PROTECTION 3.2 Storage lnslmctlons 3.3. Transport and, Handllng

5.- INSTALLATION

5.1. Mountlng S.I.l..Anchorlng Bolts 5.1.2. Levelling up

5.2 Alignment 5.21. Close-coupled ~ n n l n g 5.2.2. Runnlng on Movable Base-plate

5.3. Plpework Unlons 5.4. Auxllllary Flttlngs

6.- BEFORE STARTING

6.1. Pump testlng 62. ElecMc motor testlng 6.3. Dlesel or Petrol Englne testing

7.- STARTING AND RUNNING

7.1. Starting the unlt 72. Checldng

8.1.011 Lubrlcatlon 8.1.1.011 refllllng 8.12 011 Change 8.1.3. 011 type table

8.2 Grease LubrlcaUon 82.1. Grease Change

9.- ASSEMBLY AND DISASSEMBLY RULES

9.1. Drlve 9.2 Mechanical Seal 9.3. Pump


10.1. Monltorlng the Pumpmotor unit 10.2 Troubleshooting


1.1.- Manual Scope

The information g.ven in th:s mandal is applicable to the a!. Ihe pmps wmpnsing the series sled in secton 4. n me case of do~ot the Spansh anwage verson of the man.a. wi.1 be considered authoritative

The manufacturer reserves the right to modify technical detalls of the equipment

1.2.- Manufacturefs Detalls

This pump is a product of BOMBAS ITUR, S.A. Go Urteta - Zarautz (Gipuzkoa) Spain.

1.3.-Technical and post-sales selvlce

The identification number of the pump must alwavs be quoted in all ordem for replacement parts and when calling for Technlcal Assistance or Post-Sales Assistance. This number may be found on the pump name plate.

When asslstance Is requlred the user should contact elthel the nearest Technical Support Depahent or the Clleni Services Deparhent at Head-Oftice.

1.3.2.- Obtaining Replacement Parts . -. . .. . .. . . - . - . . . . . -. - -. .. - - - . . . . . .. . . . WARNING: Only replament parts which nave beer supplied dlrectly by (BOMBAS l T U b will have been checkec and approved by the manufadurer. The Installation or use 01 unauthorised parts may, under certain drwmstances adversely affect the normal runnlng and the safety of the equlpment The manufadurer takes, m responslblllty fo~ damage resulting from or as a consequence of the use o normriglnal park and accessories.

When ordering spare parts please lndlcate the following:

- PUMP MODEL

- IDENTIFICATION NUMBER

-TYPE AND REFERENCE NUMBER OF PART A: GIVEN IN THE CROSS-SECTIONAL DlAGRAlv (PLEASE INDICATE DIAGRAM NUMBER)

. , -'NUMBEROF PARTS REQUIRED

2.- SAFETY

Thls InWction manual Indicates Lhe bas'c InWctions fo be obssmt durirg ihe Installabbn, running and malntenanm of (he equlpment #I: t'mrafcre essenlial hat ihe personnel h dmqe of (he pump read th

21.- IdentiRcaUon of Safety Inslmctions.

In thls manual spedal safety lnstiuctlons are marked with t h ~ following symbols:

- Fallure to observe safety InsImctlons mark% with thls symbol may affect personal and Ins

- Fallure to observe safety lnstructlons markel vd!h thk symbol may entall Gw risk of electti shock.

Fallure to observe safety lnstructlons marked witi this symbol may affect the pump mechanlsm an, Ik normal running.

Marklngs will be found on'the equlpment Itself In order to: - Indicate the dlrection of rotaUon (arrows) - Pennlt the IdenUflcaUon of auxiliary connections. These marldngs must always be respected and must be ker fully leglble. 2.2.- QuallRcatlons and Tralnlng of Personnel.

2.3.- Risks incurred by failure to follow the safety Instructions. Validity of guarantees.

'Bombas ITUR S.A.' will not accept responsibility for the consequences of any failure to comply with the current health and safety regulations, during the handling, installation or operaung of equipment manufactured by it.

The operating conditions of the-pump may not be altered from those stated at the time of ordering without notifying the manufacturer.

The inappropriate use of the pump, its use outside its normal operating condiuons and its assembly or disassembly by unqualified personnel can jeopardise the following:

Human life

The pump mechanlsm and Its accessories

The normal functioning of the pump equipment

During Its period of validity the guarantee offered by 'Bombas ITUR' will be honoured only if the following wndltlons are met

- The Instructions glven In thls manual have been followed correctly.

- The equlpment has not been taken apart except by personnel elther authorlsed by our Technlcal Supporl

. . , De~~~entorsentdlreCtlY~tm_mo~~.~ct~~~ . . ....

2.4.- Compliance wlth regulations concemlng safety at work.

National Safety legislation must be observed.

Failure to observe these rules mav dace omole. the environment andlor the equlpment, at nik. it w.1 also inklidate any ctalms for wmpensation an'slng.

All safety regulations must be observed. Thls includes manufadurefs Instructions wncernlng the use of elecbical material to be used In conjunction with high voltage power- supplies.

25.- Operational Hazards.

me normal runntng of the pump may entall operational risk arislng from the following:

-Pumped llquld; Its nature, pressure, temperature ... - Rotating parts

-Type of drive

- Inappropriate Installation

26.- Safety Instructions for malntenance. lnspectlon anc

Psembly. It Is the responslblllty of the plant operator to ensure that an) malntenance, lnspectlon or assembly be carried out b) authorised and adequately qualified personnel who must bc famlllar with the work to be done and have read thls manua thoroughly.

No work may be carried out on the equipment except when I has been withdrawn from servlce and fully stopped.

The lndlvidual manuals should be referred to for detalls of tht malntenance of spedRc parts of the equlpment such as tht motor.

Once any work on the pump Is flnlshed all protectlon ant safety measures must be replaced and put back lntc operatlon.

All auxlllary wnnectlons must be reconnected and made read: for operation before the pump Is set runnlng.

When the pump Is belng started for the flrst time t h ~ appropriate lnstructlons should be followed.

The use of gloves Is iewmmended during handllng of thl! equlpment as It wntalns many small pleces such as nuts bolts etc. which could cause mlnor cuts and abraslons to thl hands.

The following hazards In the

Instructions are Intended 8 use of thls equlpment

The DumDed liquid mav cause bums. ooisonina or other Woes of i n i u ~ . It is therefore essential to:

- i7ghten all threaded connections fully, both on the pump unit itself and on all the auxiliary connections, USlng a tightening torque.

Ensure that the gaskets and seals are wrrectiy fitted and are in good condition.

- Control the temperature and flow of any leaks from around the area of the mechanical seal or packing gland. Drain away any such leaks and discharge them in a safe place.

- Take lhe necessary precautions to avoid direct contact with the pumped liquid whenever the pump is filled or primed.

Before taking the pump apart . If pump llqulds are toxic or dangerous the pump must be descontamlnated. To make It clean out the Inside by pouring cleanlng fluld In through.the lnlet plpe and emptylng It through the drain outlet The clean fluld must not make dangerous sltuatlons and It must be wmpatlble with the pump's elements.

- Take the necessary precautions to avold contact with the pump when It is being used to pump liqulds at temperatures hlgher than 40%.

~ . - . - Take the necessary precautions to avoid the risk of

exploslon if pumping llquids with a high vapour pressure. Do not allow the llquld to become hpped In the pump when It Is stopped. Open the suction or delivery valves or flt a vent connection to the Inlet slde of the pump whlch discharges the fluid in a safe place.

For rotatino Dam:

- Emure that there are no rotatlng parts whlch are no1 protected by the mrrespondlng mvers (eg. the coupling guard)

- To avold the danger of serious accldenk do not allow loose clothlng to come near the machlne and tie back long halr.

- Do :notby to free jammed rotatlng pa* manually if the 'machine Is connected to power.

When me pump Is stopped, n can remain pressufked. Before taking the pump aparl there Is to be despressured, opening dralns (or vents) which discharges In a safe place.

When the pump's mnnedto plpes whlch an Important length, It can generate water hammer In the stop. In thls case. It musl Instalate approplate anti-water hammer elemenk.

All safetv ~ l e s for the oumo motor/drive must be followed.

lnmrred installallon could alve rise to aacklna or fracture o the Dumo caslna and be a hazard to both Dersonnel and the environment It Is therefore essential to,

- Ensure proper venting of the pump before R Is put Ink operation. .

- Check that all the necessary auxlllary clrcults are working correctly before starting the pump.

- Check that the suction valves are fully opened and the plpe! free of dlrtlness and sbange elemenk.

Overload

- Do not exceed the maxlmum penltted values (o temperature, output pressure, Intake pressure, r.p.m. stated l i t he offer of sale and In the technical speclflcatlon

- Do not exceed the maxlmtur load on the lnlet or outlet llnes.

The pumps must be must be use only In me mndltions an( with the fluid Indicates In the offer and/or In the order.

UnexDected InterrYetlon of the drlve can be hazardous 01 a x m o t of the smtaneous startlna of the oumo e a u l w

should therefore take me n e w steos 1(

W e n the CONTROL S Y S W Isn't sumlnlstrated b! BOMBAS ITUR. the cllent Is renponsaMe of the full machlne including the wntrols, mmplys with the security dlrectlve a machines.

MI

1 ' i V 2.7.- Prohibition of unauthonsed modifications.

The manufaclurer, d3OMBAS ITURn, must be consulted if the wstomer wishes to make any modiiwtions to the pump unit. For safety reasons only spares and accessories authorised by aBOMBAS ITURI may be used. The manufacturer will accept no responslblllty for loss or damage If unauthorised parts are used.

2.8.- Safety lnstructlons for users and installers.

1 The hslaller must give notice of any safely risks present and not. operate the pump until such pmblems have been resolved. The operator musl give notice lmmedlalely of any change In, or modfication lo, the equipmenl lhal may pose a safely risk. Unsafe equipment must be dismanlled and taken oul of service.

.- TRANSPORTATION AND STORAGE. I 3.1.- Packaglng and protection.

After palnting &OMBAS lTURu carries out the following protective measures: - All openlngs are plugged with plastic or adhesive stoppers.

Wlth the exception of those in stalnless steel, all the vislble mechanical surfaces are mated with a temporary layer of I . . . peel off varnlsh. I

- To avold movement during handllng and transportation tne %k?ll_ent -1s. sec!rYYYYeack%e_d. Dependi?q i?! t?? customeh requlremenk the pump may oe packed In an open moden crate. In a closed wooden box or on a wooden pallet and mvered In thermally bonded plastic.

This protection Is Intended for use during transportation and short-term storage only. The following storage inshctions musl be observed at all times. 3.2.- Storage Instructlons.

These lnsbucb'ons em fwslofage of lsss than 12 m& m date of despahfi. In the case of sfwage fw longer pen'ods

please requesl manufachrmts kmg.lenn stwage l n ~ c b ' o n s

Before storaoe: - Thls eauloment must be stored In a drv enclosure. ~rotected I . . irom impacts, sunllght. dust and ~oociing.

not be stacked even when the type of . . - Both close mupled and bearing stool pumps must be

stomd on the origlnal factory supplledpallefs or In any other way that Is stable..

- The pump and Its auxlllary mndults must be empty of pumped llquld. - Il Is advisable to ave r unpainted areas with a protective film (such as vzsellne).

- Apply ON w liquld rust-prwf to the wear ring faces via the sudlon flanae to avoid them seWna UD. -~ ~~ - . - Pumps supplled on a movable base plate (tmlley st@ should 1 bs sacumd by m of, btakes o r l d n g m&anlsm M. I

A - The eleddc motor and the cables must be dlsmnnecled and a the ferrnlnal box lld closed. - Elecb?cd panels must be dlmnnecled and placed VBtucally.

After storaae: - Remove the temporary protection (part 3.1) and check the

state of all mmponents visually. - If the pump has been stored and out of use for a prolonged

period (more than 6 months) it Is necessary to: change the gland packing (if model us& it). Renew the bearing lubricant Check the state of the wupllngs. Check that the lnstallatlon Is level. Check all the auxlllary connections.

- Following a short storage period It will suffice to turn the pump shaft manually to free up the Impeller mechanlsm. I

- Forthe motor and all the other related elements, wrry out the steps desdbed In the 'afw stnrage' sedlon of the r w d v e manuds. I

- Follow the steps glven In 'starting the pump' sectlon.

If the equlprnent Is golng lo be lefl unused for a long end there Is a posslblllly of freez'ng It should be dralned

wmplelely lo avold any risk of demege behg caused by freez'ng of the llquldlnslde

5.3.- Pipework Unions,

Straln on the pump collars can cause misalignment of the flanges. To reduce strain the Ranges must be parallel and concentric. The bolts or studs used to fix the flanges must pass freely through the holes drilled in them. Do not forget to place a seal or gasket between the parts of the joint.

NARNlNG DO not use lhe pump itself as a slruclurai member ol +' 1 e nstaliation. The inlet and ouliet pipes should no1 place any slrain on the pump necks above the maximum limils. Use independent braces to hold the weight and the strain of the plpework, Pay altention to the direction of flow indicated in the diagrams.

The diametem of the pipes, valves and accessories must be calculated on the basis of the frlction losses planned for the Installation such that the fiow rates are:

-Velocity in outlet plpe: 2 to 3 mlsec

-Velocity In inlet plpe: 1 to 2 mlsea

IN THE INLET PIPE. It Is advlsable to use a coarse filter in the Inlet plpe to avold the pump drawing In lumps of dirt and debris lamer than the permitted slze. Elbows and sharp curves In the plpework should be avolded, as should fitUngs that produce abnrpt narrowing or widening of the pipe (such as cones valves etc).

WEOUTLET PIPE-snould &%e%KyTe-8a'@eafZr diam%tG than the mouth of the pump. A gate-mlve should also be fittec to regulate tne Row and avold overloading the motor. Thls valve can also be used to Isolate the pump for maintenance.

To prevenl reverse running of the pump (which entall: the sk of the impeller unscrewing) a mtainlng valve should b6 Mfed lo the outtet line (with e by-pass if a foot-valve is fitted).

1f.the.inletllne Is short (less than 20m) it must rise at all point and not have a gate valve fitted. If the pipe Is long a bleede needs to be fltted between the pump and the gate mlve tc remove all air. Thls bleeder should be dosed only wher pumped liquid only, no alr,comes out

JF OPERATED AS A NEGATIVE SUCTION LIFT PUMP Fltting a f w t valve is not necessarv but may help (he pump The inlet line must be mmpletely~alrtight and rise u h i ! towards,he pump at all points. The diameter of the plpe shouk normally be greater than that of the mouth of the pump. The difluser mne used for thls configuration needs to be eccenhi~ with-the upper part horizontal. To limit the time taken for auto primlng plpe length must not be excessive. Check that unde normal .working conditions the NPSH (Net Positive Suctio~ Head) Is at least 0.5m less than that provided by tho Installation.

V.C. ... Gate valve V.R ... Checkvalve

V.C. V.P. ... Foot valve C.C. ... Concenblc dhermne

p C.E. ... EmnMdthsermne

dlfferencs behyen the internal diameters od

I that dhsor mne lmht 1

I the enhance and e ~ t of the cone. I

If hoses are used they must be firmiy held before slarling or 1 operating the pump to avoid pump pressure causing a whiplash effect.

IF OPERATED AS A FLOODED PUMP the inlet line must be alrtight and normally of a diameter greater than that of the moulh of the pump. The diffuser cone may be either eccentric or concentric. Fit a gate valve for isolation during maintenance.

5.4.- Auxiliary fittings.

Except for th external elechical and pipework connections the unit is normally supplied assembled and ready for immediate use.

The cooling of the mechanical seal or packing gland Is performed by the internal recirculation of the pumped liquid

(Plan AP.-01). Follow the detailed insbumons in the annex to this manual Wenever It Is necessary to attach the auxiliary fittings used by these devices,

1 Note that any auxillaiy pipework Mted is only designed fo whstand the Internal forces genemted by the circulattng liquid. Therefore sublecling i t lo addiUonal forms, for example by leaning on H, Is pmhlbiled.

.- BEFORE STARTING . - . - . . . . - . . . . . . . . - . . . . - - . . . . . . ... . , . - he pump may be started only when all the machanlcal, hydraulic nd elecklcal wnnectlons listed In Chapter: 5 'INSTALLATION' ave been made. To start the pump proceed as follows.

6.1.-Testlng the pump.

When starting the pump for the first Ume or after a lengthy period of Inactivlty It Is essantial to prime it as follows:

- Diswnnect the power from the motor or remove the batteries.

- Open a vent valve In the outlet line before the gate valve at the highest point of the uppermost elbow.

- Pour llquid Into the outlet plpe untll R overRows from the vent.

- Whilst priming the pump hlrn the pump shaft manually to free It

- Block the vent hole or close the vent-valve.

Before starting the pump all parts of the drfve-shaii proledor a such as Lhe drfve-shat? guard, must be In oiaca and fl@ attached fscfews ti~hteneal..

8.2- Testlng the eledtrlc motor.

When connedlno elechical aower check carefullv that the voltage and w&nt supplied' by the mains n e b & are the same as the nomlnal voltage and wrrent lndlcated on the motors name plate

Starl the motor momentadty lo check the direction 0 mla on. This must be the same as that indicated by the arnl marked on the pump casing or bracket I f the dlrwction o mtaUon is not m m c t two phases In the motor temtlnal bol must be changed over (If R Is three phese).Saguir la: indicadones desultas en el manual del motor.

Follow the InstrudJons given In the motor manual.

6.3.- Testlng the dlesel or petrol englne.

Follow the manufactureh lnshctions supplied with the motor..

r.- STARTlNG AND RUNNING

7.1.- Startlng the pump unlt.

- Before starting the pump unk go through all the sections 0 Chapter 6: 'BEFORE START UP'.

-All the valves on both Inlet and outlet sldes must be full: oaened and once the sumo has reached its oaeraUna s u m and all alr has been eilmlriated fmm the lnlet.'the puhima: be regulated by adjusting the outlet mlve.

- Check that all alr is completely evacuated from the sudlon line durlng the selfprlmlng stage.

- In the case of a motor that does not cover the whole operating range of the pump the unit may be started w.th thr outlet valve (but never the inlet) partly closed.

- If the motor protector cuts out on start up the outlet should br closed a little. thereby further restrtang flow, until the motol starts normally.

The pump must NEVER be operated with a reduced or zerc flow as the recirculating liquld contained In the pump wil rapidly overheal leading to the risk of explosion owing to tht high pressures that can build up within the casing.

7.2.- Checklng during running

During the first few minutes of operation:

- Check that there is leakage whatsoever through tht mechanical seal. If there is the seal must be checked andlo replaced Immediately.

After several hours ooeratlon:

the bearing temperature by placing i

the nearest houslng. The normal temperafun can reach 4 P above ambient temperature bul must neve exceed 90°C.

3efOre lubricating the pump ensure that

!l- The pump Is stopped and there Is no risk of its accldentall starting. .. The bearing houslng temperature is less than 40°C so thz there is no rlsk of bums to the hands. Use a thennocouple b measure the temperature..

8.1.- Oll lubrlcatlon.

8.1.1.- Oii refill.

The pump leaves the factory wlthout oll In the bearin houslng. Once assembled thls must be fllled as follows:

- Remove the top plug from the houslng.

-Pour in oil until lls level Is between the maxhum an minlmum marks on the dlp-stick.

- Replace the top plug.

8.l.Z- Oll change.

- Before changing the oll run the pump for a few mlnute to liquefy It

- Release the top (fllllng) plug and the bottom (dralr Plug.

- Draln the oll and allow to drip.

- Replace the bottom plug and flII as lndlcated above.

8.1.3.- Table of 011s.

ISO-VG grades of olls rewmrnended lor normal us (bearing temperatures up to 70°C) for glven worklng loa r.p.m. and shaft diameter (as measured on the wuplln side).

Consult your suppller In case of temperatures outslde V lndlcated ranges or when amblent temperature Is below -5OC

8.2.- Grease Lubrlcation.

The oLmp eaves me factory wtn the oearlngs reaoy greased for the frst I000 ho~rs (approx) operatlon

For lubrication purposes a table has been included. Quantities shown are grams of grease to be applied lo the greasing points approximately every 5 months operation for pumps of the glven shaft dlarnelers (measured on the wupllng side).

8.2.1.- Changlng the grease

When changlng the grease the bearings must, first be shipped down and their seats in the base thoroughly cleaned to remove all t-aces of the old grease.

8.2.2.- Grease tlpe.

Use mnslstency 2 ilthlum grease with anti-oxidlslng additives. DIN-51502 class K2K

I.- RULES FOR ASSEMBLY AND DISASSEMBLY . - -. . .~ .. . .. 3efore beglnnlng to dlsmantie the pump ensure that

h- The pump cannot be accldenlally starled during malntenence. The motor must be disconnected hom power either by removing fuses, unplugglng, opening the circuit breaker etc. or by removing the bafterypower supply.

( - The pump Is drehed of a!! liquid and cleaned oul with an appropriate cleaner if the pumped liquld Is hazardous (hot, toxlc, Inflammable etc).

9.1.- Drlve Coupling.

DISMANTLING:

1.- Remove the mupllng guard.

2.- Unwuple the pump from the motor as lndlcated below:

2.1.- COUPLING WITHOUT SPACER.. Release the motor flxlng bolts and remove it along with the male par1 of the mupllng.

2.2.- COUPLING WITH SPACER Release the bolts attaching the wttpllng and remove the spacer. Take ofl the male part of the wupllng.

3 - f 11 ,s necessav to repa r tne p.rnp release the nJO lo ning tne cashg lo the mver an0 me rear fool.

4.- If it is necessary to remove the coupling use a puller, DO not hit the wupling to remove it as this ma) seriously damage the bearings or ball races.

ASSEMBLY:

1.- Assemble the pump (if it has been dismantled) anc tighten the wver fixing bolts.

2.- Couple up the motor to the pump as follows:

2.1.- COUPLING WITHOUT SPACER. Put the mot0 in place inserhg the male part of the mupling. Put ir the bolts but DO NOT tighten them until alignment ha: been mmpleted.

2ZCOUPUNG W m SPACER Mount the male pal of the wLpilng lnmxlJdng the teeth into me mbbw padl on the female pan Mom the spacer ard boll il in p am.

3.- Align the coupling (see Manual section 5.2).

4.- Replace the wupllng guard.

9.2.- Mechanical seal.

ASSEMBLY:

- Fit the fixed part of the mechanlcal seal. . . . . . . . , . . , . - . . -. . .. . .- . .. . . ,

- Flt the rotating part of the seal over the bushlng or shaft taklr care.not to damage the o-ring. Fa it to the bushlng (If ftied) wi a spadns bush and push it as far as ttwill go onto the shaR

- Slide on the Impeller untll the shaft or sleeve prevents It frc golng further.

- Tighten fully the Impeller retalnlng bolts.

- Assemble the rest of the pump.

DISASSEMBLY:

-To dlsmanUe the pump follow the same steps as assembly, but In the reverse order.

steps must be observed if the seal Is

- Take c m not to demege the rings during assembly.

- Do not turn the mechenlcal seal whllst dry.

l4 0 9.3.- Pump.

It is necessary to dismantle the pump almost completely order to take out the shaft, bearings, bushes (shait bushi etc.

Make use of the cross-sectional diagrams and parts list.

The following steps give a general guide to dismantling pump:

For monobloc pumps:

- Take the pump off Its mount.

- Undo the pump casing nuts and remove the housing-u: assembly with the moving parts.

- Pay special attention to the pump casing given that or own It is unstable and so must be appropriately supportel

- Undo the impeller retalnlng nut or me impeller ID Remove the impeller. The wear plate (if fltled) and the : will now be accessible.

For pumps with flexlble wupling:

- Remove the mupllng guard followed by the coupilng. described In part 9.1 (Iffitted).

- Met the bearing housing lncludlng moving parts. . . .- - -- . - -, - wear plate miliiBWb- a ~ 3 l S I V : ' .' .

. .

- Remove the impeller retalnlng nuts and take out the imps

-Take out the mechanlcal seal (see section 9.2).

- Loosen and remove the pump wver.

- Remove the dmlector and the bearing housing covers.

- Extract the shaff and bearings by banging the far side 01 pump with a plastic hammer.

To assemble the pump follow the above lnsbuctions in reverse order.

Be sum to put each of the parts back in Ule right p l espsclally the seal and Impeller components. Tighten Impeller nuts fully.


$0.1.- Monitoring

(a) If fhe environmenl is dusty. damp or hostile, shorten the period between 011 changes.

by lnstallatlon desing. pcsslbly need to lit larger lmpeler or a blgger pump. Consult manufadrer.

to the check valve or descendlng elbow in

PROBLEM

I.- Pump does move llquld

fl P u m ~ badlv orlmed. I fl prime tile oumo.

CAUSES

a) Valves (inlet or outlet) dosed

b) Incorrect rotational dlrectlon.

REMEDIES

a) Open them.

b) Chanae motor connections.

!.- Pump does n o t ellmlnate alr from lnlet

a) Alr getUng into plpework Inlet

b) No llquld In pump.

c) Inlet check-valve does not seal.

d) internal redrculatlng connection

-

a) Check plpework Is alrtlght

b) Stop pump lmmedlately and prlme it

c) Check state of gaskets and seating

d) Unblock It Remove cover on Inlet slde and dean out

1 9

' space bI;;;r; ' , ' ' - , -,

c) Bad alignment between pump and motor. c) Allgn the mupllng.

d) Lack of bearing lubricant d) Lubricate properly. . ~ . . ~.

e) Pipes shinlng agalnst pump e) Brace plpes and level up unlt

fl Excessive lubricant in bearinas. fl Draln oil from housino.

PROBLEM

.- Flow o r pressure too low.

1.- Excesslve housing temperature

CAUSES

a) Inlet or outlet valves badly adjusted.

b) Rotational speed incorrect

c) Badly primed.

d) Alr enters via seal.

e) Obstruction in pipework.

fJ impeller obstructed or worn

g) Wear rings or plate worn.

h) Back pressure too high.

a) Bearings oaoly assembled.

i.- Excessive absorbed power

REMEDIES

a) Open inlet or outlet valve fully finding operaSng point

b) Measure speed, check voltage of motor power

c) Reprime pump.

d) Dismantle seal system and check it.

e) Clean out pipes and/or

9 Dismantle impeller and check it.

g) Dismantle and change them.

h) Increase rotational speed. If this is not possible It is necessary to fit a larger lmpeler or blaaer pump. Consult manufacturer.

a) Adjust them :n thelr seats.

5.- Excesslve noise and vlbratlon

bl Cou~lina inwrrectlv fitted. Mthout sJRic'ent I b\ Check the comllna.

a) Denslty or viscosity of liquld higher than normal.

b) Bad pumpmotor alignment

c) Obs+mction lnslde pump, impeller or mouths.

d) Real head generated by pump is lower than deslgn polntcauslng hlgher Row and power.

e) Bearings worn or badly assembled.

b) Wear rings worn or badly assembled.

I e) impeller holdlng nub loose. I e) DlsmanUe pump and Ughten. I

a) Reduce delsgn polnt. or change motor.

b) Align the coupling.

c) Dlsmantle and clean pump.

d) ParUally dose the outlet mlve.

e) Change them or check their assembly.

0 Excesslve friction between rotaUng parts.

a) Bearings worn, badly assembled or badly assembled or under-lubricated.

b) Change or re-assemble rings.

d) Impeller off-balance or worn.

I f l Pioes sbainina aaalnst oumo. In race oumo and level uo the unit I

- ~

fJ Dlsmantle pump and check assembly.

a) Change bearings, reassemble them or lubricate them.

C) shafloff centre or bent I c) DlsmanUe and change.

d) Balance or replace Impeller.

g) Lack of rlgldlty In foundatlons or anchor g) Remake foundation or Ughten bolts. I bolts loose. I T.- Loss of llauld throuah the 1 a) Mechanical seal badly worn In its contact 1 a) Dismantle and replace seal. I

h) Lack of alignment between pump and motor h) Allgn the mupllng.

b) Mechanlcal seal spring broken or has lost b) Dismantle and change seal.

- rnechanicai seal

c) Mechanlcal seal o-rings broken, deformed, c) Dismantle and replace seal: I or have lost elastidty.

surfaces.

d) Sleevlng scored orwom. d) Dismantle and replace sleevlng.

e) Seal Incorrectly assembled. e) DlsmanUe, check and replace If damaged.

3.- Wear rings wear out qulckly.

a) Shafl off centre or bent.

b) Impeller off balance or worn.

c) Mlsallgnment of pump-motor.

d) Plpes shalning against pump.

e) impeller displaced

a) DlsmanUe and replace.

b) Balance or replace Impeller.

c) Allgn coupling.

d) Brace pipes and level up unlt

e) Locate In wrrect poslUon Ughten fixlng nuts.

pumpvip .

engineer ing pte l t d

Ruby Warehouse Complex. 8 Kaki Bukit Road 2. MI-23 Singapore 417841 Tel : 65-6748 3888 . '

Fax:6567488858, E-mail: [email protected] GST Reg No.: M2-0056147-3

.. .... ,<.>. ~~, .;, ~

; ,... -... l-C?L.q.i-. .: :-.'.<c .-.. SPARE PARTS LIST FOR : , . k ~ , ~ ~ ; - q : : - A f i ~ ~ ~ ~ ~ . . ' ' -

POSITIONNO. REFERS TO SPARE PARTS DRAWlNG NO. C-416

CODE

Suction piece Plug Sealing ring Bolt Nut

Washer Set screw Flap valve holding disc Flap valve Lower flap valve disc

Upper flap valve disc Nut Priming plug Gasket Nut Washer

Flange Bolt Mechanical seal Casing bolt Washer Nut

Gasket, bearing cover Shafl Sunk key, coupling Set screw Bearing end cover Gland

Ball bearing INAUC~ Dip stick Oil cap 'Seal cover '0' ring Sunk key, impeller

Page 1

QTY

-1 I PurnpTip +',\

engineering pte l td -

Rubv Warehouse Comolex.

SPARE PART LIST - POSITION NO. REFERS TO SPARE PARTS DRAWING NO. C - 416

CODE DESCRIPTION

impeller Impeller nut Wear plate Set screw Gasket

Drain plug Gasket Plug Casing Intermediate cover

Set screw B'earing housing Ball bearing EMU

Water deflector

Page 2

4 x 0 1 8 HOLES

SCALE 1: 10

SUCTION 8 DELIVERY

l ient LABROY SHIPBUILDING & ENGR PTE LTD Pump ITUR AU 50 / 25 DO9 CENTRIFUGAL PUMP Motor 5.5 KW/ 3500 RPM Date 25 AUG 08 lull 182/183/184/185 Capacity 30 M3/HR Power/Supply 440V/30/ 60Hz Dm By NYAN ;emice POWR PACK S.W COOLING PUMP Head 20 M Full Load Current Dim Unit MM

PumpQuip Engineering Pte Ltd Matl Br Casing, Imp, St St Shaft, Mech Seal Frame Size D 132s Scale 1 : 10 8 Kakl Buklt Rood 2, #01-23 Singapore 417841 Coupling CL - 140 I NPSH(Req) Insulation Tel : (65) 6748 3888 Fax : (65) 6748 8858 Weiqht 160 KG I Impeller Dia Item No

/ IP 55 Drg No A 50255.5 3

b u m q i p englnaering pt. Itd

PART LIST

FOR

Pi'n & Bush Coupling

PUMPQUIP ENGINEERING SINGAPORE Tel : 65-6748 3888 Fax: 65-6748 8858

TYPE CL PIN & BUSH COUPLING

Bolt slde I

L Female half . Male half