Preface:

The purpose of this manual is to provide relevant information and instructions regarding: Installation, operation and maintenance aspects of your pump set.Accurate implementation of the information and instructions given will optimise the use of purchased equipment.A properly designed installation ensure maximum reliability and durability in the long run.Maintenance activities like repairs and overhauls are not included in this manual.These activities are preferably performed by specific dealers with trained personal and required tools and spare parts.

Questions related to your Nijhuis product can be addressed to our service department. In case of ordering spare parts please always state pump serialnumber on your enquiries to be able to serve you quicker and better.

Guarantee:

Our responsibility is limited to the terms described in our sales conditions and amended by contractual agreements.We emphatically reset any responsibility regarding claimes as a result from: incorrect installation, improper use, inadequate maintenance and any other application contrary with the instructions described in this manual.

Dismantling of the pump within the guarantee period without written approval will immediately invalidate applicable guarantee.

Manufacturers address : NIJHUIS FIRE PROTECTIONParallelweg 47102DC WinterswijkP.O. box 1027100 AC Winterswijk - Holland

Telex : 44185Phone : *31-543-547474Telefax : *31-543-547476

Shipping address :

Freule van Dorthstraat 127102 DC Winterswijk - Holland

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Content:

Preface, guarantee, manual, address

§ 1 General1.1 Locating the pump-unit

1.2 Pre installation

§ 2 Transport2.1 General

2.1.1 Special hoisting instructions2.2 Pump skid

§ 3 Inspection3.1 Inspection of the pump-unit

§ 4 Storage4.1 General4.2 Pump4.3 Fire pump controllers4.4 Electric motors

§ 5 Installation5.1 Skid foundation with anchor bolts

5.1.1 General5.1.2 Guidelines for contructing a concrete foundation5.1.3 Erection

§ 6 Customers connections6.1 Connecting piping

6.1.1 General6.1.2 Suction piping for horizontal pumps6.1.3 Discharge piping according NFPA

6.2 Connecting sensingline pr.sw.6.2.1 General

6.3 Electrical supply (direct online)6.3.1 General6.3.2 Main (A.C.) power6.3.3 Connection between controller and electricmotor

§ 7 Aligning horizontal pump units7.1 Aligning the pump unit

7.1.1 General7.1.2 Deviations7.1.3 Coupling data7.1.4 Pump adjustment with adjusting bolts

7.1.4.1General7.2 Driver alignment with adjusting “jacks”

§ 8 System description8.1 General8.2 Eledyne controller

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§ 9 Putting the pump-unit into operation for the 1st time9.1 Before putting into operation for the 1st time9.2 First starting (on site)9.3 After first operation9.4 Possible causes of fire pump troubles

§ 10 Maintenance10.1 Preventive maintenance programme

10.1.1 General10.1.2 Weekly: Before taling into operation

10.1.2.1 E-motor10.1.2.2 Pump

10.1.3 Weekly: During operation10.1.3.1 E-motor10.1.3.2 Pump

10.1.4 Monthly10.1.4.1 Controller

10.1.5 Yearly: Before taling into operation10.1.5.1. E-motor10.1.5.2 Pump

10.1.6 Yearly: During operation10.1.6.1 E-motor10.1.6.2 Pump

10.1.7 Every three years: Before taling into operation10.1.7.1 E-motor10.1.7.2 Pump

10.1.8 Every three years: During operation10.1.8.1 E-motor10.1.8.2 Pump

10.2 Gland packing directions10.2.1 General10.2.2 Removing old packing-rings10.2.3 New packing-rings10.2.4 Mounting the new packing-rings10.2.5 Adjusting / running in of the packing

§ 11 (Dis)Assembling the pump:11.1 General11.2 Disassembling the pump11.3 After disassembling11.4 Before re-assembling11.5 Reassembling the pump

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§ 1 GENERAL§ 1 GENERAL§ 1 GENERAL

§ 1.1 Locating the pump-unit :§ 1.1 Locating the pump-unit :§ 1.1 Locating the pump-unit :

A careful chosen location for the pump-unit is of the utmost importance for maintenance as well as for operation of the pump-unit. When choosing a location for your pump-unit the following factors should be taken into consideration :

- Locate the pump as close as possible to the source of the water-supply.

- If possible, locate the pump's centre-line under the level of the water-supply source so that gravitation will help to push the water into the pump.

- Take care that both suction and discharge lines are kept as short and straight as possible to keep friction-losses as small as possible. Bends in suction as well as in discharge line should have the largest (practicable) possible radius.

- Place the pump-unit in such a way that the unit is easily accessible for maintenance, inspection and possible repair activities. Therefore take care of good illumination and ventilation in the pumproom to simplify these activities.

- Make sure there is enough space beyond the pump for a hoisting device such as a crane or a winch with enough capacity to hoist the complete unit.

- Locate the unit, where possible, in a dry, dustfree and well ventilated space.

- Whenever possible, do not locate the pump-unit on locations with a high damage risk. Therefore do not place the unit on locations with extensive traffic (human as well as vehicles). When the unit is placed on a location with extensive traffic however, make sure there is ample space for human as well as for vehicle traffic.

§ 1.2 Pre installation :§ 1.2 Pre installation :§ 1.2 Pre installation :

One of the most important factors to successful operation and maintenance of your pump-unit is a correctly performed installation of the unit. A pump-unit that has been installed correctly will remain aligned better in the long run, will show less leakages of casing as well as flanges, will show less vibrations and will demand less servicing. Another aspect that will be influenced by the installation of your pump-unit is it's service-life. A correctly performed installation will prolong the pump's service-life and diminish the risk of failures in emergency situations. A badly performed installation may damage a new pump-unit severely within a relatively short time !

§ 2 TRANSPORT§ 2 TRANSPORT§ 2 TRANSPORT

§ 2.1 General :§ 2.1 General :§ 2.1 General :

Pump-unit and/or components may only be hoisted at the suitable hoisting supports. Always use all hoist-supports when hoisting ! Hoisting of each component should always be performed in accordance with the following general instructions regarding hoisting / transporting :

- The capacity of the hoisting-device and all other auxiliary components should be enough to carry the component safely.

- Hoisting of each component has to be performed in accordance with all applicable local laws / directions .

- Hoisting and transporting should be performed by authorised personnel with the utmost care.

§ 2.1.1 Special hoisting instructions :

Apart from the above mentioned general instructions it is necessary to pay extra attention to hoisting instructions given for auxiliary components.

§ 2.2 Pump skid :§ 2.2 Pump skid :§ 2.2 Pump skid :

Depen-ding on the execu-tion of the skid the engine is

assembled onto, 2 different executions regarding the hoisting supports at the skid are possible (see figures 1 & 2 ). If the driver is assembled on a skid like is sketched in the left figure, the unit is to be hoisted by putting a chain through the open space between the skid and the plates welded on it.Make sure the hooks are fitted properly around the chain. If the driver is assembled on a skid, like sketched in the right figure, the unit is to be hoisted by attaching the hoisting-hooks around 2 pipes or bars. These pipes/bars are not part of Nijhuis' delivery. The pipes/bars should be stuck through the hollow-pipes that are welded in the skid for this purpose.The pipes/bars are to be a considerably longer than the skid's width in order to prevent the hooks slipping of the pipes/bars and/or to prevent damages to the driver. Naturally, the pipes/bars should have sufficient capacity to carry the weight of the unit.

Figure 1 Figure 2

When the driver is not assembled on a skid it must be hoisted by putting a chain through the available eyebolts. It's not allowed to hoist the engine anywhere else becauseit may damage the driver.NOTES : - When hoisting, always all (generally 4) hoisting supports have to be used.

- Hoisting/lifting should always be performed in accordance with the applicable legal laws / directions.

§ 3 INSPECTION§ 3 INSPECTION§ 3 INSPECTION

§ 3.1 Inspection of the pump-unit :§ 3.1 Inspection of the pump-unit :§ 3.1 Inspection of the pump-unit :Generally horizontal fire fighting pump units will be delivered in an almost complete assembled conditionwith smaller components such as connecting materials gauges etc. separately packed. A pump-set generally contains the following components :

- Complete electromotor on skid- Horizontal pump

At receipt of the material it has to be inspected accurately for damages and/or the presence of all components. Also check the packing-list. Any damaged or missing parts should be reported immediately to the local agent of the company that is responsible for the transport of the unit. Damages / missing parts should also be marked on the freight bill.

§ 4 STORAGE§ 4 STORAGE§ 4 STORAGE

§ 4.1 General :§ 4.1 General :§ 4.1 General :

Pumpunits are usually delivered and packed in condition for immediate installation. The way of packing in which the pump-units are shipped depends on the method of transport, distance and duration. Units that are to be shipped within Europe are usually delivered without special storage provisions. For units to be shipped out of Europe generally special storage provisions have been made for the duration of the transport. If, for whatever reason, the pump is not to be installed for a considerable time special storage provisions should be made. Nijhuis Fire Protection provides this, on special request only.

Following general directions shall be met :

- All components should be stored in the proper position. Engine and all other non - Nijhuis manufactured components should be stored in accordance with the directions given by the respective manufacturers ; these are generally mentioned in the appendices of the operating and maintenance manuals of the components.

- Do not store components in a place with a high damage risk (places with intensive traffic (human as well as vehicle)).

- Store the components in a dry, dust- and frostfree and well ventilated room.

- In order to avoid bearing damage owing to vibration during storage, e.g. due to machines operated in close vicinity, components should only be stored in rooms free of vibration.

- If components are packed in undamaged seaworthy packagings and provisions have already been taken for long term storage, these packagings should not be removed until installation. Components packed in seaworthy packagings that have not been protected for long term storage, should be removed and protected for long term storage at the moment of arrival. If possible packagings should be applied again after having protected the components.

- If components are not suitably, packed they should be covered entirely. If the room in which the components are stored isn't waterproof the components should be covered with a waterproof protectant.

- Inspect and clean the components regularly (only if not thoroughly packaged in dust- and waterproof closed packagings). If packaged, check the packagings regularly for damage and general condition.

- If components are to be stored for a long term (more than 3 months) before installation and provisions for this storage have not been made (provisions for long term storage are only being made on your special request) these should be made at the time of arrival. The most important provision to be made for this purpose is the protecting of corrodible parts of all components. Protection can be made by greasing these parts1 or, better, by applying a special preservation oil. Depending on the provisions taken, storage circumstances and the component, it can be necessary to regrease or re-apply preservation-oil periodically.

- For auxiliary components always consult the directions given by the manufacturers. These directions should always be applied in addition to or instead of the directions that are mentioned in this manual

1    ? If possible

§ 4.2 Pump :§ 4.2 Pump :§ 4.2 Pump :

- All applicable general directions mentioned should be met with.

- All pump components are to be stored in horizontal position.

- Protection of the corrodible pump-parts can be made by greasing these parts (shorter periods) or, better, by applying a special preservation-oil2. If storage is going to last longer than 6 months, or will take place under severe environmental circumstances the corrodible pump-parts should always be treated with preservation oil. Greasing will not satisfy in these cases. For extended storage periods the preservation-oil must be changed periodically. The period after which re-application of the preservation-liquid becomes necessary depends on the storage circumstances; when stored indoors in accordance with the directions mentioned in § 4.2.1 the preservation-oil should be re-applied every 18 months, when stored outdoors under a cover the preservation-oil should be re-applied every 12 months.

- When the pump is to be stored for more than 6 months the soft shaftseal packing-rings should be removed.

§ 4.3 Fire pump controllers : § 4.3 Fire pump controllers : § 4.3 Fire pump controllers :

- All applicable general directions mentioned should be met with.

- Fire Pump controllers should always be stored under cover in a dry, temperature regulated non-corrosive atmosphere, with each enclosure protected against the effects of condensation by either one of both the following precautions being observed :

* Introduction of desiccant substance such as Silica-Gel, contained within a suitable receptacle, into each enclosure. It is recommended that such a desiccant is replaced on a regular basis (e.g. every 6 - 8 weeks), since it's effectiveness is known to deteriorate with time.

* The connection of auxiliary AC power feeds to the panel anticondensation heaters (when fitted) to maintain the interior of each enclosure at a constant temperature (Note : the auxiliary AC power feed must correspond to the rated voltage of each item of equipment, otherwise damage may occur).

- It is recommended that a suitable polythene covering is employed with protective packaging as necessary to prevent damage to paintwork and exterior mounted components.

- For protracted storage periods it is advisable to utilise hermetically sealed polythene wrapping (evacuated) and then enclose each unit in an export quality packing case lined with tar-paper or equivalent.

2    ? Shell ENSIS liquid G, or equivalent.

§ 4.4 Electricmotor :§ 4.4 Electricmotor :§ 4.4 Electricmotor :

- All applicable general directions mentioned should be met with.

- If electromotors are stored in a dry, dust-free and temperature regulated room, special packing is not necessary. In all other cases of storage the motors have to be packed in plastic foil containing humidity-absorbing material (e.g. Silicagel3 ) or have to be sealed in hermetic foil, whereby they also have to be protected against sunshine and rain.

- Bigger motors are equipped with an interlocking device at the driving end for transport purposes. This interlocking device should be kept blocked until the motors are put into operation, or it has to be remounted after inspection or trial run. An interlocking device is not necessary and not available in case of axially biased bearings.

- In case the motors are equipped with sealed drainage holes condensation water inside the motor may occur which has to be removed. Then the holes have to be sealed again.

- Motors with sleeve bearings are delivered and to be stored without oil-filling in the bearings. In order to protect the sleeve bearings, including bearing journal, against corrosion the following has to be done :

* All openings should be sealed .* All threads are to be fitted with plugs.* All connection flanges are to be fitted with dead flanges.* Gaps between sealing and winding respectively sealing and housing have to be

covered (with self-adhesive stable strips).

Remove cover at bearing housing and (if possible) through this opening spray in, by means of pneumatic injection, a corrosion protective paste which has not to be removed in case of putting the motor into operation (e.g. TECTYL 511 M from Valvoline)1.Insert a bag with humidity-filling (e.g. Silica-gel)1 below the plexi-glass cover in order to avoid building of condensation water. Then the bearings have to be screwed up tight again.

In case a period of ½ year is exceeded from the date of conservation until the date of putting into operation the above mentioned conservation steps have to be repeated.

- If storage in the open is unavoidable the following has to be regarded at least :

* Protective cover against sunshine and rain has to be provided whereby there must be the possibility of air inlet and outlet in order to avoid condensation.

- If motors are to be stored for an extended period (> 2 years), further provisions have to be made. For these provisions the motor manufacturer should be consulted.

- For motors equipped with a special temperature regulated anti-condensation heater, this heater should be connected. When using an anti-condensation heater the provisions, for preventing condensation, that were mentioned before may be cancelled.

3    ? Or equivalent

§ 5 INSTALLATION :§ 5 INSTALLATION :§ 5 INSTALLATION :

§ 5.1 Skid Foundation with anchor bolts :§ 5.1 Skid Foundation with anchor bolts :§ 5.1 Skid Foundation with anchor bolts :

§ 5.1.1 General :To achieve a proper long-term functioning of the pump-unit, the pump-unit should be placed on a solid foundation of sufficient capacity made out of, for instance, concrete. The foundation's sizes should be chosen so that it will be able to carry the weight of the entire pump-unit, as well as absorbing vibration, generated by the pump-unit, sufficiently. A solid foundation will guarantee a better unit-alignment in the long-term, which will result in a longer service-life and less wear.

§ 5.1.2 Guidelines for constructing a concrete foundation :

Constructing a foundation should be done in accordance with the guidelines that are mentioned hereafter. However, it should be pointed out that these guidelines should only be seen as being guidelines, and no more than that. Therefore, if directions from e.g. concrete-manufacturer are available (for instance regarding hardening-times, mix-compositions) these should be read and applied carefully. Nijhuis Fire Protection is not responsible for the pump-unit foundation !

NOTE : For foundations, out of a material other than concrete, contact Nijhuis' Service Department.

§ 5.1.3 Erection :

- When placing the skid onto the foundation, the skid should be hoisted according to the directions given in § "Transport".

- Place the skid on a number (at least 4) of wedges or stacks of shims, thus that the space between floor and pump-skid is about 20 - 40 millimetres.

- Take care that the floor on which the skid is to be placed, is sufficiently strong to carry the weight of the unit and is sufficiently rough so that the concrete that is poured afterwards will be able to obtain a proper bond with the floor.

- Adjust the unit to level by adjusting the wedges, or , in case the unit was placed on stacks of shims, by adding / removing shims at the several places. Adjusting the unit to waterlevel should be done with respect to the worked up planes of driver-supports on the skid (these are the highest flat planes from the skid), and not with respect to the skid itself, as the skid isn't necessarily 100 % straight at all places.

- Before pouring concrete to fill the space between skid and floor, the floor should be kept moist during a considerable period, in order to saturate the floor with water so that it will soak as less water as possible from the concrete that is to be poured, which would affect the final result. The period during which the floor is to be kept wet varies, depending on the age of the floor, between 12 - 24 hours. As a guideline it can be taken that a floor that is less than one month old should be kept wet for about 12 hours ; a floor that is older than one month should be kept wet for about 24 hours.

- Before the concrete can be poured, the anchor-bolts have to be placed. When placing the anchor-bolts make sure the bolts are placed far enough under the frame (into the concrete that is to be poured) so that a sufficiently thick layer of concrete will be able to fill the space above the hook of the anchor-bolts.

Further there has to be taken care that the nuts can be tightened far enough after the concrete has hardened. Therefore take care that the nuts (and possible inclined plates) are tightened just that far that the screw-thread rises just a couple of threads above the nut.

- When pouring concrete special care has to be taken that the concrete can spread itself well around the anchor-bolts so that a good hole-less connection between bolts and concrete can arise and the bolts will be clamped firmly in the concrete.

- After the concrete has been poured it should harden out. Hardening time depends on environmental circumstances and the exact composition of the concrete and will vary from days to over a month. Further information concerning the hardening time should be obtained from the concrete manufacturer.

- After the hardening-process has been accomplished the anchor-bolts can be tightened and suction / discharge lines and other connections to the unit can be made. Tightening should be accomplished crosswise and in equal steps.

- The tightening torque’s the anchor bolts are to be tightened with, depend on bolt-quality as well as on the quality of the concrete. If required Nijhuis can deliver complete sets of foundation bolts including, if necessary, inclined plates that fulfil DIN 529.

3Piping

§ 6 CUSTOMERS CONNECTIONS§ 6 CUSTOMERS CONNECTIONS§ 6 CUSTOMERS CONNECTIONS

§ 6.1 Connecting piping :§ 6.1 Connecting piping :§ 6.1 Connecting piping :

§ 6.1.1 General :

Suction as well as discharge piping may not be connected until concrete has hardened entirely and anchor-bolts have been tightened. When connecting suction- and discharge piping the following guidelines should be applied to increase pump efficiency and to prevent future trouble. Read and apply the following advice carefully.

- Before connecting suction and discharge piping make sure that both lines are free of debris and other foreign objects that might damage pump and line system.

- Inside diameters of suction and discharge piping are to be selected in accordance with the applicable standard (e.g. NFPA-20) and should be at least as large as the inside-diameters of the respective pump flanges.

- Packing between all flanges and other connections should, in order to prevent reducing the piping's culvert, have an inside diameter that is about 5 - 10 mm larger than the inside diameter of the respective flanges.

- Selection of the materials that are to be applied for the piping (and all other piping-properties) ought to be in accordance with the applicable standard (e.g. NFPA-20).

- Suction and discharge lines should both be equipped with a compound-gauge respective a pressure gauge. Both compound and pressure gauges should fulfil the applicable conditions of the applicable standards.

- Suction as well as discharge piping should be supported as close to the pump flanges as possible in order to reduce/minimise the forces on the pump(flanges) (see figure ).

- Pump- and pipingflanges should lay perfectly parallel and centre on centre. NEVER use the bolts of the flange-connections to achieve this. Doing so will cause high tension on pump and flanges.

- Tighten the bolts of the flange-connections crosswise and in more equal steps. Tightening torque’s with which this is to be performed can be found in appendix 1.

§ 6.1.2 Suction piping for horizontal pumps:

- Suction-piping acc. NFPA shall be equipped with a listed O.S. & Y. gate-valve. A butterfly valve shall not be installed in the suction pipe.

- When the suction pipe and pump suction flange are not of the same size (suction pipe > suction flange), suction pipe and flange shall be connected with an eccentric tapered reducer in such a way to avoid air pockets (see figure suction piping).

- Avoid the use of bends in the suction pipe which rise (partially) above the pump-centreline. Doing thus will diminish the risk of air in the piping-system considerably.

- When pump and suction pipe support are mounted on different foundations and are connected by a rigid connection, the connection pump-suction pipe should be equipped with a flexible connection. The flexible connection must naturally fulfil the same stand-ards the rest of the piping has to fulfil.

- Suction piping must be hydrostatically tested for tightness according to the applicable test procedure mentioned in the applicable standard (e.g. NFPA-20).

- When the water supply can be expected to contain foreign materials, the suction pipe should be equipped with suction screening. Execution of the screening should be according to the applicable standard.

§ 6.1.3 Discharge piping acc NFPA :

Suction piping

- When the inside diameter of the discharge piping is larger than the inside diameter of the discharge flange, pipe and flange should be connected with a concentric reducer (see figure discharge piping).

- Discharge piping should be equipped with a check-valve which should protect the pump against damages caused by back-flowing water and should also maintain the pressure in the discharge system during the time the pump isn't operating. (see figure discharge piping). Discharge piping should be equipped with a control valve which is to be used by the weekly performed tests. The control valve should be mounted after the check valve.(see figure discharge piping).

1 2 3 4

Discharge piping1 = Excentrisch reducer2 = Concentrisch reducer3 = Check valve4 = Gate valve

- In between check valve and control valve a Tee should be mounted on which a branch pipe can be mounted that can be used for more duties. An example for the duty of this branch pipe is the use of it as a measuring pipe by which the generated flow can be measured (control valve should be closed when measuring). The branch can also be used for fire-extinguishing duties; water can be pumped out through this pipe as well as pumped into the system through this pipe.

- Discharge pipe should also be equipped (only for pump-units driven by a diesel-engine) with a pressure relief valve which is to be located directly after the pump (before the check valve). When a concentric reducer between pumpflange and pipe is mounted the pressure relief valve should be mounted directly after this reducer. Aim of the pressure relief valve is to protect the discharge piping, and all components that are connected to it, against damages caused by too high a pressure (caused by an overspeed of the dieselengine).

- Sizes, construction and materials of pressure relief valve, check valve, tee and control valve should be in accordance with the demands of the applicable standard (e.g. NFPA-20).

- Discharge pipe should be equipped with a branch-pipe for the engine cooling system (diesel engines only). Execution and location of this branch should comply with the demands according to the applicable standard (e.g. NFPA-20) and are discussed further in § 'Connecting cooling water system'.

- The discharge pipe should also be equipped with necessary branches for connecting the pressure switches for both the main fire pump and jockey pump. Execution and location of these pressure switches should comply with the demands to this according to the applicable standard and are discussed further in a separate §.

- These pump-units, driven by an air-cooled electromotor, the discharge pipe is to be equipped with a circulation relief valve (delivered with pumpset). It shall provide sufficient water to prevent the pump from overheating when operating with no discharge. Provision shall be made for a discharge to a drain.

§ 6.2 Connecting sensingline pressure switch :§ 6.2 Connecting sensingline pressure switch :§ 6.2 Connecting sensingline pressure switch :

§ 6.2.1 General :

The pressure switch to initiate automatic starting in case of pressure drop in the system, is mounted on the side of the controller and already electrically connected. The only connection to be made is the sensing line to the pump discharge. This connection should be in accordance with the applicable standard.

- The pressure-switchline should be made out of a corrosion-proof metal.

- The nominal inside diameter should be at least ½".

- The pressure switchline should be connected to the pump discharge pipe. The connection to this pipe should be located between check-valve and shut-off valve.

All connections, and piping should be leak-tight, thoroughly constructed, and resistant to the maximum system pressure.

Pressure Transducer:

For this project a pressure transducer has been selected and installed at the right hand side exterior of the controller. ( operating range 0 - 300PSI)This pressure transducer shall be connected to the main system as described in section “Connecting sensingline pressure switch”.The purpose of this pressure transducer is to continuously monitor the fire water pressure in the main system and to feed a volt signal ranging from 1 volt equal to 37,5 PSI and 4,5 volt equal to 300 PSI to signal conditioning module PC127. The actual measured system pressure can be read from display module PC151 at mode A.The set pressure at which the pump set shall start can be selected by pressing green set/reset push button to appraise mode. Consult applicable section of controller manual for adjusting procedures when required. There are no maintenance activities required for this pressure transducer.Complete transducer shall be replaced when, suspected, malfunctioning or the pump set when pressure transducer and/or setting are changed.

§ 6.3 Electrical supply (direct on line) :§ 6.3 Electrical supply (direct on line) :§ 6.3 Electrical supply (direct on line) :

§ 6.3.1 General :

The controller is delivered separately with the pump-unit, it should be connected at the moment of installation. The following connection have to be made ;

1) Mains ( A.C. ) power supply2) Connection between controller and electromotor 3) Connecting electromotor heater to controller(if mounted)

6.3.2 Main (A.C.) power :

Connecting the controller to the mains should be done in accordance with the control ler's connecting-schedule, that is delivered with(in) the controller (usually within the controller enclosure). The controller's operating voltage, depending on the execution and the country the controller has to operate in, is indicated on the controller-identification plate. Connecting should be done in accordance with the applicable legal safety-regulations as well as with respect to the maximum mains-power needed by the controller.

6.3.3 Connection between controller and electricmotor :

Normally electromotors have windings for C.C.W. rotation ( facing shaftend) when phases are in positive sequence. Cable size has to be calculated regarding nominal motor current ambient and cable length.

§ 7 ALIGNING HOR.PUMP UNITS § 7 ALIGNING HOR.PUMP UNITS § 7 ALIGNING HOR.PUMP UNITS § 7.1 Aligning the pump-unit :§ 7.1 Aligning the pump-unit :§ 7.1 Aligning the pump-unit :

§ 7.1.1 General :

After the unit is fastened on the foundation and piping is connected, the pump-unit has to be aligned. Although pump-units are already aligned when manufactured, it remains necessary to check and, if necessary, adjust the unit's alignment when installing, because it is possible that the unit's alignment is disturbed by forces that could occur during the transport and the connection of suction- and dischargepiping.

§ 7.1.2 Deviations :

The alignment of a pump-unit is determined by the position of the coupling halves with respect to another, therefore alignment should be performed by checking (and if necessary adjusting) the coupling half positions with respect to another. When aligning the coupling half positions, the following 3 possible kinds of deviation should be taken into account :

1) Non-parallelism of the shafts (coupling halves)2) Non-concentricity of the shafts (coupling-halves)3) Clearance in axial direction between the coupling halves

ad 1) Non-parallelism of the shafts :

Checking the mutual angle between two shaftparts (coupling halves) can be done a.o. with the help of feeler gauges. These are to be positioned at 4 places equally divided (every 90) around the circumference of the circle. The angle between the two shafts can be esti-mated by comparing the distances (in axial direction) between the coupling halves. The allowable deviations (Kw (mm)) between the largest measured axial distance (Smax) and the smallest distance (Smin), depended on the coupling size, are to be found in table 1.

Always check the angular deviation in both the horizontal and the vertical plane !

ad 2) Non-concentricity of the shafts :

Checking the deviation in the position of the centres of the shafts (coupling halves) in relation to each other, can be done with the help of a straight edge. This should be positioned over both the coupling halves (see figure non-concentricity). Just as when checking the deviations in non-alignment of the shafts, checking of the deviation in non-concentricity should always be performed in both the horizontal and the vertical plane. For pump-units driven by a diesel-engine the coupling-halves should be positioned exactly concentric in the horizontal plane ideally ; in the vertical plane though, the coupling halves ideally should NOT be positioned exactly concentric ! Ideally, the coupling halve on engine-side should lay about 0,1 mm lower than the coupling halve on pump side, when not operating.

At the moment the engine is started and oil pressure rises, an oil-film will exist between crankshaft and bearing sleeves, as a result of which crankshaft and flywheel will rise about 0,1 mm. By adjusting the vertical engine halve cou-pling position thus that it is about 0,1 mm lower in stationary condition, will be archived that the coupling halves will be properly aligned when operating. The allowable deviations (Kr) depended on the coupling size, are to be found in table 1.

ad 3) Clearance in axial direction between the coupling halves :

The 3th magnitude that is of importance when aligning the unit is the distance in axial direction between the coupling-halves. This distance shouldn't be too small in order to permit axial movements of the shafts in relation to another (these movements are caused by expansion of the shafts due to temperature changes, or are as a result of bearing wear). On the other hand, the axial distance shouldn't be too large.If the clearance between the two coupling halves gets too large, the forces the coupling has to transmit will be transmitted on a too a small part of the coupling pins and rubbers. This will cause premature wear and decrease the service-life of the coupling. The axial clearance can be estimated easily by measuring the distance with a venire calliper. Permissible clearances (S1) (minimum as well as maximum) are to be found in table 1.

Simultaneous non-concentricity and non-parallelism :

In practice, there never will be a situation in which only a deviation in concentricity or in parallelity will occur. These deviations shall always occur simultaneously. Therefore, the absolute sum of both the deviations together may not be larger than the maximal allowable deviation for one of the deviations (Kw & Kr) separately. As can be seen in the table the allowable deviations (mm) for Kw and Kr are identical. Therefore it is not important which deviation is taken as criterion for both the deviations together.

Non-concentricity

Clearance in axial direction

§ 7.1.3 Coupling data

Table 1 : General data regarding flexible N-Eupex couplings

Coupling size (mm)

S1 (mm)

P (mm)

TA

(Nm) Sw

(mm) Kw

(mm) Kr

(mm)

250 3...8 69 145 14 0,42 0,42

Explanation used abbreviations :

- S1 : The distance (mm) between the two coupling halves in axial direction, whereby the 1st number states the minimum demanded clearance and the 2nd number represents the maximum allowable clearance.

- P : The minimum clearance (mm) needed for the 3th part of the coupling to be able to move freely in order to be able to disconnect the two coupling halves without having to remove more than only the 3rd coupling-part for this purpose.

- TA : The tightening torque (Nm) with which the bolts, with which coupling part 3 is attached to part 2 (see figure N-eupex coupling) are to be tightened.

- Sw : The spanner width (mm) of the bolts with which part 3 is attached to part 2.

- Kw: The maximal allowable deviation (mm) in (non) parallelity of the shafts, measured as suggested in figure Non-parallity. Kw = Smax - Smin .

- Kr : The maximal allowable deviation (mm) in (non) concentricity of the shafts, measu-red as suggested in figure Non-concentricity.

Adjustment :

If the alignment of the unit doesn't fulfil the standards that it is to comply with, the alignment has to be adjusted. By moving pump in hor. plane with the adjusting bolts and/or moving driver in vert.plane with installed adjustingjacks (engine) or shims (e-motor)

Technical data:Model: A-250Nominal torque: 2800 NmMax. allowable speed: 2750 rpm.

§ 7.1.4 Pump adjustment with adjustingbolts

§ 7.1.4.1 General

Four adjusting bolts are positioned around the pump pedestal. Loosing two bolts and tightening the two opposite bolts causes pump movement. First loosen the pump foundation bolts. With this feature it is possible to correct coupling NON concentricity in horizontal plane. After adjusting, all four adjusting bolts and pump foundation bolts have to be re-tightened.

§ 7.2 Driver alignment with adjusting jacks :§ 7.2 Driver alignment with adjusting jacks :§ 7.2 Driver alignment with adjusting jacks :

An adjusting jack is sketched in figure adjusting supports. When adjusting the engine, proceed as follows :-Loosen the bolts (1) of all the supports somewhat, so that the engine can be moved easily to some extent.

-After having loosened the bolts (1), the threaded lock washers (3) of all supports should also be loosened. These lock washers should be loosened as far as needed for the adjusting-jack(s) (2) to be able to be turned freely (in both directions) for as far as needed to achieve proper engine-alignment. For loosening and tightening the lock-washers (3) a hooked spanner should be used suitable for lock-washers in the range from ø 80 - ø 90 mm.

-The actual adjusting is to be done by turning the adjusting jacks (2) into (or out of) the skidsupport.

-After the alignment has been adjusted within the applicable tolerances, the threaded lock washers (3) and bolts (1) should be tightened.

Figure 13

-Always check the shaft alignment in both the vertical and the horizontal plane ; even if the engine's position has only be adjusted in one of these planes. An adjustment in the horizontal (vertical) plane may also

influence the engine's position in the vertical (horizontal) plane !

If the unit's alignment is checked (and if necessary adjusted), without suction- and discharge pi-ping mounted, the unit's alignment should always be checked (and adjusted, if necessary) after having mounted suction- and discharge piping.

After the alignment procedure has been finished, the tightening torque’s of the engine/pump connections to the skid as well as of the coupling bolts should be checked. The proper tightening torque’s for the engine/pump - skid bolts are to be found in appendix 1.

§ 8 SYSTEM DESCRIPTION§ 8 SYSTEM DESCRIPTION§ 8 SYSTEM DESCRIPTION

§ 8.1 General§ 8.1 General§ 8.1 General

The fire pump controller is designed for automatic starting at loss of water pressure in the main and complies with the NFPA 20 requirements.

§ 8.2 Eledyne controller§ 8.2 Eledyne controller§ 8.2 Eledyne controller

Motor contactors are fitted on the back panel and in the event of control circuit failure they can be operated "direct on line", externally by a manual mechanical lever fitted on the side of the controller. Remote monitor volt free change over contacts are provided for :

PHASE SEQUENCE FAULT MAINS FAILURE PUMP RUNNING PUMP ON DEMAND

Only if specially ordered, the controller will be equipped with an auxiliary supply circuit for winding heaters electromotor and/or supply circuits for jockey pump and engine controller.Each controller will have his own operating instruction manual related to the controller serial nr..It's very important to read this manual carefully before operating.

§ 9 PUTTING THE PUMP-UNIT INTO OPE-RATION FOR THE 1st TIME :§ 9 PUTTING THE PUMP-UNIT INTO OPERATION FOR THE 1st TIME :§ 9 PUTTING THE PUMP-UNIT INTO OPERATION FOR THE 1st TIME :

§ 9.1 Before putting into operation for the 1st time :§ 9.1 Before putting into operation for the 1st time :§ 9.1 Before putting into operation for the 1st time :

*Check the complete installation carefully.

*Make sure all bolts and nuts have been properly tightened.

*If not already done, install a pressure gauge so that the result of pump-operation can be monitored and checked properly.

*Check suction valve is open and water level is sufficient for operating.

*Check discharge valve and / or testline valves are closed.

*Check circulation relief valve (NFPA 20 2.6) is properly mounted.

*Check that the impellers have been adjusted properly so that the pumpshaft can rotate freely

*Switch on main isolator and circuit breaker of the controller and check the mains phases have no phase sequence fault.

* CAUTIONAvoid unintentional pump starting when closing main circuit breaker.

Precautionary measures to be taken.

Make sure that remote stop (energised to stop) or pressure switch (pressure in fire system healthy) are operative before closing main circuit breaker.Negligence with these requirements may result in personal injury and will cause severe damage to pump and ancillary equipment

§ 9.2 First starting (on site) :§ 9.2 First starting (on site) :§ 9.2 First starting (on site) :

*Start the pump by initiating a manual start

*Observe that the pump starts easily and runs without excessive vibration. If there is any starting difficulty or excessive vibration, then stop the engine immediately and determine the probable cause.

*Slowly open the discharge valve until the discharge pressure reaches the desired value.

*Adjust (tighten) the gland nuts gradually over an extended period. For the proper adjustment procedure : see § 2 of the maintenance part of this manual : 'gland packing directions'.

*During the 1st operation period, check and note all gauge readings and compare them to the respective values in the pump manual. If considerable deviations from the guidelines in these manuals are met with, the cause of this should be located and corrected if necessary.

* Lock engine control lever after speed adjustment is made.

§ 9.3 After first operation :§ 9.3 After first operation :§ 9.3 After first operation :

*After the 1st running period it is recommended to check and, if necessary, to correct the alignment of pump and driver.

§ 9.4 Possible causes of Fire Pump Troubles :§ 9.3 After first operation :§ 9.3 After first operation :

In this section a guide for locating pump troubles and their possible causes are given. The causes listed are in addition to possible mechanical breakage that would be obvious on visual inspection. In case of trouble it is suggested that those troubles which can can be checked easily should be corrected first ore eliminated as possibilities.

Recommendation

It is recommended that trouble shooting procedures are carried out by qualified personnel familair with equipment and safety procedures. Always investigate problems completely. Never compromise on problem solutions, avoid JURI-RIGGING.

WARNING

De energise controller and eliminate any possible unintentional start. Short circuiting of starting batteries

cause serious sparks and possible fire.

§ 10 MAINTENANCE :§ 10 MAINTENANCE :§ 10 MAINTENANCE :

§ 10.1 Preventive maintenance programme :§ 10.1 Preventive maintenance programme :§ 10.1 Preventive maintenance programme :

§ 10.1.1 General :

Maintenance schedule

This chapter provides the minimum inspection and maintenance requirements to be a part of a total preventive maintenance program. A preventive maintenance program is essential to ensure proper functioning of the complete pump set and reduce maintenance costs to a minimum. This program shall be initiated after the pump set has passed acceptance test.Reports shall be made from each inspection, maintenance and testing activity. These reports shall be filed for future review while latest inspection / maintenance report shall be stored in the wiring diagram carrier located at the back side of controller panel door.

§ 10.1.2 Weekly : before taking into operation

§ 10.1.2.1 E-motor :

General : Electromotors do not need a special maintenance programme. However to avoid and locate possible failures at an early stage it is recommended that electromotors are inspected weekly. When checking the motors the following objects should be paid attention to :

Walk-aroundinspection : Check the motor for cleanliness, presence of moisture, loose bolts. Locate

the cause of possible failures and correct it as soon as possible. When cleaning the motor make sure this is done dry. For drip-proof motors take special care the presence of dust on the windings. Keep electromotors free from contaminating fluids or gases which could damage the windings.

Electric motor: For this project a squirrel cage electric motor make Leroy Somer FLS 355LA4, nominal speed 1500 rpm., suitable for direct starting has been selected.

The construction of this FLS cast iron motor include IP55 protection a class F insulation and suitable to operate at 50°C ambient temperatures. A 150 watt space heater has been installed to eliminate problems caused by condensation. (loss of Insulation)

The heater supply wires arebrought out to a terminal block in the motor junction box. The heaters will be switched off, by the controller, while the machine is in operation. (see cross sectional drawing e-motor)

Maintenance: The rotor has been provided with two ball bearings number 322C3.

Grease is used for lubricating purposes and shall be replaced at 4500 running hour intervals or in accordance with other maintenance schedules. Each bearing shall be provided with 60cm³ lithium based grease. (Esso Unirex N3 or equivalent)

Check annually all cable connections for damage and tighten all

connections.

Bearing arrangement

§ 10.1.2.2 Pump :

Walk-aroundinspection Perform a visual check for leakage’s, loose bolts, corrosion and filthiness,

presence of debris or foreign objects.

§ 10.1.3 Weekly : during operation

§ 10.1.3.1 E-motor :

Noises /vibrations : Check vibration and noise level. Any unusual vibrations or noises should

be located and corrected immediately.

§ 10.1.3.2 Pump :

Noises /vibrations Check the pump for unusual noises and vibrations.

Stuffing box Check leakage from stuffing-box. Leakage must be somewhere in between 40 to 60 drops / minute. Leakage may only occur between shaft-sleeve and soft packing-rings; no leakage may occur between stuffing-box and soft packing rings. Adjust stuffing-box leakage if necessary. Adjustment of stuffing-box leakage has to be performed in accordance with gland packing instructions (pages 54 to 58 of this manual).

Stuffing boxdrain Check stuffing-box waste-pipes for free flow.

Bearings Check bearing temperature. Bearing temperature may not exceed 45 C above ambient and may also not exceed 95C.

§ 10.1.4 Monthly :

§ 10.1.4.1 Controller :

Signal-lampbulbs Replace those signal-lamp bulbs that are illuminated continuously (A.C.

mains ON,(When Applicable) battery A healthy, battery B healthy) .

§ 10.1.5 Yearly : before taking into operation

§ 10.1.5.1 E-motor :

Inspections : Same as all inspections that are to be performed weekly.

Bearings : Replace bearing grease. Quality and quantity of the grease are generally mentioned on an identification plate that is attached to the motor. Regreasing should be done in accordance with the applicable regreasing directions from the motor-manufacturer.

Technical data bearings:Driven end: 6322C3 grease quant. 60cm³Non Driven end: 6322C3 grease quant. 60cm³Grease quality: Esso unirex N3 or equal

§ 10.1.5.2 Pump :

Walk-aroundinspection Perform a visual check for leakage’s, loose bolts, corrosion and filthiness,

presence of debris or foreign objects.

Bearings Check bearings and change bearing grease. For this purpose the old grease must be removed and bearings have to be cleaned .Bearings may not be filled for more than 50 % with new grease. Use Texaco Multi Purpose No. 2 Marfak or equivalent. Check general operation of the bearings and, if necessary, replace them.

Technical data bearings:Driven end: SKF 6216 grease quant. 18cm³Non Driven end: SKF6216 grease quant. 18cm³

§ 10.1.6 Yearly : during operation

§ 10.1.6.1 E-motor :

General Same as all Weekly during operation Pump inspections.

§ 10.1.6.2 Pump :

General Same as all Weekly during operation Pump inspections.

§ 10.1.7 Every three years : before taking into operation

§ 10.1.7.1 E-motor :

General : Same as all Yearly before Taking Into Operation Preventive Maintenance operations.

§ 10.1.7.2 Pump :

General The 3 yearly or 20.000 hours inspection must contain the same inspecti-ons/checks that are to be performed yearly.

Bearings Replace bearings.

Stuffing box Replace all soft packing rings at this time. Check casing (and impeller if equipped) for wear. Maximum permissible diametrical clearance between impeller and casing depends on impeller size and can be found in figure 1.

CLEARANCES IMPELLER-CASING WEARRINGsingle stage and two stages centrifugal pumps ( Tmax=80C )

Figure 1

Shaftsleeves Check shaftsleeves for damage and wear. If necessary, replace them. Permissible wear and/or damage should be considered for each case separately. It may not be necessary to replace shaftsleeves in cases where small damage or minor wear is established. Damage or wear that does (or may) influence pump performance considerably is not permissible. In cases where small damage or small wear is established, and shaftsleeves are not replaced, a more frequent inspection of the damaged or worn parts should to be performed.

Oil seal Check the oil seal ring in the bearing housing on the coupling side and

replace it, if necessary.

Felt rings Check the feltrings in both bearing housings and replace them, if necessary.

Miscellaneous Clean the entire pump thoroughly (inside as well as outside) and make sure the old flange sealant between the two casing halves is removed entirely before new sealant is applied. Flange sealant between the two casing halves should be Loctite Superfast 573. Make sure all casing bolts are tightened crosswise with the proper tightening torque (tightening torque’s : table 1 ,appendix 1).

§ 10.1.8 Every three years : during operation

§ 10.1.8.1 E-motor :

General : Same as all Yearly during Operation Preventive Maintenance operations.

§ 10.1.8.2 Pump :

General Same as all Yearly during operation PUMP inspections.

§ 10.2 Gland packing directions :§ 10.2 Gland packing directions :§ 10.2 Gland packing directions :

§ 10.2.1 General : If a large leakage flow, or a leakage in the wrong location4, should occur and the gland has already been adjusted several times (or in case adjusting doesn't result in an improvement), the packing-rings most likely are worn or damaged so that a replacement of the rings becomes necessary. When removing and assembling the rings the following procedure should be followed :

Technical data packing material:Make: BurgmandSize: 12,7mm square

§ 10.2.2 Removing old packing-rings :

10.2.2.1 Make sure the stuffing-box is not under pressure. For this purpose check :

- Readings discharge pressure gauge- Water supply to lantern-rings5

If possible, drain the water that is in the pump, until the water level has at least dropped below the lowest

stuffing-box level. Draining can be done by removing one of the plugs that are placed in the discharge

flange.

10.2.2.2 After having checked the points mentioned in the maintenance, the gland should be removed. For this purpose the gland-nuts should be removed, wherefore the gland should be pulled back as far as possible (figure 1) .

10.2.2.3 After the gland has been removed, the old packing-rings and the lantern-ring can be removed. Always replace all packing-rings ! Replacing only one or two rings will not result enough effect. Removing the packing-rings should be done with the help of a packing-extractor (see figure 2) and should be performed with ample care, in order to prevent damages to stuffing-box and/or shaft(sleeve).Make sure the packing-extractor's sharp side is pointed towards the stuffing-box and not towards the shaft(sleeve), so that in case of shooting out the shaft(sleeve) will not

4    ? Leakage should occur between shaft(sleeve) and packing-rings, NO leakage should occur on other locations, such as between packing-rings and stuffing-box.

5    ? Checking whether the water-supply to the lantern-rings is closed is only to be done in case the lantern- rings are supplied with water that is not coming from the pump's discharge.

Figure 1

Figure 2

be damaged.

The lantern-ring also should be removed in order to be able to remove the packing-rings that are placed on the other side of the ring. For this purpose the lantern-ring is executed with, generally 2, savings through which hooks can be inserted. Pull the lantern-ring out with one hook in both the savings simultaneously so that the ring can be pulled out of the stuffing-box straight. Obviously, removing the lantern-ring should be performed with the same care as is required when removing the packing-rings.

10.2.2.4 After having removed packing- and lantern-ring(s) the shaft(sleeve) and stuffing box should be cleaned and checked for damage or wear thoroughly. If shaft(sleeve) and/or stuffing-box show considerable6 wear/damage these failures should be corrected.

In case abnormal packing-wear seems to occur, it is recommended to also check whether shaft(sleeve) and stuffing-box are positioned concentric (see figure 3) and aligned, apart from wear and damage to shaft(sleeve) and stuffing-box. Also check the shaft run-out.

Also check the gland's dimensions (see figure 4). For this purpose place the gland into the stuffing-box and measure the clearance on the inside-diameter (with the shaft-(sleeve)) as well as on the outside-diameter (with the stuffing-box). These clearances should (diametrical) not be more than 1,6 mm respective 1,0 mm, to prevent that the gland will be able to contact the shaft or shaftsleeve.

Check the clearance between the bottom of the shaft (sleeve) and the stuffing-box (see figure 5). In case this clearance should be larger than 0,8 mm (radial) than mount a neckring with the proper dimensions. When using such a ring it's not possible that packing-rings are pressed between shaft(sleeve) and stuffing-box, what would cause damage to the rings.

6    ? Regarding allowable damages and/or wear to shaft(sleeve) and/or stuffing-box it is not easy to apply concrete maxim. Pumps that are applied for Fire Fighting Duty generally will operate only little; therefore, damages/wear that effect pump-efficiency and performance of the pump only limited can be allowed for economic reasons. However, wear and/or damages that might effect pump-reliability in whatever way should not be allowed. Wear and/or damages that could cause to drop the pump-capacity below the required capacity should also not be allowed.

Figure 3

Figure 4

§ 10.2.3 New packing-rings :

10.2.3.1 Only apply original packing-rings of the proper material and manufacture.

10.2.3.2 Packing usually is delivered in pre-formed rings of the proper sizes or in one spiral-formed length.

In case packing is not delivered in one of the forms mentioned above, but in one length (non-spiral formed) it is necessary to cut off the proper length that is needed for one ring. In these cases proceed as follows :

* Wind the packing-length tightly around a shaft with the same diameter as the shaft(sleeve) is (see figure 6) .

* Draw two lines on the packing-'spiral' parallel to each other in axial direction with a space that is equal to the packing-width (or packing-height, as the packing-width is generally equal to the packing-height).

Now cut rings out of the spiral7, between the two parallel lines in an angle of 45, in the

horizontal plane, with the axial direction (see figure 7).

* Packing-rings made out of a stiff material should be cut in (see figure 8) , over about 2/3 of the packing-height, on the inside-diameter on one or more spots so that the rings can be bent open somewhat when mounting onto the shaft(sleeve).

* Check whether all packing-rings are the proper dimensions, before mounting them into the stuffing-box.

7    ? This should also be done in case the packing is delivered in one spiral-formed length.

Figure 5

Figure 6

Figure 7

Figure 8

§ 10.2.4 Mounting the new packing-rings :

10.2.4.1 Before mounting the new packing-rings first check whether stuffing-box and shaft(sleeve) are clean ; also check whether the old packing-rings are completely remo-ved. Also check that the pump-shaft can rotate freely.

10.2.4.2 Always place only one packing-ring at a time and mount each packing-ring about 120 rotated with respect to the previously mounted ring. After the mounting of each ring, always check whether the shaft can still rotate freely.

10.2.4.3 Do not forget to replace the lantern-ring (if equipped) ! Before replacing the lantern-ring check the ring for cleanliness and damage.

Make sure the lantern-ring is mounted so that the ring will be placed straight under the lantern-ring water-supply connections (see figure 9), after the gland-nuts have been tightened again .

10.2.4.4 After having placed the lantern-ring, the rest of the packing-rings can be placed. Placing these rings should be done in accordance with the directions given in the maintenance.

10.2.4.5 After having placed the last packing-ring, the gland has to be mounted again. When replacing the gland, the gland-nuts should equally be tightened until they are hand-tight to loose. Check again that the shaft can still be rotated freely.

10.2.4.6 After having checked and approved that the shaft can be rotated freely, the gland-nuts should be equally and firmly tightened.

§ 10.2.5 Adjusting / running in of the packing :

10.2.5.1 Untighten the gland-nuts until they are hand-tight to loose again.

10.2.5.2 Start the pump.

NOTE : NEVER COMPLETELY LOOSEN THE GLAND-NUTS WHEN THE PUMP IS RUNNING !

10.2.5.3 After having started the pump (almost) immediately a leakage should occur between packing-rings and shaft(sleeve)8. In case no leakage should occur read and apply the maintenance.

10.2.5.4 Leakage does occur : If leakage does occur between packing and shaft(sleeve), the packing-rings have been mounted properly ; the packing should now be adjusted. When adjusting, proceed as follows :

a) Leakage should ideally be about 40 to 60 drops per minute. Generally, the leakage with

8    ? No leakage may occur between packing and stuffing-box !

Figure 9

the gland-nuts hand-tight to loose will be (much) more than the mentioned 40 - 60 drops / minute. In these cases the gland has to be adjusted.

b) Before the gland may be adjusted the pump should first have operated about 10 minutes with a constant leakage, so that leakage will be able to stabilise itself and therefore can be estimated more correctly.

c) After having let the pump operate for about 10 minutes the gland-nuts can be tightened. The gland-nuts should never be tightened more than 1/16 turn at a time. After each time the gland-nuts have been adjusted the pump should be operated for about 10 minutes again before further adjustment may be performed.

d) Repeat the steps mentioned under point c) until leakage has stabilised to the mentioned 40 - 60 drops/minute.

e) 10.2.5.5 No leakage9 occurs : If no leakage (or a leakage on the wrong place) should occur the

packing is likely to become overheated rapidly. Therefore, if leakage does not occur (almost) immediately, stop the pump and let it cool down.

Check whether the gland-nuts are still hand-tight to loose.

a) The nuts are still hand-tight to loose :

If the nuts are still hand-tight to loose, after having stopped, tighten the nuts slightly (about 1 complete turn).

b) The nuts are not hand-tight to loose anymore :

If the nuts are not placed hand-tight to loose anymore the packing will most likely have been tightened to much when the gland was mounted, this has probably caused an expansion of the packing during pump-test operation. Therefore undo the nuts slightly until they are hand-tight to loose again.

After having executed one of these procedures a) or b), the pump can be started again. After starting leakage should occur (almost) immediately. If still no leakage occurs, or a leakage on the wrong place occurs, then immediately stop the pump again.Let the pump cool down again and disassemble the gland and packing-rings again. Locate and correct the cause of the failure.

9    ? Or leakage at the wrong place.

§ 11 (DIS) ASSEMBLING THE PUMP :§ 11 (DIS) ASSEMBLING THE PUMP :§ 11 (DIS) ASSEMBLING THE PUMP :

§ 11.1 General :§ 11.1 General :§ 11.1 General :

For some checks that are to be performed during the maintenance programme as well as for possible repairs it will be necessary to disassemble the pump (partially). Disassembling, and re-assembling, the pump should be performed carefully in order to prevent damage due to an incorrect (dis)-assembling process. Therefore, disassembling and re-assembling of the pump are discussed in detail further in this paragraph. Read these directions carefully before you start disassembling the pump!

NOTES :- As already mentioned, Nijhuis Fire protection's written permission should be obtained,

in case the pump should be disassembled within the duration of the guarantee-period. If the pump is disassembled within this period without Nijhuis fire protection's permission, the guarantee may be invalidated!

- Only use original spare parts of the proper manufacture. For questions concerning spare parts as well as general information regarding the pump, always quote pump ty-pe and serial-number with all your enquiries. This will help us to deal with them efficiently.

§ 11.2 Disassembling the pump :§ 11.2 Disassembling the pump :§ 11.2 Disassembling the pump :

This paragraph is to be read in conjunction with figures 1 to 5.

Figure 1

Figure 1 : Remove the gland-nuts (A) and withdraw the gland (B) as far as possible. Remove the dowels (C) and nuts (D) from the cap (G), and turn the forcing screws (E) until the cap gets loose from the pump housing (H). Now remove cap (G) from the pumphousing (H).

Figure 2 :Remove bearing-housing bolts (I) from both the bearing-housings. After having accomplished this, the complete pump-shaft (K) including the wear rings (J) can be removed from the pumphousing.

Figure 3 : Remove the bolts (L) and bearing-covers (M) and (O). Remove bearing-nut (P) and lock-washer (Q). Make sure the lockwasher-lip is pressed back before removing the bearing-nut! Now remove bearing-housings (R).Technical data ball bearings:make: SKF 6216 ( driven end - non driven end )

Figure 2

Figure 3

Figure 4 : The wear rings (J) can now be removed from the impeller. Loosen the adjusting screws (S) and thereafter remove shoulder-ring (T), thrower (U), spacer (V), gland (B), packing-rings (W), lantern-ring (X) and impellerkey (DD).

Figure 5 : Remove shaftsleeves (AA) and (BB). These shaftsleeves should always be loosened in the same directions as the pump's direction of rotation. For removing the shaftsleeves use always the pro-per tools (shaftsleeves-spanner) on the right place. Now remove impeller (CC) and impellerkey (DD).

§ 11.3 After disassembling :§ 11.3 After disassembling :§

Figure 4

Figure 5

11.3 After disassembling :

- After having disassembled the pump (partially), all parts that are likely to be damaged (due to weather as well as to mechanical causes) should be protected in order to prevent this. If the pump, or parts of it, are to be stored : proceed in accordance with the directions mentioned in § 2, in the pre-installation part of this manual.

- Clean the bearings with white spirit or kerosene and dry them with dry, compressed air. Inspected the bearings for wear, fracture, corrosion and other damage. If necessary, renew them. DO NOT SPIN DRY BEARINGS (at high speed during a longer period) ! After having inspected the bearings, they should be greased or oiled immediately in order to prevent corrosion.

- Examine the shaftsleeves for damage and wear. If scoring is not heavy, the shaftsleeves can be reground to provide a new surface. Shaftsleeves can be reduced up to maximum 0,75 mm below the initial diameter for this purpose. If this is not suffi-cient to eliminate scoring the sleeves should be renewed.

- Check packing-rings, 'O'-rings and felt rings for damage and wear and, if necessary, renew them.

§ 11.4 Before re-assembling :§ 11.4 Before re-assembling :§ 11.4 Before re-assembling :

- Clean the entire pump thoroughly. Especially both pumphousing separating flanges to make sure all old packing (loctite) and other foreign materials are removed. Check these flanges accurately for damage and, if necessary flatten the flange surfaces.

§ 11.5 Reassembling the pump :§ 11.5 Reassembling the pump :§ 11.5 Reassembling the pump :This paragraph is to be read in conjunction with figures 6 to 13 .

Figure 6 :Make sure the impeller (CC) is mounted correctly so that the impeller's direction of rotation is in

Figure 6

accordance with the driver's direction of rotation.

Figure 7 :First mount key (DD) and impeller (CC) onto the shaft (K). Once again : attention for the direction of rotation ! Now mount the shaftsleeves (AA) and (BB). One of the shaftsleeves has left-handed screw-thread, the other right-handed. Therefore make sure the propersleeve is mounted on the propershaftside. Do not forget to assemble the rubber 'O'-rings (EE) onto the shaft-sleeves.

Figure 8 : Now mount the following parts : Neckbush (Y), lantern-ring (X), gland (B) spacer (V), thrower (U) and shoulder-ring (T). Do not forget to tighten the adjusting screws (S). Now assemble the wear rings over the impeller (CC).

Figure 7

Figure 8

Figure 9 :

Mount the bearing-housings (R) and place new feltrings (FF) when they are worn. Mount the spacers (GG), (HH) and (II). Now assemble the bearings (JJ) and (KK) onto the pumpshaft (K) and lock them with lock-washer (Q) and bearing-nut (P). After the bearings have been placed properly and the nut is tightened far enough, press one of lock washer-lips into the nut so that the nut's position will be fixed. When mounting the bearings it is to be recommended to heat the inner-ring of the bearings to about 80C (NOT BY DIRECT FIRE). Fill the bearings for only 50 % with new grease (Texaco Multi-purpose 2 marfak). Now place bearings-covers (M) and (O).

Figure 10 :Check that the stuffing-box chambers and separating flanges (A) of upper and under halves are clean. If these components are clean the complete pumpshaft can be assembled into the pumpbody. Make sure that lantern ring water-supply connections (B) are open. Also check whether the water-discharge holes that are placed opposite to it are open too.

Figure 9

Figure 10

Figure 11 : The casing flanges should be sealed with sealant. We recommend Loctite Superfast 573. Apply the loctite to the pumpbody (H); make sure it is also applied around the studs!

Figure 12 : Now mount cap (G) onto the pumpbody (H); keep the lantern rings (X) and neckbushs (Y) outside the pumphousing. Adjust the cap (G) by the two dowels (C). Now fasten the cap onto the body by tightening nuts (D). The nuts (D) should be tightened in a sequence as shown in figure 13. Tightening torque’s with which the nuts are to be tightened depend on pumpsize and material and can be found in table 1, appendix 1 of this manual.

Figure 11

Figure 12

Also fasten the bearings-housings (R) by the hexagon screws (I). Now it should be possible to rotate the pumpshaft (K) easily. After having checked and approved the shaft's ability to rotate the packingrings should be inserted. Inserting the packing rings is to be done in accordance with the directions given in § 10.2.

Figure 13

APPENDIXAPPENDIXAPPENDIX

§ Tightening torque’s :

A. Tighten the 4 "corner" nuts marked "X" -1,2,3 and 4 (see figure 1)

B. Work outward along shaft axis toward the sealhouses in opposite quarters tightening nuts in regions 5, 6, 7 and 8.

C. Work outward along the branch and in opposite quarters tightening nuts in regions 9, 10, 11 and 12.

D. Repeat the whole sequence.

Screw size

Tightening torque’s

Figure 1

Casing Materials

Irons, Bronzes

Steels, Stainless steels, High Duty Irons

lbf/ft Nm lbf/ft Nm

M 16 65 88 100 135

M 20 130 178 195 265

M 24 220 300 330 450

MAXIMUM ADVISED TIGHTENING TORQUES

FOR STANDARD METRIC BOLTS AND NUTS

ACCORDING TO ISO MATERIAL GRADES.

Quality. 6:6 8:8 9:8 10:9 12:9

Torque. Nm Nm Nm Nm Nm

Nominal thread diameter, mm.

8 16 30 33 41 50

10 33 58 66 82 98

12 57 102 114 143 17114 91 162 182 227 273

16 142 252 281 355 426

18 195 347 391 488 58620 277 492 551 693 830

22 377 670 753 941 1130

24 479 851 957 1196 143627 700 1245 1401 1750 2100

These torque settings are for general purpose use only. Torque settings may alter depending on the material used on the nuts and bolts, E.G. stainless steel, or the machine application. When in doubt please consult NIJHUIS PUMPS.