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AND
OPERATIONS MANUAL
II
II
Table of Contents
A
B.
C.
D.
E..
F.
G.
H.
VI.
4
4
4
6
7
8
9
11
STARTING,OPERATIONAND MAINTENANCE
12
A
B.
C.
D.
E.
F.
12
13
13
14
14
15
PRIOR TO START-UP
~
START-UP
NORMALOPERATIONAND MAINTENANCE
DISMANTIlNG AND ASSEMBUNG PUMP BOWLS
BEARING AND WEARRING REPIACEMENT
COMMONCAUSESOF IMPROPER OPERATION
FOR
SHORT COUPLED PUMPS
READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING
I.
RECEIVING, UN-CRATING
AND INSPECTION
A physical check of all equipment should be made against the packing list and
inspected for obvious damage incurred during shipment.
C.
Un-Crate and layout all the equipment in the order of installation on clean boards
or floor.
INSTALLATION
A
A portable or permanent derrick of sufficient strength and rigidity to lift the total
weight of the pump safely should be used. A conservative weight of the pump may
be obtained from the freight bill. The minimum travel of the derrick should be at
least 6' greater than the equipment. Hoist must have swivel hook.
One or two cable slings of sufficient strength to lift entire pump and must be long
enough to clear greatest shaft projection.
Two pipe wrenches of sufficient size to handle shaft coupling and shafting. (Always
required for hollow shaft motor drive).
III.
M.
Two sets of steel clamps to fit the column pipe. NOTE: One set required if only one
section of column is furnished.
N.
Two 4 x 4 timbers or "Ii" beams (if unit is extra large and heavy), sufficiently long
to span installation opening.
Thread and gasket compound such as Dow Corning Silastic or Permatex Form-AGasket with thinner.
S.
Two pipe wrenches of sufficient size to handle shaft enclosing tubing when appli- .
cable.
X.
Putty knife.
SPECIAL PRECAUTIONS
A
Make certain that no rags, wood scraps, etc., are lodged in any exposed openings.
Check pit depth and anchor bolt spacing against pump dimensions. lift and handle
unit carefully to prevent damage caused by bending strain being applied. DO NOT
LIFT OR LEVER ANY ITEM BY ITS SHAFT. Take extra precautions when
handling mechanical seal, since this is a precision component and most delicate.
B.
Do not allow pipe compound, solvent or any petroleum products to get to rubber
bearings.
IV.
PREPARATION
Clean all threading and flange faces with wire brush and paint with solvent. File
threading, if required, with three cornered file. The protective coating on threads
& flanges is a rust preventative and not a thread compound or gasket.
Page No.3
Clean all shafting and couplings with a rag soaked with solvent. Make certain that
all bearings are clean.
C.
If furnished, clean all tubing threads and shaft bearings thoroughly in solvent and
make certain that tubing faces are free of nicks, dents or burrs. Remove protective
caps from ends of tubing before starting.
F.
Make a physical check of the discharge head and/or baseplate for proper fit to
foundation.
G.
Check pipe ends and mating components to be sure there are no dents, nicks, and
burrs. The success of a proper pipe and tubing joint is dependent on the butt joint
of the ends.
.
H.
Check shaft ends for nicks, burrs, etc. The shaft alignment is dependent on the butt
joint of the shaft ends.
I.
Check all boxed shafting for straightness using "V" blocks and dial indicator as
follows: (See Fig. A)
1.
Start with "V" blocks as close to threads as possible. Check two or more
places between "V" blocks to within .003" to .005" T J.R.
2.
Move "V" blocks about 20% of shaft length from each end. Check the center
of the shaft and the overhanging ends and straighten as above.
3.
4.
Repeat steps until shaft checks within tolerance in both positions. Wipe shaft
clean after checking.
5.
Check ronout on impeller shaft extension by placing indicator dial toward end of
shaft and turning shaft slowly making certain that it stays to one side of the uppermost
bowl bearing. T.I.R. should not exceed .005".
Check and record total bowl lateral or end-play if prime mover is solid shaft. This
information will be required for flanged coupling assembly.
v.
INSTALLATION
H the final elevation of the plate is critical" this should be taken into account
and checked at this time.
B.
3.
Attach hex nuts to anchor bolts and snug against baseplate to protect anchor
bolt threads.
4.
Baseplate serves as a good base for the elevators and clamps to rest upon and
as a protection for the foundation.
PUMPBOWL
1.
2.
Secure the proper clamp to the upper end of the bowl beneath a convenient
shoulder. Attach the sling to the clamp for enough out on the ears to allow
it removal after setting down on beams.-(If only one sling is used).
H the bowl is equipped with a strainer, hoist bowl to vertical position being
careful not to drag strainer across floor.
4.
5.
Center bowl over installation opening then carefully lower until the clamp
ears are resting squarely on the beams. Remove the sling.
Oean the shaft threads, the discharge threads and but face or flange face and
the threads and face if tubing is furnished. Lightly oil the shaft threads and
screw coupling on halfway. Place a rag over the coupling to prevent entrance
of foreign matter during the next step in assembly.
Slide shaft into bottom of column pipe and allow it to protrude approximately l5" below bottom end of pipe. Make certain that sleeve area if
furnished, is toward the top 0 fthe pipe. TIe a series of half hitches to the column pipe an to the shaftwith the 3/ 4" rope. Attach the sling to the clamp ears
as descnbed under Section B, Step 2
3.
Hoist column to the vertical position, be sure not the drag shaft across floor.
Before centering column over bowl, tap side of column to remove any loose
matter.
4.
Swing column over bawl, align shaft. Remove rag from shaft coupling, lowet:
until shaft contacts coupling then remove rope. Hold coupling turn shaft (left
hand threads) until shaft ends butt., Place one pipe wrench on coupling and
one on line shaft. Vertically aligned and tighten securely. Remove wrench
marks form shaft and coupling with a flat file and emery cloth.
S.
Sa.
6.
7.
8.
Lower assembly, slide beams in close to column, reset clamp ears on beam
and remove sling.
9.
If there is more than one section of threaded columna separate spider is used
Slip spider over shaft with lock ring up (if rubber bearings used), thread
spider into coupling until it seats against lower pipe face and tighten. To
insure that spiders tightened sufficiently against pipe face, use a spider
wrench made of pipe with slots to slip over spider arms.
..
--
jI<
..J
D.
9a
If column is flanged, clean flange recess and spider ring O.D.; slip spider over
shaft with lock ring up (if rubber bearings used) and seat into spider recess.
10.
Clean shaft threads and face thoroughly and thread coupling on for half its
length. Cover coupling with a rag to prevent entrance of foreign matter.,
1L
If there is more than one section of column, repeat the above outlined
procedure for each additional section until all column is assembled. Note
that if the top column section is over 5 ft., two lugs are provided ~d the clamp
should be secured directly below and against the bottom of these. Clean tile
top flange face (or end of pipe if head connection is threaded) and the shaft
projection thoroughly. Do not assemble the shaft coupling to the top piece of
shaft.
2.
... Slide the correct tubing section with shaft into the column pipe allowing the
tubing to protrude about 6" below the pipe end and the shafting to protrude
about 6" beyond the tubing end. Tie a series of half hitches to the pipe, to the
tubing and then to the shaft with 3/4" rope. Attach the sling to the clamp as
described under "Section B, Step 2".
3.
Hoist column to the vertical position "tail in" with the rope. Do Not Drag
Shaft Across Floor. Before centering column over bowl, tap side of column
to remove any loose matter.
5.
Lower assembly until tubing contacts thread bearing then remove rope.
Apply a small amount of compound to the upper bearing threads, place one
pipe wrench on the tubing extension and one wrench vertically aligned on the
tubing and tighten. If the tubing is coated with any special application, any
touch-up required resulting from using the pipe wrench should be done now ..
7.
After the column has been lowered and is resting on the setting beams, pour
about a half cup of oil into the tubing if unit is to be oil lubricated. Apply joint
compound to the leading threads of the line shaft bearing, oil bore lightly.
Slide over shaft and thread into tubing for half its length. It should not be
necessary to exert any side pressure on the shaft to start the bearing. Such
H the column is threaded and if the setting is deep enough to require a spider,
slip the spider over the tubing and force into pipe about an inch or two below
the top end. Spacing of Black Wide Spiders is generally 20 ft. from the bowl
and from the head and 40 ft in between.
Sa.
H the column is flanged the male register will be on the bowl and all top
flanges, the lower flange and the head will be female registers. Oean the
registers in the flanges. Slide the spider over the tubing and into the column.
9.
Continue assembly as outlined under Section "C'. Steps 10 & 11. Prior to
assembling next tubing joint, pour about 1/2 cup of oil into last tubing if unit
is to be oil lubrication. Also, use the bearing as a means of checking
~gnment (Step D-7). Note that the tope end of the tope piece of tubing is
chamfered and filed smooth on the ODe and has extra long threads for the
tension.
Wipe a thin layer of joint compound on the top flange face (or if connection
is threaded, on the top column threads). Remove the stuffing box from the
head. Oean the flange mounting face (or threads if head connection is
threaded) and the other machined face of the head thoroughly. Attached
sling, hoist head and center over column, align studs with holes in flange, then
lower until head is resting squarely on flange. Install hex nuts and tighten. (H .
there is an underground outlet, align the head in relation to the outlP.tas close
as possible to the final position).
H an underground outlet is being used, make certain that it is properly
orientated with relation to the head.
H an adjustable top flange or threaded head is used, the head can be readily
turned to orient it to the below ground outlet, as well as relation to the top
shaft. A measurement should be made from the outlet centerline to the head
bottom and the head turned until the correct dimension is achieved. Back the
packing ring off to allow ample working room, fill the chamfer on the lower
end of the flange with lampwick packing that has been pre-coated with joint
compound. Use a generous amount of packing and wind the packing around
in such a manner that it will.tighten when the packing ring is screwed into
place. Screw the packing ring up against the flange or bottom of the head and
tighten.
E.
2b.
If the adjustable flange is being used in conjunction with tubing, the top of the
tubing should be approximately 1-1/2" below the tension box mounting face
of the head after the flange is adjusted.
3.
Hoist head slightly, remove clamp from top piece of column remove setting
beams and clean surface of baseplate or foundation. If there is an auxiliary
line to the bowl bearing or thermo-well, that portion immediately below and
tying into the head should now be installed. Properly orient discharge outlet
and align mounting holes with anchor bolts and lower until head is resting
squarely on foundation.
4.
4a.
4b.
4c.
4d.
box register into the head. Align mounting holes with taps in head,
install and tighten capscrews.
b.
srYlE 76 - GREASELUBRICAlED
PUMP - ENCLOSED LINE SHAFf
- Refer to Style 76, grease lube, drawing for complete assembly instructions
(supplied with seal).
Run a fine flat file over the surface of the head to remove any nicks or
burrs., Thoroughly clean face and register with solvent. Wipe a thin
layer of light oil over surface. This will help prevent rust and will also
facilitate slight driver shifting during coupling alignment.
d.
Attach the erector sling to the driver lifting lugs. Hoist driver sufficiently to allow easy access to mounting, remove nicks and burrs with
fine flat file and thoroughly clean with solvent. If there is insufficient
head room to install the driver shaft after placing the driver on the
head, lower the drive shaft through the quill, keyway end up, install the
. Hoist driver sufficiently to clear stand, swing over pump head and
slowly lower until motor is resting on ring. Proper orient conduit
box or drive shaft, align mounting holes and install BUT DO NOT
TIGH1EN capsrews.
Oean the drive shaft thoroughly and dress the threads and ~eyway
-Nith3 cornered file if necessary. lift shaft and carefully lower it
through the quill (end with keyway goes toward the top) and allow
shaft to contact head coupling. Remove rag and clean shaft face.
Hold head coupling from turning and rotate drive shaft until it
seats. Slip driver coupling over shaft and seat on driver. Install key .
in keyway using bar in holes provided in coupling with back up
wrench on head coupling, tighten, drive shaft. Remove key and
coupling.
Make a temporary electrical connection to motor, "BUMP" starter
to determine correct rotation (CCW as viewed from above). If
power is not available. Do Not make final drive shaft connections
(Stews i & j) until power is available and correct rotation is determined.
h.
Place the key on the drive plate over the hollowshaft against the
drive shaft. Turn the Rotor observing the clearance between key
and shaft, shift driver until the key touches all around. Tighten cap
screws.
i.
Slide clutch over drive shaft, seat against drive plate, install and
tighten bolts.
j.
Turn clutch until keyway in shaft and clutch align, install and seat
glb key. Thread adjusting nut onto shaft until lit seats against top
of clutchy. Hold the clutch from turning., turn adjusting nut until
shaft is pulled to its upper most position (pump bowl impellers will
be in uppermost position) counting the number of complete turns
to accomplish this. Back the adjusting nut off exactly half of the
total turns found above (this will place impellers in correct running
position for enclosed impellers, align holes in adjusting nuts with
taps in clutch, install and tighten machine screws. Place top cover
on driver and secure. Adjust open impellers so that they will run
0.015 inches off.
MISC. ASSEMBLIES
1.
LUBRICATOR - Install the lubricator and breaker to the discharge head.
Refer to the lubricator assembly drawing. Connect the 1/4 n copper line from
the lubricated tank to the stuffing box inlet port.
.
2.
DISCHARGE PIPING
a.
Above the floor piping should be installed in such a manner as to
eliminate the possibility of the discharge head being placed in a strain
or beingthrownout of alignment. Gate valves, check~ves and other
piping items must not depend upon the pump head for support.
b.
d.
3.
4.
AIR RELEASE VAI..VB - Install the air release valve, piping and manual
valve, if furnished, to the pump head or just beyond on the discharge piping.
It is suggested that if a throttling valve is not furnished, a throttling device be
used on the discharge side of the valve to restrict the discharge of air to insure
Make prelude, drain, grease line to tail bearing,etc., pipe.connections. Route piping so that is will not interfere with normal maintenance procedure.
All connections to the motor such as main leads, space heater leads,
thermocouple leads, etc., should be made in accordance with specifications,prevailin~
b.
VI.
STARTING.
PRIOR TO START-UP
1.
Perform initial servicing on the driver as recommenced by the driver manufacturer. Also perform initial servicing on all auxiliary assemblies ifrequired
3.
H air vent is manual, make certain that valve is opened partially but not all
the way. If air vent is automatic but equipped with a valve, make certain that
valve is opened partially but not all the way.
4.
Hthere is a control valve on the discharge side of the pump, make certain that
it is partially open and that pump will not be damaged ifnormal back pressure
is not available until long line, etc. is filled.
5.
Humt is oil lubricated, fill lubricator with good grade SAE 10viscosity rating,
low cold pour point mineral oil. Manually open needle valve and allow about
a cup of oil to drain into tubing. RE-FIILLUBRICATOR.
6.
H unit is open line shaft and equipped with prelubrication, turn on prelubrication some time before start-up and allow it to run a short time after
start-up.
7.
B.
INITIALSTART-UP
1.
Energize starter and after pump has come up to speed and all air has been
exhausted, regulate control valve to achieve desired pressure.
2.
If the air vent is manual, close off after airis exhausted. If air vent is automatic,
determine whether air was exhausted too quickly causing the pump to jerk
violently when the valve closed or too slowly and regulate manual valve or
throttling device to correct this.
3.
Regulate lubricator to allow aboutt 5 drops per minute for each 50 ft. of
setting.
c.
6.
Check for excessive vibration. If this is evident shut down unit immediately
and begin checking for cause.
7.
Adjust packing gland, to allow some leakaie past the packini. After running
it for a number of hours, check gland and if it is hot to the touch, loosen until
it becomes no more than warm to the touch.
14
6.
H the bowl bearings are pressure greased lubricated apply about one turn for
D.
7.
8.
Quench or
Remove shaft coupling. Remove hex nut that secure top intermediate to bowl and slide off end of shaft. Discharge adapter need not be.
removed from top intermediate unless bearings or seals are to be
replaced. Loosen set screw in impeller hub and slide impeller off end
of shaft. Remove impeller gib key.
b.
Repeat step "a" until all stages have been dismantled. After the
bottom intermediate has been removed, the shaft can be removed
from the suction nozzle bearing.
c,
d.
Slide impeller shaft into suction hub, then slide lower intermediate on
shaft and attach to suction nozzle.
e.
Assemble all remaining stages as outlined under stages "c" and "d".
E.
2.
3.
chamfered bore end of the hub to prevent shearing the outer surface. The hub
bore and the bearing should be lubricated with water to aid the pressing
operation. DO NOT LUBRICATE WI1H OIL OR GREASE.
4.
Hbearings are of Teflon or of a:similar plastic material, make certain that the
locking set screws are removed before pressing bearings out. like graphite
bearings, plastics are not particularly strong and should, therefor, be pressed
in with an arbor or screw press with a properly fit mandreL H original bearings
were locked in, drill and tap bearings at original lock position (or.drill and tap
bearing anJ hub at new location), and install locking set screw. It is also
recommended that the O.D. of the bearings be roughed up slightlywith a file
and good grade neoprene cement be applied to the bearing prior to pressing.
5.
Wear rings can be removed by cutting the cross section with a chisel and
prying on end inward until it is loose in the bore. To install, make a mandrel
to fit the wear rings and press in with an arbor or screwpress. In an emergen~,
the wear rings could be installed by gently and evenly tapping around the' top
edge with a wood block and hammer or plastic hammer.
H impeller skirts are equipped with wear rings, first remove the locking set
screws securing the rings to the skirts. Cut the wear ring cross section with a
chisel and force off. It might be possible to knock off or use a wheel puller for
removal without requiring any cutting. Heat on the ringwill assist in removal.
To install, make a mandrel to the fit the on. of the wear rings and press on
flush with the bottom of the impeller skirts. In an emergency, these rings can
be installed as described in step 4. Drill and tap for three 1/4" - 20 UNC x 1/
4" set screws 120 degrees apart at the ring to skirt joint and install stainless
steel set screws.
H discharge nozzle seals must be replaced, make certain they are always
installed with their lips pointing down. They are used primarily to keep water
out of the enclosing tube more so that to keep the oil in the tube.
F.
2.
3.
4.
Cogged suction.
e.
Incorrect rotation.
f.
Excessively womimpeller.
g.
Insufficient submergence.
h.
EXCESSIVE POWER
a.
b.
c.
d.
e.
Shafting bent.
f.
g.
VIBRATION
a.
b.
c.
d.
Shafting bent.
e.
f.
Breaking suction.
b.
3.15 -103
II
5.
c.
e.
BREAKING SUCTION
SHORT
COUPLED
PUMPS
Page 10. 18
FIGURE
SHAFT CHECKING
DIAL INDICATOR
AND STAND
SUBSTITUTE
,-
.-_'_
-r BLOCKS
SAWING60-to90-
MADE BY
NOTCH IN
2-X -BOARD
,I
1. START
WITH
THE
-r
BLOCKS
BLOCKS
STRAIGHTEN
3. IF BENDING
4. REPEAT
TO POSITION
OF THE SHAFT
STEPS UNTIL
STRAIGHTENING.
AS POSSIBLE.
SHAFT
CHECK
CHECKS
WITHIN
TOLERANCE
POSITION
IN BOTH
ENDS.
POSITIONS
WITHOUT
REQUIRING
ANY
SHORT
COUPLED
PUMPS
Pap Mo. 19
"A" DIAMETER
OF SHAFTING
".-
1-
1 .,-
1V.-
1 ", -
1 ,-
2.,-
2''''-
"B"DISTANCE
GRIP FROM
SHAFT
6-
8-
,,-
15-
19-
2.-
30-
36-
THIS PROCEDURE
WILL ELIMINATE
TIGHTEN
BENDING
SHAFTING
WITH
LUBRICATED
SHAFTING.
THE SH4FT
AT THE
IN W4TER LUBRICATED
MARKS.
CORROSIVE
WATER
SHOULD
BE TIGHTENED
SHORT
COUPLED
PUMPS
Pa&eNo. 20
FIGURE
ENCLOSED
LINESHAFT
c:
TIGHTENING
INSTRUCTIONS
MA"NOMINAL
SIZE OF TUBING
MB" DISTANCE
GRIP FROM
CENTER OF TUBE
.12
CHAIN
TONG
DIRECTLY
TIGHTENING
OF BELL-LJKE
DISTORTION
AT THE JOINT
TUBING THREADS
SHOULD
THREADS
PRESSURE.
BEARING WHICH WILL RESULT IN THE FREEZING OR GAULDING OF THE BEARING TO THE SHAFT.
RE
THE
SHORT
COUPLED
PUMPS
Pale 10. 21
FIGURE
'0
dEAD /d.IGNHENT
SHAFT.
TAKE
AT EACH
DO NOT INSTALL
PACKING AND GLAND
UNTIL HEAD HAS
BEEN AUGNED.
ITA.
SHORT
COUPLED
Pale 10;22
.
..
FIGURE
PUMPS
--
HEAD
GREASE FITTING
SPUT PACKING GLAND
STUDS
HANGER BOLTS
HANGER FLANGE
PACKING.
LOCK RING
SHORT
COUPLED
PUMPS
Pale 110. 23
FIGURE
LUBRICATED COLUMN
COUPLED
_10.24
WATER
".
PROOUCT..~UBRICA~ED
BOWL ASSEMBLY
A..
UNESHAFT
SHAFT COUPUNG
STEEL
PUMP SHAFT
4165.5.
BEARING
BRONZE
MAIN BEARING
STEEL
DISCHARGE
COLUMN
STEEL
0.0. THREAD
DISCHARGE
NOZZLE
48 CLASS30
CAST IRON
PLUG
CAST IRON
CAP SCREW
STEEL
DISCHARGE
TOP INTERMEDIATE
48 CLAS5-30
CAST IRON
COLLET
ST':EL
INTERMEDIATE
BRG.
BRONZE
INTERMEDIATE
BOWL
48 CLASS.3Q
CAST IRON
..
Co10C5 STEEL
BRONZE
BEARING
IMPEu.ER
BRONZE
.0
SAND COLLAR
BRONZE
SETSCREW
BRONZE
CAST IRON
SUCTION CASE
'8 CLASS30
CASTIRON
SUCTION PIPE
STeEL
S.S.
SHORT
COUPLED
PUMPS
Page 110. 2S
FIGURE
DRIVE SHAFT
OIL HOLE
HEAD
TENSION BEARING
LOCK BOLT
TENSION BOLT
TENSION GLAND
TENSION TUBE
HANGER BOLT
HANGER FLANGE
PACKING
LOCKNUT
SHORT
COUPLED
Pace 1Co. 26
PUMPS