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GUARANTEE........................................................................................................... 3
HOW TO USE THIS MANUAL..................................................................................4
1. SAFETY PRECAUTIONS....................................................................................6
2. GENERAL DESCRIPTION OF VBN PUMPS.......................................................8
2.1 Casings and impellers................................................................................................................... 8
2.2 Rotating Assembly and Bearings...................................................................................................8
2.3 Technical Data............................................................................................................................... 9
2.3.1 High/low temperature applications.........................................................................................9
2.3.2 Pump serial number...............................................................................................................9
4. INSTALLATION..................................................................................................12
4.1 General........................................................................................................................................ 12
4.2 Pump installation and foundation................................................................................................12
4.3 Pump - motor alignment..............................................................................................................14
Introduction.................................................................................................................................. 22
Maintenance and Inspection schedule........................................................................................23
Major Inspection checklist............................................................................................................24
Factory replacement parts...........................................................................................................24
GUARANTEE
Seller guarantees to Buyer that the equipment at the time of shipment is free from
defects in material and workmanship and conforms in all respects to the agreed
technical specifications. This guarantee shall be ineffective and shall not extend to :
This guarantee shall not cover normal wear parts (as per API 610 - VIII ed. - 1.4.32),
such as wearing rings, bushings, shaft seals and bearings, nor gaskets / O rings,
after pump disassembling.
This guarantee shall be ineffective if the guarantee period indicated in the Purchase
Order, with reference to the time of shipment, has elapsed.
Sellers sole obligation under the foregoing guarantee is limited, at Sellers option, to
replacing or repairing defective equipment.
The guarantee contained herein is made only to and for the exclusive benefit of
Buyer and does not extend to any subsequent purchaser or user of the equipment,
unless specifically mentioned in the Purchase Order.
STATEMENT
Pompe Gabbioneta pumps comply with the following European Directives :
Machinery Directive
PED
Electro Magnetic Compatibility Directive
98/37/CE
97/23/CE
89/336
and amendments.
Refer to the Documentation Section for the Declaration of Conformity and/or the
Declaration of Incorporation, as applicable to the specific Purchase Order.
01 - Safety Precautions
1. SAFETY PRECAUTIONS
This pump has been designed to provide safe and reliable service within the
designated specifications. It is a pressure containing, rotating machine; therefore,
good judgment and proper safety practices must be exercised by responsible and
qualified personnel to avoid damage to the equipment and surroundings or possible
serious injuries.
It is assumed that the operators safety department has an established safety
program based on a thorough analysis of industrial hazards. Before installing and
operating or performing maintenance on this pump, it is suggested to the operator to
review the safety program and ascertain that it covers the hazards arising from
rotating machinery and pressure vessels.
Proper installation and continued maintenance of protective guards and shutdown
devices and other safety devices are necessary for safe pump operation.
It is important that due consideration is given to all hazards resulting from the
presence of :
electrical power
hot liquids
toxic gases
flammable liquids and gases.
Noise levels of the pump unit are given in the Data Sheet supplied in the
Documentation Section of the manual.
This manual contains four types of hazard seriousness messages. They are as
follows :
danger
immediate hazards which will result in severe personal injury or death
caution
hazards which could result in serious injury to the pump operator and others, or
extensive damage to the pump unit or surroundings.
warning
hazards which could result in damage or malfunction to the pump or its parts,
leading to subsequent downtime and expense.
01 - Safety Precautions
note
a message to clarify or simplify an operation or technique or to avoid a common
mistake.
major warnings
DO NOT START OR OPERATE this pump unless the installation has been verified
to be correct and all pre-startup safety and control functions have been checked.
DO NOT START OR OPERATE this pump unless you have a complete
understanding of the location and function of all upstream and downstream
equipment that may affect the flow of liquid to or from the pump.
NEVER WEAR NECKTIES or other loose clothing while in the proximity
of the pump or auxiliary equipment.
NEVER DISCONNECT THE SUCTION OR THE DISCHARGE FLANGES
of the pump, without first isolating the pump from the inlet and outlet
systems by closing and tagging block valves. Open connections
not protected with block valves should be covered with blind
flanges, rated for the pressure conditions that may prevail.
ALL DRAINS must be opened to depressurize the pump.
DO NOT REMOVE any covers, guards, gland housings,
drain covers, plugs etc, while the unit is operating.
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS
that are not described in this manual.
02 - General description
of VBN pumps
02 - General description
of VBN pumps
03 - Vertical pumps:
Transport &
intermediate
storage
10
03 - Vertical pumps:
Transport &
intermediate
storage
Refer to API Practice 686 - 1996, Chapter 3, as a "minimum acceptable guide" for storage and
protective care.
11
04 - Vertical pumps:
installation
4. INSTALLATION (1)
4.1 General
Proper installation of pump and driver is vital for successful operation of the system.
It is for this reason that competent and experienced personnel should be employed
during installation.
Refer to the Certified Drawing in the Document Section of this manual, prior to
installation.
The following recommendations and instructions are provided to assist the
purchaser and/or his contractor. Fully qualified labour, including qualified supervision
is required for proper installation, start-up and subsequent operation.
The services of a Pompe Gabbioneta serviceman or authorized personnel are
recommended for supervision of installation and start-up of the pump.
To achieve satisfactory operation, the following steps must be carried out in
sequence :
Refer to the certified outline drawing and carefully read all installation notes,
piping connection details, dimensions and any other special data.
Remove all protective coatings and foreign matter from the unit.
Provide a proper and adequate foundation for the pump sole plate or suction
barrel (if any).
Insert shims around each anchor bolt and level suction barrel flange.
Grout the suction barrel to the foundation as required.
12
04 - Vertical pumps:
installation
The mounting plate shall be installed in accordance with the construction drawing
and leveled with a master level or a precision machinist's level.
The mounting surface is to be leveled within 40 m per meter (0.0005 in/ft) by
adjusting the jacking screws and inserting shims.
13
04 - Vertical pumps:
installation
14
05 VBN pumps:
Start-up and
Operation
15
05 VBN pumps:
Start-up and
Operation
The following is a recommended list of items that should be checked before start-up:
examine suction and discharge piping for manually operated check valves
and re-circulation line. All check valves must be fully open, before start-up;
identify the pipe section fitted with the temporary suction strainer (if any). The
installation of this strainer (refer to fig. 1) is a recommended practice to
prevent dirt or welding slags from entering the pump, which may damage the
impeller and other internal components. The strainer must be made in
stainless steel, with an open area from 3 to 5 times the cross section of the
suction piping. ( 14 mesh is a recommended practice )
identify the differential pressure gauge, installed on the strainer. This gauge
must be monitored to detect clogging and need for cleaning or replacement.
visually inspect the unit, the grouting and the anchor bolts for any missing or
improperly fitted component;
check the correct installation of the re-circulation valve, if included in the
scope of supply;
check oil levels;
check water cooling lines, if installed;
check flushing lines to seal(s) against pump and seal manufacturers
instructions;
on motor driven units, check electrical connections and motor auxiliaries
against motor manufacturers instructions;
on turbine driven units, check steam piping and turbine auxiliaries against
turbine manufacturers instructions
16
05 VBN pumps:
Start-up and
Operation
Fig. 1
17
05 VBN pumps:
Start-up and
Operation
The constant level oiler maintains a constant level of oil in the bearing housing as
long as there is oil in the bottle and the oiler operates properly.
warning
The presence of oil in the constant level oiler does not necessarily
mean that oil in the bearing housing is at the proper level.
warning
CLEANLINESS is essential for long and trouble-free service of the bearings.
Care must be taken to ensure that NO FOREIGN MATERIAL enters bearing
housings or constant level oilers when performing maintenance operations.
18
05 VBN pumps:
Start-up and
Operation
close the gate valve on the discharge pipe and open the valve on the suction
pipe
open very slowly the hand valves on the vent line(s), if installed, or
temporarily remove vent plug(s), so as to fill completely the pump; this
operation will bring the system pressure up to the suction pressure;
when the pressure gage indicates that the suction pressure has been
reached, fully open the suction valve;
close the valve(s) on the vent line(s) or re-install the vent plug(s);
start-up the driver according to manufacturers instructions. Check
mechanical running. When the driver has reached its normal operating speed,
check pump discharge pressure against the shutoff pressure indicated on the
data sheet.
slowly open the discharge gate valve until the required flow and pressure are
reached.
19
05 VBN pumps:
Start-up and
Operation
caution
Pump operation at SHUT-OFF (discharge valve closed) is allowed
for a max of 20 seconds, after which the valve must be opened.
Failure to comply with this practice may result in dangerous
OVERHEATING of the pump and SEIZURE OF THE ROTOR.
5.4 Pump operation
During pump operation, regularly check oil levels, bearing temperatures and
vibration levels.
Bearing temperatures may vary depending on type and size. Continuously rising
bearing temperatures or abrupt temperature rises are indicative of premature wear
of bearings and short term failure.
Recommended TEMPERATURE SETTINGS are listed in the following table :
TYPE
of
BEARINGS
TEMPERATURE
GAUGE
LOCATION
ALARM
TRIP
antifriction
bearings
bearing
outer race
87
95
thrust bearing
shoe
87
95
line bearing
shoe
87
95
hydrodynamic
bearings
20
05 VBN pumps:
Start-up and
Operation
ALARM SETTING
TRIP
proximity probe
(m peak to peak)
65
100
velocimeter
(mm/s RMS)
5.4
8.5
These limits apply to the broad band r.m.s. values of vibration velocity and
displacement, in the frequency range from 10 Hz to 1000 Hz, and are valid for
operation at the rated flow rate of the pump.
The vibration levels indicated on the table are applicable only for the vibration
produced by the machine itself and not for the vibration which is transmitted to the
machine from external sources.
When an excessive background vibration is suspected, measurements should be
made with the machine shut down, to determine the degree of external influence.
If the vibration with the machine stationary exceeds 25 % of the value measured
when the machine is running, corrective action is recommended, to reduce the effect
of background vibration.
5.4.1 Standby operation
Pumps that are not running continuously are in standby operation, where they
must be ready to operate at any time with little or no advance notice.
Pumps on high or low temperature duties are very sensitive to temperature
gradients that may affect intern cwedefxdxxdal clearances, due to differential
thermal expansion of rotating and stationary components, resulting in rubbing or
seizure at the wear rings or bushings.
Therefore, a circulation system (heating jacket) must be foreseen by the plant
operator to keep high temperature pumps at a specified and uniform temperature
during standby operation.
warning
No attempts should be made to rotate the shaft of a HOT STANDBY PUMP,
unless the pump has been accurately and uniformly warmed-up.
21
05 VBN pumps:
Start-up and
Operation
close the discharge gate valve and shut down the driver, following the specific
instructions;
close the suction gate valve and the valves of the auxiliary systems.
note
In some applications, both the seal flushing and the heating pump system must be
maintained open during pump shutdown, to prevent the formation of crystals.
22
06 - Maintenance
& Servicing
23
06 - Maintenance
& Servicing
Frequency
daily
monthly
every 6 months
Check cooling jacket on bearing housings for sludge or
sediments.
24
06 - Maintenance
& Servicing
Parts to be inspected
Inspect for
Action required
Wear Rings
Sleeve
Antifriction bearings
Replace bearings
Hydrodynamic
bearings
Wear, scratches
Mechanical seal
Gaskets
----------------------------------
25
06 - Maintenance
& Servicing
The following is a list of recommended spare parts that should be kept in inventory
at the users plant to handle all repairs, excepted the most extensive ones :
The serial number, identifying the pump, should be used in all inquiries and parts
orders. The serial number is an alphanumeric code, consisting of 5 digits and 1
letter (item).
This number appears on the nameplate and is stamped on the discharge flange
O.D. of the pump casing.
26
07 - Faults : causes
and remedies
Probable Cause
Corrective Action
direction
5. Impeller(s) damaged
6. Worn wear rings
Pump loses
prime after startup
Insufficient
discharge
pressure
8. Viscosity too high or see Check actual liquid against pump data
n 4 & 7
sheet
27
07 - Faults : causes
and remedies
Pump overloads
driver
9. Specific
gravity
or
viscosity of the pumped
liquid different from the
rated ones
10. Head
and
capacity
different from the rated
ones
11. Wrong alignment
12. Mechanical defects : bent
shaft ; internal rubbing
Pump vibrations
Bearing failure
Seal failure
25. Improper flushing of seal Check flushing line(s) for circulation of the
cavity
flushing liquid
26. Wear of the shaft sleeve
See Mechanical Defects n 13
28
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
caution
NEVER DISCONNECT SUCTION OR DISCHARGE FLANGES of the
pump without first isolating the pump from the system by CLOSING
AND TAGGING BLOCK VALVES. Open connections not protected
by block valves must be covered with blind flanges.
ALL DRAINS must be opened to depressurize the pump.
caution
DO NOT remove any COVERS, GUARDS, GLAND HOUSINGS etc.
while the UNIT IS IN OPERATION.
caution
NEVER SUBSTITUTE A BOLT of unknown or lesser grade
for an original bolt supplied with the pump. DO NOT MIX BOLTS
during disassembly. Failure to use the proper grade bolt could
result in serious FAILURE of pressure containing components.
warning
MAINTENANCE PERSONNEL should be thoroughly FAMILIAR with the pump
and accessories, before attempting any maintenance or service.
A complete reading of this manual is recommended.
warning
Maintenance personnel must be aware that the USE OF NON-GENUINE
Pompe Gabbioneta parts shall VOID ALL WARRANTY clauses.
29
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
warning
When RESTARTING a pump after repair or maintenance, always treat the pump
as if it were A NEW PUMP being started for the first time. Refer to section 5.
warning
CLEANLINESS is ESSENTIAL for long, trouble-free service of
bearings and rotating components in general. Take care to ensure
that no foreign material enters bearing housings or constant level oilers,
when performing maintenance operations.
note
Before proceeding to pump disassembling, disconnect auxiliary piping,
remove instrumentation and, in general, all ancillary equipment.
30
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
8.2 General
Any pump part can be replaced in the field using instructions presented in this
section, if qualified personnel and facilities are available. If not, it is recommended to
call on a service representative from Pompe Gabbioneta to supervise the field
repairs.
Before disassembling VBN pumps, it is important to understand that the locknut
(42/16) controls the axial adjustment of the complete rotating assembly, whose total
end float is approximately 8 10 mm.
For correct operation of the pump, the rotor is normally lifted 5 6 mm from its
lowest setting.
Prior to pump disassembly, it is recommended to:
1. ensure that the pump and the barrel have been depressurized and drained
through the proper drain connections;
2. lock the setting tabs into the slot of the mechanical seal sleeve;
3. unscrew the set screws of the mechanical seal cartridge, according to the
instructions given in the Documentation Section of this manual, to loosen the
seal cartridge from the shaft;
8.3 Bearing housing - removal
VBN pumps are fitted with antifriction bearings mounted inside an oil-lubricated
bearing housing . To remove the complete bearing housing from the pump, refer to
cross section and proceed as follows:
Remove constant level oiler (50) and oil level gage (50/1);
Unscrew the screws on the upper flexible coupling;
Mark the setting of the rotating assembly, (e.g.: distance from upper coupling
flange to locknut) to facilitate reassembling.
Remove screws (28/147) and unscrew locknut (42/16) until the rotor reaches
its lowest setting. Remove the spacer from the coupling between motor and
pump.
VBN pumps with two couplings
Unscrew screws (28/27) on the lower coupling (410/5).
Unscrew screws (28/33) between bearing housing (174) and motor bracket
(26/1)
Hoist the complete bearing housing (174) with shaft (5/3) and remove it from
the pump. Lift slowly and carefully.
VBN pumps with one coupling
Using a suitable puller, remove coupling half and key (14/1).
Remove fan (228), if installed.
Remove shaft locknut (42/16) after removing screws (28/147).
Unscrew screws (28/33) between bearing housing (174) and motor bracket
(26/1).
31
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
Hoist the complete bearing housing (174) and remove it from the pump. Lift
slowly and carefully.
Alternatively, install the rig, shown in fig. 1. When specified by the Purchase Order,
this rig is supplied to facilitate removal of the complete bearing housing. Proceed as
follows:
Install pulleys (A) on the bearing housing (174) and pulleys (B) on the upper
flange of the bracket (26/1), with eye bolts (C):
Install cables (D) as shown on the figure. Using suitable pullers (not
supplied), gradually lift the housing from position to position .
Using screws (E), install bars (F) on bracket (26/1), under the bearing
housing.
Lower the bearing housing until it rests on the bars (position ').
Remove the cables and manually slide the housing to position , where it
can be hoisted and moved to the maintenance shop for disassembly.
Remove plug (57/2) and drain the oil from the bearing housing.
Using a suitable puller remove coupling half and key (14/1), if not already
removed.
Remove fan (228), if installed.
Remove shaft locknut (42/16) after removing screws (28/147), if not already
done.
Remove screws (28/4) and bearing cover (38/5) with oil deflector (22/1).
Note that the angular position of the bearing cover is defined by a dowel.
Mark the position of the dowel on the bearing housing, to facilitate reassembly.
Remove distance sleeve (12/2) or anti-rotation ratchet, if installed.
Using a suitable puller remove the bearing adapter sleeve (43) and the key
(14/16) from the shaft (VBN pumps with two couplings).
To remove the bearing (25/8) from the adapter sleeve, lift the tab on
lockwase (64/5) and unscrew oil flinger(100). Remove lockwasher (64/5).
Using a suitable puller remove the bearing from the adapter.
warning
When removing or replacing antifriction bearings mounted on the adapter,
NEVER PRESS or apply force on THE OUTER RACE, as this may
damage the internal components of the bearing.
NEVER HAMMER on either the inner or outer races.
note
32
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
33
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
Fig.1
34
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
Replace lockwasher (64/5) and tighten oil flinger (100) according to torque
values given on Table 1. Bend the lock tab to lock the flinger into position.
35
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
36
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
Tighten set screws on the mechanical seal cartridge, as specified by the seal
instruction manual and remove the settings tabs.
on VBN pumps with two couplings, the mechanical seal cartridge can be
removed without removing the bearing housing. Proceed as follows:
Unscrew screws (28/27) on upper coupling half (410/5) and gradually bring
the pump rotor to its lowest setting (the total end play must be 7 to 8 mm).
Unscrew screws (28/27) on lower coupling half (410/4) and remove the
coupling spacer (410/3).
Remove screws (185/5) and unscrew locknut (42/4) on the lower coupling
half (410/4).
Using a suitable puller, remove the half coupling and the key (14/6) from the
pump shaft
The mechanical seal cartridge can now be removed according to the
instructions contained in the Mechanical seal Instruction manual - Refer to
the Documentation Section.
on VBN pumps with one coupling, the mechanical seal package can be
removed according to the instructions contained in the Mechanical seal
Instruction manual (refer to the Documentation Section), after removing the
bearing housing according to Section 8.3.
notes
All SHARP edges must be REMOVED before mounting the mechanical seal.
Care should be taken during mounting of the O rings to
prevent damages with spanners, pins etc.
The shaft or the shaft sleeve should be lightly lubricated
before installing the mechanical seal.
NO LUBRICATION is required on the FACES of the seal.
NEVER OPERATE a mechanical seal DRY, unless so required
by the mechanical seal instruction manual.
To replace the mechanical seal, follow the instructions given in the Documentation
Section of this manual and reassemble the pump in reverse sequence, i.e.:
37
08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals
38
09 - Inner Parts
replacement
VBN Pumps
39
09 - Inner Parts
replacement
VBN Pumps
warning
The impellers are secured to the shaft with a sliding fit and a key.
Separation of the impellers from the shaft may require a puller,
due to the presence of crusts or scales.
DO NOT apply HEAT to ease removal of impellers or sleeves.
To complete column and shaft disassembly, proceed from the opposite end, i.e. from
the discharge end of the pump.
Unscrew nuts on stud bolts (36/6) and separate the discharge head from the
column.
Unscrew nuts on bolts (54/34) and remove columns (151/1), (151/2) etc.
Unscrew set screw (185/6) on shaft coupling (410/6) and slide the coupling
along the shaft until split rings (20/4) can be removed.
Remove keys (14/21).
Bushing (147/1) can be removed from the carrier inside the column, by pressing it
out.
Shaft sleeve (87/3) can be removed after removing circlips (20).
9.2 Wear rings - removal and replacement
Impeller and casing wear rings can be removed using a suitable puller, after removal
of the set screws.
Replacement of wear rings requires drilling and tapping of new holes for the set
screws.
note
After replacement of the wear rings,
impeller re-balancing is required. Refer to section 9.3
40
09 - Inner Parts
replacement
VBN Pumps
9.3 Balancing
Impellers of VBN pumps shall be dynamically balanced to the unbalance limit
specified by the applicable standard , i.e. ISO 1940 Grade 1.0.
Before proceeding to the balancing, calculate the residual admissible weight with the
formula:
where:
p =residual admissible weight
Pe
P =impeller weight
p
r r =impeller radius where material is removed
e =residual admissible eccentricity of the
center of gravity (C.G.)
grams
kg
mm
m
The value of e is given by a diagram and can be found in the following table for the
most commonly used rotational speeds.
rotational speed
(rpm)
1450
1750
2950
3550
6.3
5.6
3.15
2.8
Balance each impeller by removing some material from the discs, at radius r, by
milling or grinding.
9.4 Rotor replacement
From the discharge end of the pump, reinstall column and shaft sections as
previously described, in reverse sequence.
From the suction end of the pump proceed as follows:
Install circlip (20/11), coat the shaft with light oil and install shaft sleeve
(87/20).
Coat sleeve (87/20) with light oil and install bearing bushing carrier (254).
Tighten nuts on stud bolts (36/6). torque as per Table 1.
Install split ring (102), impeller key (14) and impeller (6).
Complete pump reassembling in reverse sequence, lift the pump and install
it into the suction barrel (or sump).
Tighten nuts on stud bolts (36/9) - torque as per Table 1.
41
09 - Inner Parts
replacement
VBN Pumps
note
Correct tightening brings COVER (26) IN CONTACT with suction barrel flange.
Using a feeler gauge, check metal-to-metal contact
between cover and flange of the suction barrel at various angular positions on the
cover outer diameter.
Install mechanical seal gland and seal cartridge as per instructions given in the
Documentation Section of this manual.
Complete pump reassembling as per Section 8, in reverse sequence.
Table 1 :
Bolt Size
(mm)
M6x1
M8x1.25
M10x1.5
M12x1.75
M16x2
M20x2.5
M24x3
M30x3
M36x3
M42x3
M48x3
M48x2
Bolt Material
(inch)
1/4 x 20 UNC
5/16 x 18 UNC
3/8 x 16 UNC
1/2 x 13 UNC
5/8 x 11 UNC
3/4 x 10 UNC
1 x 8 UNC
1 x 8 UN
1 x 8 UN
1 x 8 UN
2 x 8 UN
2 x 12 UN
A 307 A
A 193 B8
A 193 B8M
5
10
20
30
100
140
350
700
1100
2000
3000
A 193 B7
7
15
30
45
150
210
520
1050
1650
3000
4500
6000
42
09 - Inner Parts
replacement
VBN Pumps
Table 2 :
43
09 - Inner Parts
replacement
VBN Pumps
Attachment 1:
44
09 - Inner Parts
replacement
VBN Pumps
Attachment 2:
45