Installation

Operating

and

Maintenance Manual

PUMP - CZ-IOM-Ball Bearing

For Tag No.

0GAF01AP001/002/003

0GAF02AP001/002

03AP001/002/003/004

0GCK04AP001/002

0GCNP01AP001/002

0GCNP02AP001/002

0GR01AP001/002

0GR01AP001/002
 OPERATING MANUAL
Doc No. OPM/CZ/001

BA/e 1210

Sulzer Pumps India Ltd. 9, MIDC, Thane Belapur Rd,

Digha, Navi Mumbai - 400708
1 Tel. (091)022 55904321, Fax (091) 022 55904306
 Contents Type: CZ

1. GENERAL REMARKS
1.1 Guarantee
1.2 Delivery and purchase information
1.3 Type of operating manual
1.4 Service data Service control

2. SAFETY
2.1 Marking of instruction in the operating manual
2.2 Qualification and training of personnel
2.3 Danger on non-observation of the safety regulations
2.4 Safety- guided working
2.5 Safety instructions for user / operator
2.6 Safety instructions for maintenance, inspection and assembly jobs
2.7 Prohibition of unauthorized rebuilding measures or alterations
2.8 Inadmissible operating modes
2.9 Explosion Protection

3. TRANSPORTATION AND STORAGE

3.1 Transport and lifting
3.2 Preservation and Storage

4. DESCRIPTION
4.1 Description of the pump
4.2 Bearing bracket and lubrication

5. INSTALLATION OF THE PUMP

5.1 Mounting
5.2 Alignment of coupling
5.3 Suction and discharge pipework
5.4 Ancillary equipment
Minimum flow device

6. OPERATION
6.1 Commission
6.2 Shut-down
6.3 Service control

7. MAINTENANCE AND OVERHAUL

7.1 Maintenance - Pump general
7.2 - Shaft seal
7.3 - Bearing lubrication
7.4 Overhaul - Dismantling of the pump
7.5 - Inspection of wearing parts
7.6 - Assembly of the pump

8. OPERATING FAULTS
8.1 Symptoms / Possible cause of faults / Remedies

2
1. GENERAL REMARKS

In the case of further questions, of spare part orders and other correspondence please mention
always the SULZER Serial No. and pump type. Both can be gathered from the rating plate of the
pump. Copyright remains property of SULZER.

1.1 Guarantee
Guarantee is assumed according to the contractual agreements.

1.2 Delivery and purchase information

See cover sheet of operating manual

1.3 Type of operating manual (Acc. to DIN 8418 and VDMA 24 292)
Documents no.: see cover sheet

Service address: see cover sheet

Issue: 2001

On document check / release

Date of release

Revision submitted on

Revision released on

3
0000/e1-0-00-000
01
1.4 SERVICE DATA - SERVICE CONTROL
02
1.4.1 Data
03
Sulzer Serial-No.:

Refer Documents and drawings of each pump item for details

04
Position-No.:
05 Medium delivered
3
06 Capacity m /h
3
07 Minimum capacity m /h
08 Differential head m FS
09 NPSH - R m
10 Differential pressure bar
11 Suction pressure norm./ max. bar
12 Discharge pressure norm./ max. bar
o
13 Pumping temperature (PT) C
3
14 Specif. grav. at PT kg/m
15 Pump input kW
16 Speed 1/min.
17
1.4.2 Lubrication
18 Oil (according to DIN 51 524) see also 7.3
o
19 Oil temperature C
20 Quantity of oil per bearing frame Liter
21
1.4.3 Cooling
3
22 Cooling water m /h
23 Pressure normal/max. bar
o
24 Temperature outlet max. C
25
1.4.4 Heating
26 Heat exchanging medium
27 Pressure normal/max. bar
o
28 Temperature entry max. C
29
1.4.5 Flushing (shaft seal)
30 Flushing / Sealing medium
3
31 Quantity min. m /h
32 Pressure bar
o
33 Temperature of flushing medium C
34
1.4.6 Flushing (wear ring)
35 Flushing / Sealing medium
3
36 Quantity min. m /h
37 Pressure bar
38
1.4.7 Quench
39 Quench medium
3
40 Quantity min. m /h
41 Pressure bar
42
1.4.8 Safety technical limit data
43 Max. allowable working pressure bar
o
44 Max. allowable working temperature C

4
0000/d1-4-02-000
2. GENERAL SAFETY
This manual contains basic information, which has to be observed on the installation, commissioning,
operation and maintenance. Therefore this operating manual has to be available constantly on site for
the use of service or site personnel and has to be read prior to commissioning and/or
assembly/disassembly of the pump.
Not only have the general safety instructions to be observed, which are given under this main point
"Safety", but also the special safety instructions given below in the operating manual.

2.1 Marking of instructions in the operating manual

The safety instructions contained in these operating instructions, which if not observed - may result in
harm to persons,

are indicated with the general danger sign

or, in the case of warnings against electrical

voltage, with

and in terms of explosion protection with the

special sign
For safety instructions which if not observed
may cause risks for the machine and its
operation, the word ATTENTION is inserted.
Indications which are directly attached at the machine itself such as
- arrow for rotational sense
- marking for fluid connections etc.
have to be kept in good, legible condition, as they have always to be observed.
2.2 Qualification and training of personnel
The personnel for service, maintenance, inspection and assembly has to hold the necessary
qualifications for this kind of jobs. Range of responsibility, competence and the monitoring of the
personnel have to be fixed clearly by the user. In case the personnel should not have the required
knowledge, they have to be trained and instructed. This may be undertaken by the manufacturer of the
machine, if required, on user's request. Further the user has to ensure that the personnel has a complete
understanding of the contents of the manufacturer's instruction manual.
2.3 Danger on non-observation of the safety regulations
By non-observation of the safety regulations danger may arise for persons as well as for environment
and machinery and may lead to a complete loss of any claims for damages.
- Non-observance may lead for example to the following dangers:
- Failure of important functions of machine/plant
- Failure of required procedures of maintenance and repair
- Endangering of people by electrical, mechanical and chemical impacts
- Endangering of environment by leakage of dangerous materials
2.4 Safety-guided working
The safety regulations given in this operating manual which consist of national regulations on accident
prevention, as well as company- internal job, operating and safety regulations issued by the user, have to
be observed.

5
2.5 Safety instructions for user / operator
- In case hot or cold machine parts may lead to any danger, they have to be secured by user against
touching.
- Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.
- Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be
disposed of in such a way as to prevent any endangering of people and environment. Legal
regulations have to be observed.
- Endangering by electricity has to be excluded (details see for example in the regulations by the VDE
and local energy suppliers).
- The special safety instructions in the following paragraphs of this operating manual have to be
observed.
2.6 Safety instructions for maintenance, inspection and assembly jobs
- The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by
authorized and skilled personnel only, who have been adequately informed by studying the operating
manual carefully.
- Basically any works on the machine may be carried out only during shut-down of the machine. The
procedure described in the operating manual for the shut-down of the machine has to be strictly
adhered to. The machine has to be locked against unauthorized or involuntary start-up.
- Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be
worn. There is a risk of injury as a result, for example, of such objects getting caught or pulled in.
- Pumps or aggregates delivering media hazardous to health have to be decontaminated.
- Immediately following the end of the works, all safety and protective devices have to be reassembled
respectively have to be put to work again.
- On a repeated start-up all points given in the paragraph initial commissioning have to be observed
again.
2.7 Prohibition of unauthorized rebuilding measures or alterations
- Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer.
Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee
safety. The use of other parts may lead to a loss of the manufacturer's liability for the consequences.
2.8 Inadmissible operating modes
- The operational safety of the delivered machine is only guaranteed by proper use acc. to the data
under section 1.4 of the operating manual.
- The limits given in the data sheet must not be exceeded in any case.
2.9 Explosion Protection
- Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g.
electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at
separately.
- Improper operating methods that result in the specified temperatures being exceeded (exceeding or
falling short of the operating data, falling short of the minimum delivery flow, reduction or failure of
cooling water or circulation delivery, etc.) should be avoided at all costs.
- Before starting the pump make sure that the pump system (suction pipe, pump casing and shaft seal)
is completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere
in the system.
- Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters,
ammeters, etc.).
- Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe
operation.

6
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
General remarks
For all transport jobs the general rules of engineering and regulations on the prevention of accidents have to
be strictly observed.
These are especially
VBG 1 - General regulations
VBG 5 - Power-driven working devices
VBG 8 - Lifting devices
VBG 9 - Cranes
VBG 9a - Load suspension device with hoists and conveyors
The above regulations are applicable in the area of the Federal Republic of Germany, in other countries the
appropriate regulations have to be observed.
For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.
Transport
Transport devices (including vehicles) have to be checked for the admissible load weight. Total
weight of the delivered goods see dispatch documents. The load has to be secured during transport
against shifting.
Lifting
Check of the load suspension devices / ropes
It has to be assured that admissible, undamaged ropes and lifting devices will be used. The loading
capacity of the lifting devices and the ropes has to be suitable to take up the weight of the goods to
be lifted. Load weight indications of the delivered units are given in the installation plan respectively the
dispatch documents.

Never stay within the range of suspended loads. Sling rope as

market on
Fastening of the sling ropes on crates crate
The points for the fastening of sling ropes on closed crates are
marked. As the center of gravity (mass) cannot be recognized in
closed crates, the sling rope fastening has always to be done at the
marked spots. See sketch 3.1-1.
Sketch 3.1-1
Fastening spots for units
In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these
spots by shackling the rope. See sketch 3.1-2. Typical example: pump shape may vary due to pump type
ordered.
like this
If required use traverse

Sketch 3.1-2

Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete
assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened
parts during assembly and disassembly

E000/e3-0-00-001 Page 1 7
3.2 PRESERVATION AND STORAGE
A. General remarks
This information will enable you to store your pump effectively and safely. Should further information be
desired, or should particular problems arise which are not covered sufficiently please contact your nearest
Sulzer representative.
The following storage instructions apply only to the pump and may not be appropriate to furnished
auxiliary equipment. Follow manufacturers instructions for all other components of the pump system.
The preservation measures required for storage depend on the despatch preservation. The pump unit
can be stored in a clean and dry warehouse without maintenance measures up to the time given by the
dispatch preservation.
B. Preservation for despatch
Standard packing:
When the pumps are shipped, smooth outside faces are sprayed with Tectyl 506 and pump internals
with Mobilarma 524 (or equal product). Attention: this is not suitable as long-term preservation; 6
months are max. allowed time for storing.
Seaworthy packing:
The pump is despatched with PE-foil welding and with added moisture absorber. Sea-worthy packed
pumps can be stored up to one year without any special maintenance if the packing is not damaged.
Special packing:
On special request the pump can be packed in aluminium foil (with moisture absorber). In this case the
preservation time amounts to 2 years without special maintenance.
If the seaworthy or other special package is removed, only the standard preservation is
ATTENTION effective, i.e. if no further measures are taken, the max. storage period will be 6 months.

C. Intermediate storage
Pumps which are not installed and commissioned immediately after delivery can be stored for the period
determined by the dispatch preservation.
ATTENTION To avoid the forming of condensate and consequently corrosion (especially in the gap
areas), bearing damage and contamination, a dry room, possibly with constant
temperature as well as a clean, shock- free storage space has to be selected.
In each case unfavourable climatic circumstances will have a negative influence on
ATTENTION
period of proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed:
ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand,
etc.) the connection flanges of the pumps have to be plugged airtight..
D. Longterm storage - preservation
General
ATTENTION The pumps should always be longterm- stored in her functional position, that means that
horizontal pumps should be stored horizontal and vertical pumps should be stored in
vertical position. Align and support the pump as required.
In case of long term storage a number of precautions must be observed to prevent pump damage. It is
recommended to enter all storage inspections and preservation measures in an log.

8
Long term storage may be required for:
1. New pumps witch are not commissioned.
The pump can be stored as described in Intermediate storage. After the dispatch preservation time
measures have to be taken to protect the equipment against corrosion damage.
2. Stand by pumps or pumps affected by a longer shut down of the plant.
The long term storage procedure depend on the material used in pump construction (cast iron, steel,
stainless steel, special alloys), medium delivered and environmental conditions (freeze damage) see
following table.
Material of Medium delivered
construction Neutral Aggressive
Hydrocarbon, ... Water, ... Seawater, ... Acids, ...
Cast iron B A - -
Steel B A - -
Stainless steel B B A
Special alloys B B A
A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium
and after draining (and drying) be protected with a preservative. For this purpose the disassembly of the
hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure
described below in section I. to IV.
B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure
for the bearing housing as described in the sections below.
Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the manufacturers.
2. Protection of not painted outer parts of the pump
Pump outer parts: e.g. - raised faces of flanges
- pump shaft
- coupling
- connections for small conduits etc.
We would urgently advise against using normal lubricating oil as a rust preventative. For the preservation
of bright pump parts, the mineral-oil industry has developed special rust preventatives which at first are
liquid and are applied manually, by means of brushes, spray nozzles or aerographs. After the evaporation
of the solvent, a wax-type cover will remain.
This protective film can be removed by means of solvents or alkaline cleansing agents (see section V.).
We recommend heavy preservation oil / wax
- Rust Ban 397 from ESSO
- Ensis Fluid K from SHELL
- Tectyl 506 from VALVOLINE
Other rust preventatives of the same quality may however be used as well. The average time of
protection is 1-3 years. Rust preventatives are rust-preventing agents which however do not remove rust.
For this reason, it is a prerequisite for the application of rust preventatives that the parts to be protected
are clean and rustfree. The surface of the parts has to be cleaned carefully before the respective rust
preventative is applied.
3. Protection of the interior of the pump
If the hydraulic pump part (casing parts, impeller, wear rings) are made of non-corrosive stainless or
special alloy, no protective measures (instead of flushing, case A) are required. Note: Bearing housing
and bearings have always to be protected.
Pump interior parts: e.g. - pump casings
- stuffing box chambers
- bearing housing, bearings, ...
For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70
mm2/s should be used.

9
We recommend the rust preventatives
ATTENTION The rust preventative for the pump interior have to be selected according to the gasket or
seal materials used.
Gasket or seal material: Rust preventative
Perbunan (NBR), Viton (FPM), Teflon (PTFE): - Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
Ethylene-propylene (EPDM): - Klber Syntheso D 220
4. Proceeding in case of longterm preservation
General
Protect the pump and attachments with a vinyl-coated nylon tarpaulin.
Lash tarp evenly to provide drainage that does not form pools. Maintain sufficient air circulation with
minimum 10 cm clearance between tarp and pump parts.
Protect pump from blowing sand, dirt or (sea) water.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. The use of
any preventative is not recommended.
Soft packing:
ATTENTION If the pump is supplied with a stuffing box packing installed, the packing has to be
removed and replaced by a special packing which is to remain in the stuffing box
chamber during the preservation time, only.
Preservation packing material recommended: Synth. fibres, with PTFE impregnation (e.g. Chetra 1711
GS or Hecker 1820). The packing chamber is filled completely with the separate packing rings.
Pump casing
Pump suction and discharge flanges: At first the raised faces of the pump flanges have to be cleaned
thoroughly and preserved with one of the rust preventatives mentioned under 2. On smooth flanges and
those with annular tee-slots, flat gaskets should be placed; in case of slotted flanges, 2 gaskets should be
placed in the slot, and all the sockets have to be closed tightly by means of metal covers. Blind plate shall
be fixed with minimum 4 bolts. The connections for the cooling water/circulation lines etc. should also be
closed by means of normal steel plugs.
Protection procedure: Fill (or spray) pump casing with rust preventative (see 3.) Drain the preservation
oil thoroughly and repeat this procedure every 6 month. In case of spaying in the case internals repeat
procedure every 3 month.
Bearing housings
Close bearing housing connections tightly with plugs or covers. Remove filler plug on the top of bearing
housing and fill bearing housing with rust preventative (see 3.).
In case of unfilled pump casing the rotor should not be turned manually. To avoid
ATTENTION
corrosion damage at bearings, drain the preservation oil and refill it on top of the housing
(drive- and non-drive side). Repeat this procedure every 3 month.
E. Maintenance of the longterm stored pumps
Visual inspection: The exterior of the stored pump unit should be conducted every 30 days and
inspected for surface damage, dirt or animals in the pump area.
Note: Should water, condensation, sand, dirt or other contaminant enter the pump unit, through
package/tarpaulin damage or improperly positioned covers, the cause of the problem must be eliminated
and the equipment thoroughly dried and cleaned before re-storing.
Maintain rust prevention coatings: If any rust is observed, measures should be taken to remove rust
and protect against it..

10
Filled pump parts: At the parts which are filled with rust preventative (pump casing / bearing housing)
the condensate should be drained every 6 months; rust preventative should be added, if required.
ATTENTION According to manufacturers indications, the rust preventative has to be drained and
refilled every 12 month *. If the rust preventative is not renewed within this period the risk
is to be taken by the storage keeper. In order to have a guarantee for the proper execution of the
maintenance instructions, we recommend to establish maintenance sheets.
If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than
after 6 months.
F. De-preservation procedure
Surface protected parts
In most cases the protection film must not be removed. If required remove rust preventative by the
following cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be
used.
Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety
precautions specified by the manufacturers.
Note: Do not use nitro thinners!
Pump casing
Drain pump casing thoroughly, it may be possible to lift the pump to fully drain the pump casing (see job
specific drawings). If required flush pump casing. For absolutely cleaning the disassembly of the hydraulic
part of the pump becomes necessary in most cases.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer
seals are subject to material specific and time-based alteration (aging) witch might reduce the efficiency
of the seal, therefore we recommend after a storage time for more than 3 years to change the seal rings.
Packing: Before commissioning, make sure that the preservation packing is removed and replaced by
packing rings of the quality provided for operation.
Bearing housing
Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the oil
thoroughly. Flush bearing housing with lubricating oil and allow to drain. Mount constant level oiler (if
removed) and refill with lubricating oil as given in the pump operating manual.
Dispose of rust preventive oil according to statutory regulations. Do not put into waste
water by any means..

G. Additional Information
When the pump is removed from storage special care have to be taken. Clean pump and equipment
surfaces (piping, coupling, driver,) and inspect:
Minimum checks Additional recommended checks
Inspect for completeness Inspect bearings (if any sign of
Check all pressure case (plugged) openings contamination be detected, replace brg.)
and connections for tightness Inspect shaft seal and change all
Check for any sign of cracks or damage elastomer seal rings
Check pump rotation, check for correct gap Install additionally suction strainer
between stationary and rotating parts
Check coupling alignment
Check all fasteners for tightness
Check service data (are the pump suitable)
If the pump has been stored for more than 3 years we recommend to open and inspect at
ATTENTION least bearings and shaft seal before start-up. If the pump has been stored for more than 5
years we recommend to disassemble the pump and change all gaskets and seal rings.

11
12
5. INSTALLATION OF THE PUMP
5.1 Mounting (see dimension drawing / installation plan)
General
Good planning and preparation result in fast, simple and correct installation. Safe running conditions with
maximum accessibility are assured. When preparing for installation of the machine, it is necessary to take
the following aspects into account:
The main dimensions, connections, position of fixing bolts etc., are shown on the dimension
drawing/installation plan.
Suitable lifting devices must be available for installation and repair work. Good lighting is important and
sockets for portable lights should be available. The pump should be readily accessible from all sides.
The pump foundations and type of installation should be designed so that vibration is kept to a minimum
both during operating and when the pump is at rest, otherwise the pump life will be reduced.
A drain must be provided so that gland leakage, cooling water (open system) and liquid drained from the
pump during overhaul can be led away.
The draining of the pump respectively the disposal of the leakage for pumps delivering toxic,
explosive, hot or in any other ways dangerous fluids, must not lead to any endangering of
operator(s) and environment.
Following manufacture the pump flanges and external tappings are protected by plastic plugs which
should not be removed before the pipework is ready to be attached to the pump. The pump should be
protected, if further site work is necessary nearby.
The foundation or any other necessary building work must be finished, set and dried. Roughen and clean
the foundation. All preliminary work for erection must be completed. With large units, suitable door and
wall openings are to be provided for transport to the installation site.

Grout selection
Select a nonshrinking grout that is compatible with the highest and lowest temperatures to which it may be
2
exposed. Use concrete from a concrete company with a final strength of 25 N/mm (B25) or better.
If the service of a concrete company is not available the figures given below may be taken as a guide.
- The concrete mixture suitable for grouting machine baseplates should contain 300 to 350 kg cement
3 3 3
per 1 m of concrete. The sand and gravel proportion for 1 m of finished concrete (1.2 m mixture) is
as follows:

For grouting of the foundation bolts: 65% Fine sand grain size 1 - 5 mm
35% Coarse sand grain size 5 - 10 mm
water as required
The use of so called fast cement with short setting time is possible.

For grouting (filling) of the baseplate: 40% Fine sand grain size 1 - 5 mm
60% Coarse sand grain size 5 - 15 mm
100 - 140 liters of water
ATTENTION Only clean, washed sand may be used. The water-cement ratio has a decisive influence
on the final strength of the concrete.
A high concrete strength will be attained with high standard strength of the cement, low water-cement
ratio, and compacting by vibrating.

0000/e5-1-00-000 page 1 13
Installation of pump and driver
ATTENTION With separate baseplates for pump and driver first erect the pump, then align the driver.
- Roughen and clean the foundation. Walls of the grouting holes must have rough surfaces and must be
free from pollution. Remove any loose particles, dirt or oil-soaked concrete. All baseplate surfaces
which will be in contact with grout must be clean. Remove rust, paint or other extraneous material.
- Attach wire rope slings to the baseplate transport eyes (see 3.1 transport/lifting) and lift the baseplate
with pump and driver. Insert foundation bolts into the holes in the baseplate and tighten the nuts a few
turns.
- Lower the baseplate carefully into position on the foundation. The foundation bolts have to be lowered
into the foundation holes.

Levelling
- Align the pump horizontally with the aid of steel shims of varying thicknesses. Three support points are
sufficient for baseplates up to 1600 mm long - one on each longitudinal side of the baseplate, to the left
and right of the drive and another on the short side near the pump Provide proper grouting clearance
between foundation and baseplate (see installation plan).
Check levelling in the direction of the pump axis and also at right angles along the
ATTENTION horizontal flange with a spirit (machinists) level. The flanges must be vertical on
horizontal branches. See sketch 5.1.1. Max. permissible variance 0.5 mm over 1m.

spirit level
pump flange foundation bolt baseplate

disc sheet metal

shim

concrete
shaft foundation

5.1.1 Levelling the unit 5.1-2 Grouting foundation bolts

Grout in the foundation bolts

- Before grouting wet the foundation holes. Fill foundation holes with concrete.
- After setting tighten the foundation bolts and check horizontal alignment again. If the position of the
pump has changed, correct alignment.
Do not bend the baseplate since this will cause development of vibration and noise
ATTENTION
during operation or the alignment of the coupling will not possible.

- Before grouting the baseplate align the coupling as described under 5.2 (alignment report).

Completion of grouting (when properly aligned)

ATTENTION Grouting of the machine into the foundation is a very important part of the installation.
Problems can arise, if materials are of poor quality, which may show up early or after
several months of operation.

0000/e5-1-00-000 page 2 14
- Build a dam around the foundation. Forms must be strong
grout hole
enough to withstand the grout pressure. Attach a chamfer baseplate
strip on the form inside, at grout grade elevation, to provide
a neat beveled edge. See sketch 5.1-3.
chamfer strip
- Finish grouting the baseplate in conformity with the
corresponding installation plan. Fill the baseplate with thin- grout
bodied concrete through grout holes. Take care that the
baseplate is completely filled with grout, vibrate as
necessary.
The concrete must neither dry out nor freeze
ATTENTION
during the first 48 hours. During this time the
o foundation
temperature of the foundation should not fall below 10 C. The
o o
optimum temperature for the setting process is 20 C +/-10 C.

- If necessary: Seal the grout openings by covering with a 5.1-3 Grouting of baseplate
quality paint or with grout hole covers.

When the concrete has set, re-tighten foundation bolts and check coupling alignment, see 5.2
(alignment report).

0000/e5-1-00-000 page 3 15
5.2 ALIGNMENT OF COUPLING
General
Before aligning the coupling, and with the pump and driver uncoupled, check the direction
ATTENTION
of rotation of the driver corresponding with the direction of rotation arrow on the pump.
Flexible couplings need very careful alignment of the shafts which can be achieved by
ATTENTION
placing thin shims under the machine feet. Negligence in alignment will destroy the coupling
and damage the pump and motor bearings, too.
Misalignment types
There are three basic types of misalignments between the pump and driver shafts:

1. Angular misalignment 2. Parallel offset 3. Axial distance

Shafts with axes that Shaft with axes parallel Shaft with axes parallel
intersect at a point but offset but wrong distance
Assembly
The assembly of the coupling must be carried out in accordance with the coupling manufacturer's instructions
in the appendix. For mounting the coupling halves onto shaft see also 7.6.
Axial shaft distance
The axial distance between the coupling halves must be observed. Please see installation drawing and hints
on coupling assembly in the appendix.
The shaft of a driver without a thrust bearing must be set in proper running position before
ATTENTION
distance between shafts is adjusted. Refer to driver manufacturer instructions.
Alignment
General
Any change in elevation can be accomplished by shimming between equipment feets and baseplate
pedestals. The maximum number of shims is four. After alignment tighten pump foot fasteners according the
given torques (see pump foot tightening torques) and check alignment.
Alignment of non-spacer couplings
With standard non-spacer flexible couplings, alignment can be checked with sufficient accuracy using a
straight edge placed across the full width of the coupling halves. This check should be carried out at 90
intervals around the coupling periphery. The amount of parallel misalignment between the two coupling
halves can be measured by inserting feeler gauges underneath the straight edge (see fig.).

1000/e5-2-00-000 Seite 1 16
Alignment of spacer couplings
Every alignment check must be preceded by a run-out
measurement at the coupling flanges.
Record the results always in a log. All readings for radial and
axial misalignment are determined in the gauge positions: top,
o
bottom, right and left, i.e. every 90 , while both shafts are
simultaneously turned.
Alignment should be carried out with clock gauges in radial
and axial direction (see fig.). The maximum admissible axial
misalignment is 0,05 mm on diameter, although 0,03 mm is
preferable. The maximum admissible radial misalignment is
0,1 mm on diameter, although 0,05 mm is preferable.

Optical Alignment
Instead of using a clock gauge assembly, optical (laser)
alignment equipment may be used. Laser optical alignment is
the most exact shaft aligning method. The transmitter is a
laser diode mounted on one side of the coupling and the
prism is mounted on the other side. The laser beam emitted
by the laser diode is reflected by the prism to the localizer.
The offset can be detected by rotating the shafts.

Final alignment
Final alignment check is done only after pump system is brought to normal operating temperature.
ATTENTION If misalignment above the admissible values given is found, the causes must be ascertained
and eliminated. In most cases, the cause is unduly high forces and moments on the pump
branches, which arise through expansion of the adjacent pipework. See also 5.3.

Pump foot tightening torques

For the transport the tie bolts have to be tightened at the pump feet. After alignment of coupling, the fasteners
pump-baseplate have to be tightened with the tightening torques shown in the table below.

thread size tightening torque

nominal diameter MA in Nm
(mm)
M 16 60
M 20 120
M 24 220
M 27 350
M 30 480
M 33 680
M 36 900
M 42 1500
M 48 2400
M 56 3900
M 64 5900

1000/e5-2-00-000 Seite 2 17
5.3 Suction and discharge pipework
General
Pipe diameters will have already been determined at the planning stage and many factors unknown to the
pump manufacturer will have been taken into account. As a general rule the liquid velocity should not exceed
2 m/sec in the suction pipework and 3 m/sec in the discharge pipework. It is also good engineering practice
for the suction pipework to be at least one pipe size larger than the nominal bore of the suction flange. A few
useful hints are given below which should be observed when the pipework is installed.

ATTENTION In case the possibility of dangerous recirculation may occur after shut-down of pump,
especially with "emergency trip out", back-flow preventors have to built in.
Assembly
ATTENTION The pipework must be supported in an adequate manner to ensure that no bending moments
or stresses caused by the weight of the pipework or thermal expansion are transmitted to the
pump flanges (install an expansion piece). The pipework flanges must be parallel to the pump flanges.
On flooded suction applications, the horizontal sections of the pipework should descend towards the pump
and on suction lift applications they should steadily rise towards the pump to prevent air locking.
The pieces should be designed and constructed so as not to obstruct the free flow of the liquid. The transition
from small to large pipe diameters must be gradual. As a general guide the length of a concentric taper piece
must be 5-7 times the difference in pipe diameters.
Where flanged joints are used ensure that the gasket is correctly centred so that the bore of the pipe is not
restricted.
Sudden reductions in pipe cross sectional area and sharp bends should be avoided especially in the suction
or inlet pipework, as these greatly increase the frictional resistance within the pipework. A high frictional
resistance within the suction or inlet pipework leads to reduced pressure available at the suction branch. Too
low pressure leads to cavitation at the impeller inlet.
Multi-pump installations should have separate sucton pipes to each pump. Excepted are duty and standby
pumps which may have common suction pipework since only one pump operates at any time.

Cleaning the pipework

ATTENTION Before a pumpset is commissioned, all traces of foreign bodies and impurities must be
carefully flushed out of the supply tank and pipework. Where pipework has been welded, all
welding slag etc. must be removed.

Pressure test
ATTENTION The pipework should be pressure tested in accordance with the statutory regulations.

Pipe fittings
ATTENTION Fittings having the same nominal bore of the pipework should be used. If the pump branches
have a smaller nominal bore than the fittings suitable taper pieces should be used. The shut-
off valve in the suction pipework should not be positioned immediately upstream of the pump suction branch
to prevent turbulence entering the pump. The valve should be positioned with the handwheel horizontally or
vertically downwards to prevent air pockets forming.

E000/e5-3-00-000 18
5.4 ANCILLARY EQUIPMENT
General
Ancillary equipment is used to monitor the pump (measuring equipment for pressure, temperature etc.)
and to maintain operation (cooling, flushing, sealing etc.). The extent depends on the application and
installation requirements. For type, position and dimensions of the ancillary connections please see
installation drawing.
In case the failure of any auxiliary devices (e.g. cooling, circulation) may lead to an inadmissible
pressure build-up in the pump suitable safety devices have to be installed by user (e.g. alarm,
emergency shut-down or similar).
Do not mix up connections. After laying the pipes (and also after repairs), check the pipe
ATTENTION
runs.
The following instructions may be used as a guide insofar as they apply to the pump as delivered.

Ancillary pipework
- Drainage of the pump casing can be effected by leading a pipe into the drip tray of the baseplate or into
a collection pipe. Isolating valves must be installed in the pipe and must have a pressure rating at least
equal to the rating of the casing.
The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead
to any endangering of operator(s) and environment.

- Gland leakage from the shaft seal can also be led into the drip tray or collection pipe.
The leakage of dangerous fluids has to be drained or quenched in such a way as to prevent any
dangers to persons and environment.

- Cooling through cooling liquid: Connections and scope see installation plan or separate drawing
respectively. Don't confuse inlet and outlet connection. (Inlet lowest, outlet highest point of cooling
chamber). For the adjustment of cooling water quantity regulating valves are installed in the supply
pipings. At open system lead the drain pipings over a funnel.
- Flushing and / or sealing of the shaft seal: Connections and scope see installation plan or separate
drawing respectively. For pipings which lead to a heat exchanger, pressure transmitter or supply
reservoir, a vent possibility is provided at the highest point. In case of thermosyphon revolution the
biggest pipework diameter possible will be used. Supply piping is layed evenly ascending and without
sharp bend.
- Quench: In case the necessity arises to quench any leakage from the mechanical seal see 1.4.7 for
information on quench media and quantity.

Pressure measuring equipment

- The start-up and monitoring of the operating point of the pump is made easier with pressure gauges.
See also 6.1 and 6.3. Pressure gauges should be mounted on a common gauge panel and connected
to the tappings in the pump branches or adjacent pipework using a hydraulic tube with an expansion
loop. Isolating and vent valves should be installed in the pipework for ease of maintenance.

Bearing monitoring (impact impulse measurement, only possible with antifriction bearings)
- Advancing bearing damage can be recognised and monitored by means of impact impulse
measurement. This requires a special measuring unit which is connected near the bearing through
screw fittings (e.g. SKF connecting nipple No. 1649013 and SKF measuring unit MEPA 21 A).

Temperature measuring instruments

- If pump operates near the vaporization point of liquid, thermometers are recommended for control of
liquid temperature. See also point 5.4 "Minimum flow device". At installation of thermometers in the
pipework let submerse the temperature gauge at least 40 mm into the fluid. At pressures over 16 bar
use protection tube (DIN 43763).

- If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid
vaporization in the sealing range (see 1.4.5).

0000/e5-4-00-000 Page 1 19
- At heating the max. temperature of heat carrier has to be controlled (see 1.4.4).
- A measuring possibility of cooling water outlet temperature is favourable, as the adjustment of outlet
o
temperature smaller than 40 C avoids deposits in the cooling water pipings.
- At pumps with high loaded bearings numeros controls of bearing- or oil temperature are required. If
necessary control by means of contact thermometer. Execution and measuring points see pipework
scheme or installation plan. Limit values see 7.3 and 1.4.2.
- It's useful to control temperature under sound insulation covers with tele-indication. Align such a way,
that oil- or bearing temperature respectively of pump and driver cannot exceed the permitted limit.

Flow indication or flowmeters

- According to technical requirements flow indicators are installed in the reflux of supply pipework. Don't
start-up pump before auxiliary pipings are open and the liquid stream can be determined on flow
indicator.
- If there is danger for mechanical seal in case of too low circulation, a flowmeter is installed in the
circulation piping, which causes alarm when circulation quantity decreases or which shuts the pump
down.

Electrical connections
Electrical connections for motors and controlling devices may only be implemented by skilled
personnel.

The instructions of the electrical equipment manufacturers have to be observed as well as the valid
national regulations on electrical installations and the legal regulations of the local power suppliers.

0000/e5-4-00-000 Page 2 20
Note: In accordance local-safety standards these instructions must form part of every operating manual.
Safety instructions for pumps which operate in the partial load region. The following information may be
disregarded, if the pump supplied never runs in the partial load region.

Minimum flow device

General
In the partial load region (when operating the pump near zero flow) almost the total pump
ATTENTION
power is imparted to the flow as thermal energy. If this flow is less than a certain minimum
(see 1.4.1), heating will occur and continue until the liquid boils, causing severe damage to the impellers and
casing wear rings leading to eventual breakdown of the pump. In case of mechanical seals a destruction of
the seal parts has to be expected in addition. To avoid this there must always be a certain flow of liquid
through the pump.

A device must be fitted in the discharge pipe immediately after the pump, which guarantees minimum flow
even with closed discharge valve. The following devices have proved successful in use:

a) Automatic leak-off non-return valves operate such that as the flow decreases the
minimum flow line automatically opens and an integral throttle element controls the
minimum flow. The contrary happens on increasing the capacity. The minimum flow line is
directly flanged to the automatic leakoff non-return valve.

b) Constant by-pass. A by-pass line is fitted between the pump and the discharge valve,
which also leads back to the suction tank. A throttle is built into the pipe which determines
the flow rate. With this type it should be remembered that the by-pass quantity also flows
with the discharge valve open, which reduces the efficiency of the pump. It must be
considered carefully whether it is worth buying an automatic leak-off non-return valve.

Minimum flow line or by-pass

The minimum flow line is not supplied by the pump manufacturer. It must be provided by the
ATTENTION
operator. The pipe must always lead from the pump to the suction tank. For shut-down and
disconnection for maintenance, a shut-off valve must be fitted in the minimum flow line, but must be locked
open before commissioning. If several pumps are installed to operate in parallel and the minimum flow
pipework connects into a common header, it is necessary to install a non-return valve in each feed piping.

Never operate below pump minimum flow (see 1.4.1). Operation at minimum flow should be
ATTENTION
maintained for no longer than 2 hours in any 24 hours of operation.

E000/e5-4-01-000 21
6. OPERATION
6.1 Commission
ATTENTION The items described individually have to be carried out, as far as applicable, step by step
during commissioning.
With electric drive it has to be assured by qualified personnel that the necessary protection measures
work. Earthing, reset, residual current failure operated device etc. have to be ready for service acc. to
approval by skilled personnel.

Before commissioning
a. Connections: Check bolted connections and plugs. Inspect ancilliary pipework for correct installation.
b. Lube: Rinse bearing housing with light oil and allow to drain. Fill with lubricating oil, see also 1.4.2/7.3
and lubricant table T3. Check for correct oil level in sump.
c. Alignment: Check alignment of coupling. Be sure shaft rotates freely.
d. Shaft seal: Check mechanical seal (see 7.2). In case of double-acting mechanical seal fill of and vent
sealing system.
e. Filling the pump - feeding operation Filling the pump - suction lift
- Open shut-off valve in inlet line - Fully open shut-off valve in suction pipe
- If existing (see installation plan) Open vent(not - If existing (see installation plan) Open vent(not
valid for self-venting casing) valid for self-venting casing)
- Shaft sealing chamber has to be vented (see - Shaft sealing chamber has to be vented (see
also 5.4 Flushing and Sealing) also 5.4 Flushing and Sealing)
- As far as existing: Close vent when pumped - Fill pump (suction pipe must have foot valve)
medium flows without bubbles - Turn pump rotor slowly
- Turn pump rotor slowly - As far as existing: Close vent when pumped
- Mount coupling guards medium flows without bubbles
- Mount safety guard
Before starting the pump, the suction piping, pump case and shaft seal chamber must be
ATTENTION
completely filled with liquid.
f. Check: Switch on the driver for a short time to check the direction of rotation and smooth running of the
rotor (see direction of rotation arrow at the coupling).
An alteration of the rotational sense of the electric driver may only be carried out by a skilled electrician.
g. Minimum flow: If fitted, open and lock the valve in the minimum flow line (see also 5.4 - para. Leak-off
Device).

Pump start-up and Operation (max. start-up frequency 12 starts/hour)

a. If available, put ancillary equipment into operation (e.g.sealant pressure), open the valves in the ancillary
pipework, vent pressure gauge (see also 5.4).
b. Start-up with unpressurised system
- Close shut-off valve in the discharge pipe (minimum flow must be guaranteed).
- Start driver
- Open discharge valve slowly, until the differential pressure drops to the value given on the data sheet.
c. Start-up with pressurised system (precondition is non-return valve in discharge pipe)
- Start driver with open discharge valve
Warning: The differential pressure must not fall below the design point even with plants with fluctuating
system pressure. Note: The pressure gauge on the discharge side shows the differential pressure plus the
suction pressure.
d. Observe ammeter reading. The full load amps given on the rating plate of the motor must not be
exceeded.
Inadmissible operating modes

E000/e6-1-00-000 page 1 22
 Overloads have to be avoided by all means as they may lead to a failure of parts due to too stringent
mechanical requirements. Overloads occur, if the pump is run beyond its original application range,
i.e.
- exceeding of the max. admissible speed
- exceeding of the max. admissible inlet pressure
- exceeding of the max. admissible temperature
- exceeding or remaining under the operating range of the pump
- running of the pump without proper deairing of pump interior
- running of the pump without required safety devices ( safety valves, electrical overload protection
etc.)
- operation of the pump with closed or strongly throttled shut-off device in the discharge line without
having a minimum flow device (exception: during start-up).
- operation of the pump with closed shut-off device in the inlet line (dry running)
- operation of the pump for the delivery of fluids, for which the materials of the pump are not suitable
- operation of the pump with wrong sense of rotation
- operation of the pump with inadmissible bearing lubrication or with wrong lubricant

Operating modes like that and other inadmissible operating modes may lead to heavy damage on
the pumps and other parts of the plant. Danger may arise by the bursting of pressure-holding parts
and people within the range of danger may be hit by pieces or fluid, which may be hot, aggressive or
toxic, as the case may be. There may be mortal danger.

6.2 Shut-down (observe sequence)

a. If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shut-down is
for a short time only. For lengthy shut-downs, for repairs and where there is no non-return valve, the
discharge valve must be closed.
b. Stop the driver, when doing this pay attention to whether the rotor runs down smoothly.
Standby service
Ancillary systems as cooling- , sealing- and quench systems are operational. Standby pumps should be
started at regular intervals to ensure their readiness for immediate service. We recommend to start-up the
pump unit once every month and run for 30 minutes.
Extended shut down
c. If the pump works on a suction lift and is not to be left ready for start-up, the suction valve should also be
closed.
d. If existing, close quench piping.
e. If fitted, close the valves in the ancillary pipes with the exception of the cooling water, which should only be
switched off when the pump has cooled down.
Freeze damage, preservation
f. If there is danger of frost or prolonged shut-down, empty and, if necessary, protect the pump casing,
bearing housing and cooling chambers. See also 3.2.

The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead
to endangering of operator(s) and environment.

E000/e6-1-00-000 page 2 23
6.3 Service Control

Checking the duty point (design point)

Particularly important at the initial start-up:

- Check the speed.

- Read the discharge pressure and subtract the suction pressure.

Convert this pressure (generated pressure) to a head and compare it with the generated head shown on
the pump duty plate at the corresponding speed.

generated pressure (bar) x 10 200

generated head (m) =
3
density of liquid (kg/m )

3
generated head (m) x density of liquid (kg/m )
generated pressure (bar) =
10 200

- The generated pressure must not fall below this value, otherwise the maximum allowable capacity could
be exceeded, the driver could be overloaded or the suction pressure could fall below the minimum
required by the pump.

Checking the capacity

pump characteristic curve
The capacity is determined from the pump performance
curve and the generated head (m) as calculated
above.
Head in (m)

- Find the calculated value of the generated head on

the vertical axis of the performance curve.* Draw a
horizontal line through this point until it intersects the
curve. The corresponding capacity is read on the
horizontal axis vertically below the point of
intersection.

3
Capacity in (m /h)

E000/e6-3-00-000
24
7. MAINTENANCE AND OVERHAUL
7.1 Maintenance - Pump general
The pumpset should be checked for smooth, almost vibrationless running in service. To
ATTENTION
assess the vibrational behaviour the following regulations and guidelines could be used, e.g.

DIN / ISO standards 5199

ISO standard 10816 / 1

Horizontal pumps, which are fastened to the foundtion with anchors should not exceed a vibration speed of
4,5 mm/s. Vertical pumps, as well as horizontal pumps being mounted on buffer elements, should not
exceed a vibration speed of 7,1 mm/s. When determining the measured values pump should operate at
design point, see Chapter 1.4 (in case pump is operating at partial load or overload the vibration behaviour,
f.e. by cavitation, will be influenced negatively). Measured values which are too high can also be caused by
the plant (pipings/accessories) or by other vibration sources (machines). In order to determine the reason
for high vibration values a vibration analysis is necessary.

In order to judge the conditions of the antifriction bearing a monitoring by means of shock pulse
measurement is recommended.

Pay attention to normal running noises. If any vibrations, unusual noises or faults are observed stop the
pumpset at once. Ascertain the cause and rectify (see 8.1).

During shut-down (according to operating requirements) check the alignment of the coupling (at least
once a year). Re-align if necessary.

Monitor ancillary equipment during operation: (if fitted)

Gauges: pressure, temperature, ammeter at regular intervals

Cooling: flow and temperature

Flushing/Sealing: pressure, temperature, (quantity)

Any deterioration in pump performance not caused by alteration or furring of the pipework is probably due
to wear of the pump internals. The pump should be taken out of service and overhauled. See section 7.4 to
7.6 for details on overhauling the pump.

It is recommended to enter operating data and also data on lubrication, repairs etc. in an operating log.

Standby pumps should be started at regular intervals to ensure their readiness for immediate service.
During a prolonged shut-down the pump (and cooling system if fitted) should be drained and protected.

E000/e7-1-00-000 25
7.2 MAINTENANCE - SHAFT SEAL
Single-acting mechanical seal with throttling bush (for make, type and size see sectional
drawing)
General remarks
In the case of mechanical shaft seals the exit of the medium delivered is prevented by two plane parallel
lapped ring surfaces which are pressed together with the help of spring force and liquid pressure. Seal rings
(stationary and rotating) are sealed against adjacent pump parts with the help of adjoining sealings (as for
example O-rings) serving simultaneously as elastic bearing.
A non-sparking throttling bush with a small diameter clearance (max. 0,7 mm), installed in the slide ring
cover, limits the leakage in the case of a mechanical seal failure to a minimum. At the same time the outlet of
normal leakage along the shaft is avoided and a limited feed of quench agents becomes possible.

The quench outlet has always to be opened during operation. The quench inlet may be
ATTENTION
closed, if there is no quench feed.

Conditions
In order to have trouble-free operation a liquid film has to form between the slide faces and
ATTENTION therefore the following conditions have to be fulfilled by the medium delivered:
- sufficient lubricating properties
- evaporation temperature higher than working temperature
- no impurities in the slide ring region
If auxiliary facilities like
- flushing
- blocking
- quench
- cooling
- heating
- cyclone separator/filter (in case of an impure medium delivered)
are necessary for arriving at the operating conditions required the details given in paragraph 1.4.3 / 1.4.4 /
1.4.5 / 5.4 and in the installation plan of the pump have to be observed.

Maintenance
The maintenance of the mechanical seal is limited to the control of the leakage, of the temperature and, if
fitted, to the auxiliary facilities.

ATTENTION A small leakage of the mechanical seal is normal. It is impossible, however, to make special
statements with regard to the leakage of the mechanical seal, as the quantity of leakage
depends on a lot of different factors (e.g. size, material, liquid pumped, temperature etc.). In case of high
leakage seal ring pairs may also leak. If so the damaged parts have to be replaced. Secondary seals (e.g. O-
rings) have to be replaced during each assembly. Rotating and stationary seal rings must be replaced
together.

0000/e7-2-01-002 26
For Bearing details and Oil Quantity refer table below

27
Bearing details and oil capacities

Oil
Bearing Antifriction bearing Antifriction bearing sizes capacity
frame sizes Normal bearing Reinforced bearings (Litre)
Pump end and drive
Pump end Drive end
end
30 6306 / C 3 NU 306 3306 0,35
40 6308 / C 3 NU 308 3308 0,5
50 6310 / C 3 NU 310 3310 1,1
B.UA
60 6312 / C 3 NU 312 2 x 7312 2,0
BG *
B.UA
70 - NU 314 2 x 7314 3,1
BG *
B.UA
85 - NU 317 2x 7317 3,1
BG *

*B.UA (FAG); BG (SKF)

28
29
30
Filling-in of oil with constant level oiler (Type Adams)

Remove air release filter at the bearing bracket and tilt back oil reservoir of the constant level oiler. Fill oil
through the opening at the bearing bracket until the branch of the constant level oiler begins to fill up. Then fill
the reservoir with the same oil and put it back into its original position. Repeat this procedure until a minimum
of 2/3 of the reservoir remains filled up.Screw in air release filter. Check the supply in the reservoir at times
and refill, if necessary.

Function
When the oil level within the bearing bracket drops, the upper edge of the oblique cut of the drain pipe gets
free. Oil flows from the supply reservoir until the former oil level is reached and the oblique cut of the drain
pipe is immersed again.

Oil reservoir tilted back Oil reservoir original

refill here
Oil level

branch

gasket

ATTENTION
Make sure that the glass container is tightly
closed. If necessary
replace gasket. Turn glass container hand-
tight into threadet
cover. Check firm seat.

Oil replacement
For oil replacement proceed as follows:

1. Shut down pump.

2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage bores and
size of the screw plugs see installation plan or dimension sheet.)

3. Remove screw plug, drain oil thoroughly. Tighten screw plugagain securely.

4. Fill bearing bracket with fresh oil as described above.

Dispose of used oil according to statutary regulations.Do not put into waste water by any
means.

0000/e7-3-01.001
31
 183.01
920.01 344.01 102.01

922.01

230.01

920.01 452.01
451.01 344.01
361.01
523.01

32
 452.01 451.01
920.01
451.01 344.01
523.01
452.01

451.01 344.01

920.01 452.01

940.02
507.01
360.01

33
34
 320.01

932.01
932.01

360.01

507.01

452.01 523.01 458.01

451.01
461.01 920.01

452.01

940.01

523.01

35
940.01

523.01

451.01

400.01

102.01 920.02
183.01

36
8. OPERATING FAULTS
Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable
operating faults in the plant.
There is usually a certain connection between the different types of faults. It is, therefore, expedient to list
and compare the symptoms as well as the possible causes. Assistance can be found for individual
operating faults in virtually all cases.
8.1 Symptoms / Possible causes of faults / Remedies
Symptoms Possible causes of faults
1 Pump does not work. Driver out of service, speed too low
No discharge
Rotor blocked
pressure.
Wrong direction of rotation
(Failure at startup)
Pump not primed
Suction valve/line blocked
Foot valve blocked or damaged
Impeller passages blocked
2 Loss of discharge Suction pipe not completely full
pressure after startup Too much air or gas in the pumped
liquid
Leakage of air into pump suction
3 Pump flow too small. Suction or Discharge valve not fully
Differential pressure open
too low. Suction strainer blocked
Efficiency loss Minimum flow line open, minimum
flow valve damaged or bypass orifice
worn
Furring of the pump internals and/or
pipework
Impeller passages blocked
Pump internals worn (gap
clearances)
4 Pump vibrates or Coupling alignment faults
causes too much Worn shaft coupling
noise
Suction valve not fully open
Suction strainer blocked
Pump runs with cavitation
Piping strain, excessive high nozzle
forces and moments
Foundation too weak, base not or not
correctly grouted
Impeller damaged or blocked
Bearings damaged
Unbalanced rotor causes in
vibration
Shaft bent
0000/e8-1-00-000 page 1 37
Remedies
Check - refer to manufacturers
manual
Check and correct
Check-refer to pump rotation arrow
Vent pump
Inspect and correct
Inspect foot valve
Inspect pump internals
Fill the system
Check operating data (1.4)
Check and correct (seal)
Check valve position and correct as
required
Disassemble and clean strainer
Check minimum flow line, minimum
flow valve, bypass orifice (5.4)
Clean and flush pipework.
Disassemble and clean pump
internals.
Disassemble and inspect pump
internals
Disassemble and inspect pump
clearances (7.5)
Check coupling alignment (5.2)
Check coupling condition and
replace
Check and correct (open fully)
Disassemble and clean strainer
Check operation data (1.4). Create
more pressure at the pump suction.
Piping should be properly supported
to prevent strains from being
imposed on the pump
Inspect foundation bolt tightening
and baseplate grouting (5.1)
Inspect pump internals
Disassemble and replace bearings
(7.4 to 7.6)
Check balance of coupling, driver
and pump rotating parts
Disassemble and check shaft runout
(7.4 to 7.6)
Symptoms Possible causes of faults
5 High shaft seal Seal flush insufficient (flow rate) or
temperature. missing
Wrong orifice size or worn orifice
High leakage of
mechanical seal. Solids block seal rings/springs
Short shaft seal life
Vaporisation in the seal ring area
Seal fluid not suitable (abrasive)
Seal rings, auxiliary gaskets (O-rings)
or springs damaged
Dry operation of seal. Seal system
not correct filled or vented
Seal face material inadequate
Pump shaft bent
6 High bearing Pump not running at operating point
temperature. Coupling alignment faults
Short bearing life. Too much grease or oil in the bearing
Oil level too low or high
Wrong lube oil quality
Bearings loaded during assembly
Improper bearing cooling (air / water)
Bearings damaged
Excessive pump thrust
Shaft bent
7 Lube oil leakage Oil level too high
Labyrinth seal or shaft seal ring
improperly installed
Bearing cover gasket or seal
damaged
8 Excessive pump Pump not running at operating point
internals wear of Insufficient suction pressure.
Operating fluid differs from specified
- Corrosion
value (temperature, specif. gravity...)
- Erosion
Materials of construction not
- Loss of material compatible with medium delivered
9 Pump Operating below minimum flow
overheating/seizure (pump dry running)
0000/e8-1-00-000 page 2 38
Remedies
Check flow requirements
Check size, flow requirements
Disassemble and remove solids,
review application
Check circulation flow or cooling
requirements (1.4, 7.2)
Review application, install filter or
separator
Disassemble and replace damaged
seal parts (7.4 to 7.6)
Fill and vent shaft seal
chamber/system
Review application with seal
manufacturer
Check shaft runout at seal area
Review operating parameters (1.4)
Check coupling alignment (5.2)
Check and correct (7.3)
Check and correct oil level (7.3)
Verify that recommended lubricant is
used (7.3, T 3). Change lube oil.
Examine assembly and condition of
bearing and associated parts (7.4-
7.6)
Check air intake (environmental
temperatures under noise hoods).
Check cooling water requirement
(1.4)
Disassemble and replace bearings
(7.4 to 7.6)
Check hydraulic balance device,
balance pipe. Disassemble and
inspect pump internal clearances
(7.4 to 7.6)
Disassemble pump and check shaft
runout (7.5)
Check and correct oil level (7.3)
Examine assembly (labyrinth
leakage bore downwards)
Disassemble and replace
gaskets/seal (7.4, 7.6)
Review pump operating parameters
with a Sulzer representative, make
necessary correction to unit design.
Refurbish pump with correct parts,
clean system. Assemble filter or
separator.
Review hints for minimum flow. (1.4,
5.4) In case of seizure disassemble
and repair unit.
9. ANLAGEN / ENCLOSURES
Anlagen zu
Sulzer Auftrags-Nr. Bei Rcksprache unbedingt angeben
Documentation for Always quote this number
Sulzer Serial-No.

9.1 Verzeichnis der Anlagen zur Betriebsanleitung

Table of enclosures for operating instruction
Leistungswerte- Diagramm Performance data-diagram
Kennlinie Performance curve

Dimensionszeichnungen Dimension drawings

Fundamentzeichnung Foundation plan
Aufstellungszeichnung Installation plan
Mazeichnung Dimension plan

Anlagenzeichnungen Plant drawings

R + I Schema P + I Diagram
Gerteliste Device list
Zirkulationsschema Circulation layout
Khlschema Cooling layout

Schnittzeichnungen Sect. drawings

Kreiselpumpe Centrifugal pump
Teileliste - Pumpe Parts list - pump
Wellendichtung Shaft seal
Teileliste - Wellendichtung Parts list shaft seal

Zubehr Accessories
Kupplung Coupling
Mindestmengeneinrichtung Minimum flow regulation
Antriebsmaschine Driver
lversorgungsanlage Oil supply system
lpumpe Oil pump
lkhler Oil cooler
lfilter Oil strainer
Getriebe / Regelkupplung Gear unit / Gear type coupling
Mech. Wellendichtung / Zubehr Mech. seal / Accessories

Spez. Armaturen Spec. Armature

Sonderunterlagen Special documents

9.2 Anlagen (im folgenden Anhang, Reihenfolge nach Verzeichnis)

Enclosures (in the following annex, sequence acc. to table)

39