Operation & Maintenance Manual

CUSTOMER APPLICATION DATA SHEET

NAME:

PO. NO:

INVOICE NO:

OPERATING DATA:

LIQUID NAME:

SP. GRAVITY:

OPERATING PRESSURE

SUCTION PRESSURE

PUMP MODEL

PUMP SPEED

MOTOR RATING

COUPLING TYPE

BARE SHAFT PUMP

DATE:

DATE:

VISCOSITY:

CAPACITY

PORT SIZE

DIRECTION OF ROTATION

BHP @ PUMP SHAFT

MOTORISED PUMP SET

OPERATING TEMPRETURE

Authorised by :

INDEX

Chapter Page No.

1 General Description 1

2 Installation 2.1 Handling & Storage 22.2 System Design & Installation 3

3 Maintenance 3.1 Cleaning in Place (CIP) 43.2 Maintenance Schedule 53.3 Disassembly 63.4 Assembly 9

4 Clearance Chart 13

5 Trouble Shutting 14

6 Part List 16

7 Pumps Speed Selection Chart 17

8 Test & Warrantee Certificate 18

GENERAL DESCRIPTION1

1

Lobe Pump

Lifting hook

Geared Motor

Base Frame

Bare Shaft Pump

Pump with drive unit

Installation 2

2

Installation 2

Pump-1 Pump-2

Suction Line

Discharge Line

3

Maintenance3

4

Maintenance3

5

Maintenance3

6

Maintenance3

7

Maintenance3

8

Maintenance3

9

Maintenance3

10

Maintenance3

11

Filler Gauge

Maintenance3

12

CLEARANCE TABLE4

4.1 Lobe rotor clearance Table

Pumps Model Pumps Model

ALB 100 S/L

ALB 150 S/L

ALB 200 S/L

ALB 250 S/L

ALB 300 S/L

ALB 400 S/L

Front Front

0.150

0.150

0.150

0.200

0.300

0.350

Rear Rear

0.150

0.150

0.150

0.200

0.300

0.350

SideSide

0.250

0.250

0.250

0.250

0.350

0.400

0Between Lobe @ 1800Between Lobe @ 180

0.150

0.150

0.150

0.200

0.300

0.350

All dimensions are in mm

4.2 Pump shaft Alignment :

Parallel alignment: ± 0.2mm max

Inclination alignments: ± 1° max

0.2

00

mm

Parralel alignment

o±1

Angular alignment

Cleara

nce b

etween lo

bes

radia

l cle

ara

nce

Front Rear

13

Probable Causes Solutions

Incorrect direction of rotation Reverse motor.

Pump not Primed.

Insufficient NPSH available.

Expel gas from suction line and pumping chamber and introduce fluid.

Increase suction line diameter. Increase suction head. Simlify suction line configuration and resuce length. Reduce pump speed.

Fluid vaporising in suction line. Increase suction line diameter. Increase suction head. Simplify suction line configuration and reduce length. Reduce pump speed.

Air entering suction line. Remake pipework joints.

Strainer or filter blocked. Service fittings.

Fluid viscosity above rated figure. Increase fluid temperature. Decrease pump speed. Check seal face viscosity limitations.

Fluid viscosity below rated figure. Decrease Fluid temperature. Increase pump speed.

Fluid temp. above rated figure. Cool the pump casing. Reduce fluid temperature. Check seal face and elastomer temp. limitations.

Fluid temp. below rated figure. Heat the pump casing. Increase fluid temperature.

Unexpected solids in fuid. Clean the system. Fit strainer to suction line.

Discharge pressure above ratedfigure

Check for obstructions i.e. closed valve. Service system and change to prevent problem recurring. Simplify dicharge line to decrease pressure.

Gland over-tightened Slacken and re-adjust gland packing.

Gland under-tightened adjust gland packing.

Se

izu

re

Pa

cke

d g

lan

d le

aka

ge

Me

ch

an

ica

l se

al le

aka

ge

Problem

No flo

w

Under

capacity

Irre

gula

r dis

charg

e

Low

dis

charg

e p

ressure

Pum

p w

ill not prim

e

Prim

e lo

st

aft

er

sta

rtin

g

Pu

mp

sta

lls w

he

n s

tart

ing

P

um

p o

ve

rhe

ats

Moto

r overh

eats

E

xce

ssiv

e p

ow

er

ab

so

rbe

d

No

ise

an

d v

ibra

tio

n

Pu

mp

ele

me

nt

we

ar

Pump speed above rated figure. Decrease pump speed.

Pump speed below rated figure. Increase pump speed.

Pump casing strained by pipework.

Check alignment of pipes. Fit flexible pipes or expansion fittings. Support pipework.

Flexible coupling misaligned. Check alignment and adjust mountings accrdingly.

Insecure pump drive mountings. Fit lock washers to slack fasteners and re-tighten.

Shaft bearing wear or failure. Refer to pump maker for advice and replacement parts.

Insufficient gearcase lubrication. Refer to pump maker's instructions.

Metal to metal contact of pumping element.

Check rated and duty presures. Refer to pump maker.

Worn pumping element. Fit new components.

Suction lift too high. Lower pump or raise liquid level.

Fluid pumped not compatible with materials used

Use optional materials.

No barrier system to prevent flow passing.

Ensure discharge pipework higher than suction tank.

Pump allowed to run dry. Ensure system operation prevents this. Fit single or double flushed mechanical seals. Fit flushed packed gland.

Faulty motor. Check and replace motor bearings.

Pumping element missing Fit pumping element.

Trouble Shutting Trouble Shutting

14

5

1

23

4

13

12

10

11

9

8

20

22

37

39

19

24

23

25

38

5

6

7

36

35

34

33

32

31

30

28

29

27

26

41

40

16

17

15

14

18

21

15

Parts list

16

1. nut, front cover2. front cover3. O'Ring, Front cover4. stud5. hex cap nut6. O'Ring for lobe sealing7. lobe8. nut, pump casing9. washer10. dowel11. stud, pump casing12. shims13. pump casing 14. bolt, clamp plate15. seal clamp plate16. m e c h a n i c a l s e a l ,

stationary parts17. m e c h a n i c a l s e a l ,

rotary parts18. seal spacer19. drain 20. bolt, bearing cover

21. Bearing cover 22. oil seal bearing cover23. bolt, back cover24. back cover25. oil seal, back cover 26. bolt, clamp plate27. clamp plate28. locking ring outer29. locking ring inner30. timing gear31. ring nut, bearing lock32. bearings, rear33. bearing spacer34. bearings, front35. stator shaft36. rotor shaft37. gear casing38. oil inlet39. oil indicator40. blot, base41. base

6

Pump Speed Selection Chart 7

* Speed of the pump should not exceed from the chart * Pump operating speed depends upon liquid viscosity

pump speed chart

liquid viscosity (cst)

upto 1500

1500 - 5000

5000 - 15000

15000 - 30000

30000 - 50000

50000 - 100000

100000 - 200000

pump operating speed (rpm)

1000

750

500

380

300

200

150

17

TEST & WARRANTEE CERTIFICATE8

18

TEST RESULT

PUMP NO :

RATED CAPACITY

PRESSURE

CAPACITY

POWER CONSUMED

SPEED

MODEL :

RATED PRESSURE

TEST DURATION :

TEST TEMP.

TEST MEDIA

KGF/CM2

LPM

HP

RPM

Signature :

QC DEPARTMENT

Other Products

ANI ENGINEERS Plot no. 2716, G.I.D.C. Estate, Phase-IV, Wadhwan 363 035. Surendranagar (Guj.) India. Ph.: +91-2752-241479, Fax : +91-2752-242479 Web : www.anivaryapumps.com, E-mail : mail@anivaryapumps.com