s 4 N O U N CODE 178 183 1 W PART. N A M E ST U F F I N G BOX STUDS CASING COMPLETE ROTOR COMPLETE P A C K E D BOX 008 014 016 064 118 2*6A 279 A 291 397 4 1 7 456A S H A F T SLEEVE SEAL CAGE G L A N D PACKING
CAP SCREW (GLAND} G L A N D WASHER G L A N D NUT
KEY - SHAFT SLEEVE • RETAINING RING PIPE PLUG O - R I N G (SHAFT SLEEVE) C A R T R I D G E SEAL 2*6A 2 7 9 A 429 G L A N D WASHER G L A N D NUT M E C H A N I C A L S E A L C O M P L E T E C O O L E D S T U F F I N G BOX EXTENSION • STUFFING BOX BUSHING ?<«6B ' W A S H E R - ' 264 • S T U F F I N G BOX EXTENSION 279B NUTS
4S6B O-RING (STUFFING BOX E X T E N S I O N ) • USED O N L Y W I T H , A -PACKED BOX
(PLED STAFFING BOX EXTENSION .RTR1W5E SEAL r m E X P L O D E D V I E W 1 S T U F F I N G B O X P A R T S D A P U H P 6 - 2 5
NOUN CODE PART NAME
0 2 1 B E A R I N G BODY 023 B E A R I N G CAP 028 ' / T H R U S T C O L L A R
029 A _ _ J X W E L - PIN.IB_BG, BODX TO_C ASIN G)
1-0 2 9 B "7" D O W E L P I N ' I B R G , CAP TO B O D Y ) 064 ' K E Y - THRUST C O L L A R
097 B R E A T H E R CAP
1 1 8 A CAP SCREW.(BRG. BODY T O C A S I N G ) 1 1 8 B CAP SCREW (BRG. CAP TO B O D Y ) 11BC. CAP. SCREW (END COVER TO H O U S I N G ) 1 1 8 D CAP SCREW ( L A B Y R I N T H S L E E V E ) 128 LOCK N U T - ( T H R U S T C O L L A R ) 158 B E A R I N G END COVER 172 • - SUPPORTING H E A D 178 S T U D ( M A I N OIL PUMP) IBS C O U P L I N G ( M A I N OIL PUMP) 191 B E A R I N G L I N I N G
219 M A I N OIL PUMP
2 S 7 A S H I M , - (THRUST C O L L A R ) ? 5 7 8 S H I M ' - { T H R U S T BRG.J 2S6A NUT (DOWEl PIN) 2S8B . NUT ( M A I N Oil PIN)
2S9A ' S E T SCREW (BRG BODY A D J U S T I N G ) 259B SET SCREW (LOCK NUT)
2 6 2 A _ G A S K E T R,,{BRG BODY TO CAP) 262B G A S K ' E T - ' (CNO COVER) 262C GASKET, - ( M A I N OIL PUMP) 294 L A B Y R I N T H \ S L E E V E 308 SEAL. RING (THRUST B E A R I N G ) 3 1 5 A L O C A T I N G PI'N; (B'RG., L I N I N G ) 3 1 5 B ^ L O C A T I N G > ! N (END C O V E R ) 3 2 5 '•'. K I N G S B U R Y . T H R U S T B E A R I N G 333 EYE B O L T '' " " " V I 4 1 7 P I P E ' P L U G : , ,. 456 0:RI N G ( L A B Y R I N T H SLEEVE)
333
NOON CODE PART NAME 021 BEARING BODY 023 BEARING CAP
029A DOWEL PIN (BRG. BODY TO CASING) 029B DOWEL PJN (BRG. CAP TO BOOY) 097 BREATHER CAP
118A CAP SCREW (BRG. BODY TO CASING) 1188 CAP SCREW (BRG. CAP TO BODY) 118C CAP SCREW (LABYRINTH SLEEVE) 1«1 BEARING LINING
268 NUT {DOWEL PIN)
259 SET SCREW (BRG, BODY ADJUSTING)
202 GASKET
-294 LABYRINTH SLEEVE
315 LOCATING PIN 333 EYE BOLT 417 PIPE PLUG
450 0»RING (LABYRINTH SLEEVE)
E X P L O D E D V I E W # s
" P L A I N B E A R I N G // S L E E V E: B E A R I N G - F O R C E F E E D L U B E /
NOUN CODE PART NAME 001 006 060 068 170 184 315 407 441 LOWER H A L F CASING R I N G - CASING
CHANNEL RING (LOWER HALF) • STUFFING BOX BUSHING
GASKET - MAIN PARTING FLANGE ROTOR COMPLETE
LOCATING PIN
CENTER BUSHING (LOWER HALF) T H R O T T L I N G BUSHING
006
BOX BUSHING IS NOT USED "WITH J L K S K B°X ^ ^ O N INCOMBINATION E X P L O D E D V I E W 92 A S S E M B L Y O F1 L O W E R H A L F B U S H I N G S A N D R O T O R T O C A S I N G D A P U M P R m ^
E X P L O D E D V I E W J 6 T H R U S T B E A R I N G
S L E E Y F . / K . T . B , - F O R C E F E E D L U B E
N O U N CODE P A R T N A M E / 0 2 1 B E A R I N G B O D Y . 023 B E A R I N G CAP ' 0 2 8 T H R U S T C O L L A R ' - . , 029 A • - — D O W E L ' P I N (BRG: BODY TO CASING). ' 0 2 9 B D O W E L PIN,.(BRG, CAP T O B O D Y ) 054 K E Y - T H R U S T C O L L A R ; • . 097 B R E A T H E R CAP
1 1 B A CAP SCREW (BRG.; BODY T O / C A S I N G ) 1 1 8 B CAP SCREW (BRG. CAP TO B O D Y ) n e e . CAP SCREW (END COVER T O - H O U S I N G ) 1 1 8 D CAP SCREW ( L A B Y R I N T H S L E E V E ) 128 LOCK N U T ( T H R U S T C O L L A R ) 158 B E A R I N G E N D COVER -172 S U P P O R T I N G H E A D 178 S T U D ( M A I N OIL PUMP) " 185 C O U P L I N G ( M A I N OIL. PUMP) 191 B E A R I N G L I N I N G 2 1 9 M A I N O I L PUMP 2 5 7 A S H I M - ( T H R U S T C O L L A R ) 2 5 7 B S H I M ( T H R U S T BRG.) -2S8A N U T (DOWEL PIN) 2S8S N U T ( M A I N OIL PIN) .
2S9A SET SCREW (BRG ' B O O Y A D J U S T I N G ) 259B SET SCREW (LOCK NUT)
2 6 2 A G A S K E T - (BRG BODY TO CAP) 2 6 2 B G A S K E T - ( E N D C O V E R ) 262C G A S K E T - ( M A I N OIL PUMP) • 2S4 L A B Y R I N T H - S L E E V E 308 SEAL R I N G ( T H R U S T B E A R I N G ) 3 1 5 A L O C A T I N G ' PIN (BRG. LINING). 3 1 5 B L O C A T I N G ,PIN'• {E:ND'.C0VERV'j ;'1 3 2 5 K I N G S B U R Y T H R U S T ' B E A R I N G 333 EYE 8 0 L T : . . ' • 4 1 7 PIPE P L U G ' V ' ' ' • 4 5 6 O - R I N G ( L A B Y R I N T H SLEEVE)
N O U N CODE 003 A 0 0 3 8 006
010
011 262 291 408 M O P A R T N A M E • IMPELLER ASSEMBLY L H . * IMPELLER ASSEMBLY R.H, R I N G - CASING S H A F T K E Y - IMPELLER R I N G - SPLIT K E Y - THROTTLING StEEVE CENTER SLEEVE S L E E V E - T H R O T T L I N G ' I M P E L L E R A S S E M B L Y 0C3A/B CONSISTS OF CC3 00* 005 259 I M P E L L E RRING IMPELLER (FRONT! R I N G - IMPELLER (BACK) SET SCREW
A
EXPLODED VIEW. #1 TYPICAL ROTOR ASSEMBLY
N O U N CODE 001 002 006 029 A 029B 029C 060
088
11BA 11BB 170 178 179 184 246 , 4 0 7 4 1 7 4 4 1 PART NAMELOWER HALF CASING UPPER HALF CASING RING - CASING
DOWEL PIN (CENTER BUSHING! DOWEL PIN (CHANNEL'RING) DOWEL PIN (CASING)
CHANNEL RING (UPPER HALF) • STUFFING BOX BUSHING CAP SCREW (CENTER BUSHING) SCREW - JACKING
GASKET (MAIN PARTING FLANGE) STUD (MAIN.PARTING FLANGE) CAP NUT (MAIN PARTING FLANGE). ROTOR COMPLETE
WASHER (MAIN- PARTING FLANGE) CENTER BUSHING (UPPER HALF) ' PIPE PLUG
T H R O T T L I N G B U S H I N G .
• THIS STUFFING BOX BUSHING IS NOT USED WITH A COOLED STUFFING BOX EXTENSION IN COMBINATION W I T H A PACKED BOX
•.029C
^ E X P L O D E D V I E W # 3 : . " A S S E M B L Y O F U P P E R ' H A L F .
SECURING THE PUMP .TROUBLE SHOOTING
Trouble Shooting Chart
SECTION 4 LUBRICATION . LUBRICATION SYSTEM
Pressure Switch No. 8 pressure Switch No, 7 MAKE PERIODIC INSPECTIONS OIL.SPECIFICATIONS.
ASTM Standards OIL TEMPERATURE
CLEANING THE LUBRICATION 'SYSTEM PRIOR TO OPERATION SECTION 5
• STUFFING BOX STUFFING BOX PACKING
PACKING INSTALLATION
STUFFING BOX PACKING REMOVAL
SECTION 6 MAINTENANCE GENERAL PREVENTIVE MAINTENANCE .TORQUE VALUES -COUPLING REMOVAL DISMANTLING PROCEDURE
Plain Bearing Removal
Removal Of Stuffing Box Parts Rotor Removal
Dismantling The Rotor
Heating Impellers For Removal
3-5 3-7 3-7 4-1 4-1-4-1 4-2 4-2 4-2-5-1 5-2 •5-3 6 - 1 6 - 2 . 6 - 2 6-2 6 - 2 6-4 6-4 6-4 6 - 6 6-6
INSPECTION AND RENEWAL OF PARTS PARTING FLANGE GASKET
•HE BUILDING PUMP
Re Building Rotor
Indicate And Dynamic Balance Rotor Installing Rotor In Casing
Assemble Stuffing Box Extension Check Rotor Vertical Lift
Check Rotor Acial Float - Packed Box Check Rotor Axial Float - Mechanical Seal Horizontal And Vertical Shaft Alignment Centralize Rotor Axially
Final Bearing Assembly
Set Thrust Bearing Axial End Play
Final -Asserab 1 y — 6 - 8 6-11 6-12 6-12 6-13 6-13 -6-14 6-15 6-15 6-16 6-16 6 - 1 8 6 - 1 8 6 - 2 0 - 6 - 2 0 SECTION 7
PARTS ORDERING INSTRUCTIONS ORDERING INSTURCTIONS
Rotor Assembly Drawing And Parts List Pump Assembly Drawing And Part3 List
SECTION 8
7-1 62068127, 2 Pgs. 62068135, 4 Pgs.
DRAWINGS AND PURCHASED COMPONENT INSTRUCTIONS General Arrangement Drawing And L.N. Notes Item No. General Arrangement Drawing And L.N. Notes Item No. Lube Piping Drawing 4 P.L. Notes
Lube Oil Console Drawing Kingsbury Thrust Bearing Tuthill Oil Pump (Main) DeLaval Oil Pump (Auxiliary) Yarway Valve Drawing
Yarway Valve Instruction Sheet
Waldron Coupling Drawing Item No. Waldron Coupling Drawing Item No, Waldron Coupling Instruction Sheet
Motor Information Turbine Information .Outline Drawings Instruction Manual -1 62068937, 3 Pgs. 2 62068945, 3 Pgs. 62063045, 2 Pgs. 62064100, 2 Pgs. 5JJ 62059175, 0RFD-1 C3E-87 62065735, 044399-5506 Series 5300 1 62081278, 2 Pgs. 2 62081476, 2 Pgs. Type WSP, 25M0201 To Come X-664413, X-663416 No. 100-M
LIST OF EXPLODED VIEWS
, #1 ROTOR ASSEMBLY 6-22
#2 ASSEMBLY OF LOWER HALF BUSHINGS AND ROTOR TO CASING 6-23
#3 ASSEMBLY OF UPPER HALF BUSHINGS AND CASING 6-24 #4 STUFFING BOX PARTS | 6-25
#5 PLAIN BEARING 6-26 #6 THRUST BEARING 6-27
INTRODUCTION SECTION 1
INTRODUCTION
a •
This manual contains instructions for installation, operation and mainten-ance of your Ingersoll-Rand Centrifugal Pump. It has been designed to provide safe and reliable service. However, it is both a pressure vessel and a piece of rotating machinery. Therefore, the operator(s) must exercise good judgement and proper safety practices to avoid damage to the equipment and surroundings and prevent personal injury,
r
The instructions in this manual are intended for the guidance of personnel with a general training in operation and maintenance of Centrifugal Pumps.
It. is our hope that you will be come acquainted with its content as an aid to better pump performance. This manual should be read in its entirety before installing, and/or operating the equipment. The Assembly Drawings (included in Section 7) and General Arrangement Drawing (included in Section 8) should be consulted for accurate details and determination of specific optional features that are furnished with your pump. All numbers in paren-thesis () following part names correspond with "Exploded View" Noun Codes. EXAMPLE:"T1-003A) - Exploded "View f 1, Noun Code #003A - Impeller Assemb1y. Exploded Views are included in Section 6.
SAFETY
It is assumed that your-safety department has established a safety program based upon a thorough analysis of industrial hazards. Before installing and operating or. performing maintenance on the pump and associated components described in this manual, it is suggested that the safety program be review-ed to ensure that it covers the hazards arising from high spereview-ed rotating machinery.
It is .also important that due consideration be given to those hazards which arise from the presence of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases and flammable liquids and gase3. Proper installation and .care of protective guards, shutdown devices and over pressure protection equipment should also be considered an essen-tial part of any safety program.
Also essential are special precautionary measures to prevent the possibility of applying power to the equipment at any time when maintenance work is in progress. The prevention of rotation due to reverse flow should not be overlooked.
In general, all personnel should be guided by all the basic rules of safety associated with the equipment and the process.
DESCRIPTION
'The "DAn Pump is a multi-stage, single suction - opposed impeller, horizon-tally split volute pump.
The suction and discharge nozzles are cast integral with the lower half
casing,
Rotating parts are accessible by removing the upper half casing which can be removed without breaking suction and discharge piping.
;CASING
The casing provides for immediate containment of the liquid being pumped, while directing the flow of liquid from the suction nozzle to the impellers and subsequently through the volute to the discharge nozzle.
The casing halves, are sealed by the use of a gasket and are joined together by studs, which are installed in the lower half casing and fastened with washers and cap nuts,
IMPELLERS
The Impellers are single suction, enclosed type, one piece construction and are dynamically balanced.
They are fitted with renewable impeller rings (front and back) which are held in place by headless set screws.
The impellers are keyed, have a shrink fit to the pump shaft and are held in axial position by a split ring.
CASING RINGS
Casing rings are positioned over the impeller front rings. These rings are tubular and renewable,
CHANNEL RINGS
Renewable channel rings are positioned over the impeller back rings. They divide the casing into stages. These rings are horizontally split and are held together by dowel pins.
CENTER SLEEVE
-A renewable type center sleeve is used under the center bushing. The center sleeve is tubular and keyed to the shaft (via the impeller key).
CENTER BUSHING
The renewable center bushing is horizontally split, the two halves are held together by socket head capscrews and taper dowel pins. It is held in position by the raised annular ring of the bushing engaging the annular 'groove in the casing.
The center bushing in conjunction with center sleeve divide the casing at the center (back to back) impellers.
THROTTLING SLEEVE
Renewable type throttling sleeve is used under the throttling b u s h i n g . The throttling sleeve i3 tubular, keyed, has a shrink fit to the shaft, and are held in position by a split ring.
1-3
•THROTTLING BUSHING
Renewable type throttling bushing is used. It is held in position by the annular ring -of the bushing engaging the annular groove in the casing. The throttling bushing, in conjunction with the throttling sleeve, allows pressure to be blead off thru the balance line, so that pressure on the stuffing boxes is balanced. The throttling bushing also balance the axial thrust of the pump rotor,
SHAFT
The high strength shaft is ground over its entire length to close toler-ances, The shaft is designed to transmit the required power without vibra-tion and is stepped at each impeller fit for ease of assembly and disassem-bly.
. SHAFT SLEEVES.
Renewable shaft sleeves are provided with pumps equipped with packed stuf-fing boxes to protect the shaft at the stufstuf-fing box areas. The sleeves are tubular type, keyed to the shaft, and held in position by the retaining
ring3,
BEARING LININGS
The bearings are carbon steel backed, babbitt lined, sleeve type insert bearings. The bearing inserts are mounted in the bearing bodies and kept from rotating by means of stop pins. The bearing inserts are renewable. THRUST BEARING (Refer to Kingsbury Thrust Bearing Drawing)
N
The Kingsbury thrust bearing is of the equalizing type having six thrust shoes on each side of the thrust collar and is consequently capable of transmitting the thrust load in either direction. The thrust is transmitted through the thrust collar to the shoes, by the 3hoes to the shoe supporting elements, and thence to the bearing body and the foundation,
STUFFING BOXES
The stuffing boxes are cast integral with the casing. The suction and discharge end stuffing boxes can be equipped with a cartridge type mechani-cal seal or stuffing box packing.
COOLED STUFFING BOX EXTENSION
A cooled stuffing box extension is offered on this type pump as an option. This extension is inserted into the stuffing box and has a cooling jacket through which cooling liquid is circulated.
CHECK UPON ARRIVAL
Your pump was carefully checked at our shops pri'or to shipment to assure its meeting the requirements of your order.
It is suggested that the pump be inspected upon arrival and that any irregularities arising due to s h i p p i n g be reported i m m e d i a t e l y to the carrier.
CARE DURING STORAGE
If it is necessary to store the unit any length of time before installa-tion, find a location where it will be protected from unfavorable weather and is vibration free.
The nozzle covers provided with the unit should be.i"left in place during storage.
Electric motors (pump driver) should not be stored in damp places"without special protection (refer to motor manufacturers instructions).
RUST PREVENTIVE
Internal parts of the .pump and bearing housings are protected prior to shipment with a thin film polar type rust preventive [pump internals (Fer-rocote 5684), bearing housings (MIL—C—16173 Grade 3)3. This can be removed out by flushing with petroleum solvents.
External machined surfaces are protected with durable drying type . rust preventive (MIL-C-16173 Gr ade 1). This can be removed with kerosene or safety solvent (TOWER NO. 392).
External non-machined surfaces are painted with one coat of gray enamel followed by a coat of multi-color speckle lacquer.
Exception: External non-machined surfaces of the pimp (if operating above 200 Degrees F.) are painted with a high temperature aluminum base paint. Parts on parts orders are protected with a thin film polar type rust preventive, This can be removed with petroleum solvents.
LIFTING EQUIPMENT
.
MAKE SURE THAT ANY EQUIPMENT USED TO LIFT THE PUMP OR ANY OF ITS COMPONENTS IS CAPABLE OF SUPPORTING THE WEIGHTS ENCOUNTERED, MAKE SURE THAT ALL PARTS ARE PROPERLY RIGGED BEFORE ATTEMPTING TO LIFT,
TO LIFT UNIT
pump, driver and bedplate can NOT be lifted as a unit. Driver must be removed from bedplate before lifting.
To lift punp and bedplate or just bedplate, sling bedplate from all lifting eyes. Failure to do this will result in permanent deformation of bedplate, TO LIFT DRIVER
Refer to .driver manufacturers instructions. TO LIFT PUMP
Install sling from overhead hoist and under bearing housing mounting brack-ets (cast portion of casing that bearing housings attach).
DO NOT. LIFT ENTIRE PUMP FROM CAST LIFTING LUGS ON UPPER HALF CASINGS. THESE LUGS ARE FOR LIFTING UPPER HALF CASING ONLY.
TO LIFT UPPER HALF CASING
Rig to overhead hoist from cast lifting lugs provided. TO LIFT PUMP ROTOR
Using slings that will not damage shaft, rig around shaft close to the impellers and to overhead hoist. Carefully lift rotor from lower half casing.
SECTION 2 INSTALLATION
LOCATION
Inatill th« unit cloae to the souroe of the liquid to be pumped.
When selecting the location, be sure to allow adequate space for opera-tion as well as for maintenance o p e r a t i o n s involving d i s m a n t l i n g and inspection of parts.
Head room is an important consideration as an overhead.lift of some type is required.
The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to permanently support the bedplate at all p o i n t s . The most satisfactory foundations are made of reinforced concrete. These should be poured well' in advance of the"installation to allow proper time for drying and curing.
The General Arrangement Drawing will furnish anchor bolt locations, size of bolts, etc.
FOUNDATION
ALLOW &OUS TO WOJfCT (QA Gl OUTING UND£f KDPl>Tt
TEMPLATE FOR HANGING FOUNDATION BOLTS
The sketch below illustrates a recommended foundation bolt arrangement. Notice the large washer with lugs at the bottom. It should be welded to the bolt and' pipe sleeve to prevent turning.
Allow a little more than the specified threaded bolt length above the rail of the bedplate. The excess can always be cut off if not needed,
A rough finish top surface is best when applying grout.
INSTALLATION CHECK LIST 1. Level Bedplate
2. Grout Bedplate
3. Align Shaft/Coupling 4 , Piping '
5. Check Coupling Alignment
LEVEL THE BEDPLATE
Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any loose pieces of cement and roughen the top with a chisel to afford a good hold for grout.
NOTE
Coupling bolting and spacer piece (when used) must be removed from between pump/driver half couplings before lifting bedplate with pumping element.
NOTE
When lifting bedplate with pumping element, sling bedplate from all lifting eyes provided. Failure to do this may result in permanent deformation of bedplate.
P r e p a r e enough iron w e d g e s or shims to be placed on each side of each foundation b o l t . These w e d g e s should be about 4 to 6 inches l o n g , 2 to 3 inches wide and thick enough to allow for 1 1/4 inches of grout under the edge of the bedplate. Place wedges as shown in sketch.
Level the bedplate by using a machinist's level on the machined surfaces of the pump and driver p a d s . When the b e d p l a t e is l e v e l e d , p u l l down the foundation bolts so they are 3nug, The bedplate may have been disturbed by tightening down the foundation bolts, therefore, recheck with level and make necessary adjustments by wedges or shimming.
As a final bedplate a l i g n m e n t check on spacer type couplings, install a mounting bracket for dial indicator on driver hub. Fasten or clamp indi-cator on mounting bracket so that dial indiindi-cator button is contacting face on p u m p h a l f coupling and zero the dial i n d i c a t o r , ( N o n - s p a c e r type coupling should be checked with tappered wedge or feeler gages.)
Rotate the driver half coupling (in direction of pimp rotation) 90 degrees. Record this reading.
R e p e a t this procedure until r e a d i n g s have been taken at (4) 90 d e g r e e positions.
Using this procedure shim and/or wedge bedplate until pump and driver are within ,003 inch.
GROUTING
Build a dam around the f o u n d a t i o n . It is a matter of personal preference whether the leveling wedges under the b e d p l a t e should be removed after g r o u t i n g . If you do w a n t to remove the w e d g e s , c a r e f u l l y m a r k their locations before pouring grout.
BUILD DAM AROUND FOUNDATION BEFORE POURING GROUT
Use a q u a l i t y , high strength, non-shrink grout - mix and install per manu-facturers instructions.
Holes are provided in the b e d p l a t e to permit pouring the grout and stirr i n g , They also act as aistirr v e n t s . Fill undestirr the b e d p l a t e c o m p l e t e -l y , s t i r r i n g to assure proper d i s t r i b u t i o n of the g r o u t . Check to see that the grout flows under the edges of the bedplate evenly.
NOTE
Do not vibrate bedplate" when grouting, make sure bedplate is vented properly and all areas as indicated on G e n e r a l Arrangement Drawing are thoroughly puddled to prevent any resonant problems.
W h e n the g r o u t is t h o r o u g h l y h a r d e n e d , remove the dam and w e d g e s , if desired, filling in the holes they leave with grout.
2—4
SHAFT/COUPLING ALIGNMENT C A U T I O N
SHAFT ALIGNMENT M U S T BE C O R R E C T FOR SUCCESSFUL O P E R A T I O N . RAPID WEAR, N O I S E , VIBRATION AND ACTUAL DAMAGE TO THE EQUIPMENT MAY BE CAUSED BY SHAFT MISALIGNMENT. THE SHAFTS MUST BE ALIGNED WITHIN THE LIMITS GIVEN.
Adjustment to correct the alignment in one direction nay alter the alignment in another d i r e c t i o n . Always c h e c k in all d i r e c t i o n s a f t e r making any adjustment.
Coupled e q u i p m e n t m u s t be aligned to m i n i m i z e u n n e c e s s a r y s t r e s s e s in s h a f t s , bearings and coupling, Flexible couplings will not compensate for appreciable m i s a l i g n m e n t . Foundation settling, thermal expansion, nozzle loads resulting in b e d p l a t e / f o u n d a t i o n d e f l e c t i o n and v i b r a t i o n during operation may require the full coupling misalignment capability,
TYPES OF MISALIGNMENT
There are two types of shaft misalignment; angular and offset. Therefore, t w o sets of m e a s u r e m e n t s and c o r r e c t i o n s are r e q u i r e d . Both types of m i s a l i g n m e n t can occur in horizontal and vertical planes and are present in most applications.
A, Angular Misalignment
In angular misalignment, the centerline of the shafts intersect, but are not on the same axis.
B. .Offset Misalignment ! In offset m i s a l i g n m e n t , the shaft c e n t e r l i n e s are p a r a l l e l but do n o t
intersect.
NOTE
ANGULAR MISALIGNMENT
OFFSET MISALIGNMENT COMBINATION OFFSET AND
ANGULAR MISALIGNMENT
ALIGNMENT
A. Measure Gap
The first step in shaft/coupling alignment is to bring the pump and driver shafts into their proper axial position. The shaft gap or distance between c o u p l i n g hubs m u s t be in accordance with the certified General Arrangement Drawing and must be measured with pump and driver shafts in the center of their axial end f 1 o a t . Motor with sleeve bearings are to be aligned with rotor at magnetic center.
Move driver to insure proper gap distance. NOTE
It is recommended that the pump hold down bolting be torqued and pump be dowelled before taking any alignment m e a s u r e m e t s . This makes the pump the fixed machine and the d r i v e r the movable machine. In certain cases, how-ever, it may be impractical to move the driver, therefore, the pump may have to be m o v e d . When this case exists, the pump should not be dowelled until after final alignment.
B, Measure Angular Misalignment
Refer to "ALIGNMENT DATA SHEET'1 and examples. CAUTION
PUMP. SHAFT' SHOULD NOT BE ROTATED MORE THAN 'NECESSARY WHEN ALIGNING SHAFTS, DAMAGE COULD OCCUR TO INTERNAL W E A R I N G PARTS WHICH ARE LUBRICATED BY THE PUMPED LIQUID. ,
The angular m i s a l i g n m e n t c a n ' b e s t be determined by the use of a hand-held i n s i d e m i c r o m e t e r , marked "B" on sketch. All measurements should be taken at the same radial distance from the shaft centerline, as close as possible to the hub outside diameter. The location, of these measurements is defined as the n D" dimension on the "ALIGNMENT DATA SHEET". Do not move the shafts a x i a l l y while rotating the shafts and taking measurements. Both hubs must be rotated together to cancel possible hub face runout. The relative mea-s u r e m e n t (top minumea-s b o t t o m , r i g h t m i n u mea-s left) imea-s the i m p o r t a n t number.
1. Mark both coupling hubs at 3.6,9 and 12 o'clock positions so they can be rotated together and at 90 Degree intervals.
2. Starting with the 12 o'clock m a r k i n g s of both hubs in the top center position, measure the gap at top, bottom, right and left side. Record these d i m e n s i o n s oh "ALIGNMENT DATA SHEET" Sheet 1, Part 1 in the 0 Degree Colunn,
Right side and left side are determined when viewing the driver coupling from the pump.
3. R o t a t e b o t h shafts 90 degrees in the d i r e c t i o n of pump r o t a t i o n . Measure gap d i m e n s i o n s at the four (4) l o c a t i o n s as in Step 2. Record on "ALIGNMENT DATA SHEET" - Sheet 1, Part 1 in the 90 Degree Column.
H. Repeat Step 3 until m e a s u r e m e n t s have been taken at the four (4) 90 Degree po sit ions.(0,90,180. and 270 Degrees),
5» Rotate both shafts to the starting position (12 o'clock markings at top center) and recheck dimension recorded in Step 2.
6. For 0,90,180 and 270 Degree Columns, subtract the bottom from the top and left from r i g h t . Record in their r e s p e c t i v e blocks on Data Sheet. Watch sign notations!
7. Total the d i f f e r e n t numbers (reading across), divide by 4 and record the average . Record in "Open At " the shaft relative angular
The inside faces of the d r i v e r and pump half hubs must be parallel within
.001".
C. Measure Offset Misalignment
Offset m i s a l i g n m e n t is measured using a dial indicator on the outside diameter of the coupling hubs and rotating the hubs together to cancel rim surface inaccuracies.
1. ' Starting with the 12 o'clock m a r k i n g s of b o t h hubs on top c e n t e r , fasten or clamp an indicator on driver hub, marked "A" on sketch, with dial indicator button contacting alignment surface on the pump hub.
*
2. Zero the dial indicator,
3. Rotate both coupling hubs (in the direction of pump rotation) 90 Degrees and take a r e a d i n g . Record on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2 in the proper right side or left side blank (right or left sides are determined when viewing the driver half coupling from the punp) .
4. Repeat Step 3 until readings have been taken at the four (4) 90 Degree positions (top center, right, bottom and left).
NOTE
position
NOTE
5. Rotate both shafts to the starting position (12 o'clock markings at top center) and verify indicator returns to zero.
NOTE
The sum of the top and bottom r e a d i n g s should a l w a y s e q u a l the sum of the left and right'readings. If the sums are not equal, check for indicator bracket d e f l e c t i o n h u b s u r f a c e i r r e g u l a r i t y o r l o o s e r a d i a l bearings, 6. Using -the formula- on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2, subtract the top from the b o t t o m i n d i c a t o r r e a d i n g , divide by two (2), Thi3 will yield the vertical misalignment.
7. Using the formula on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2, subtract the left from the right indicator reading, divide by two (2), Thi3 is the horizontal misalignment.
8. Circle the proper high or low and left or right position of the driver hub, using the rules given on the Data Sheet.
NOTE
The outside d i a m e t e r s of pump and d r i v e r c o u p l i n g h u b s m u s t be aligned within .003" TIB.
D. Movement Calculations ("ALIGNMENT DATA SHEET" - Sheet 2)
1. Sketch the r e l a t i v e d r i v e r shaft position in the side and top views. These sketches will assist visualizing the required equipment m o v e .
2. Alignment depends upon the relationship between D, LI and L0 G X L
Use the formula D determine the required move. NOTE
D = Diameter of the c i r c l e at which angular m i s a l i g n m e n t readings were taken (not coupling diameter).
Gy = Gap difference (top minus bottom) taken from Sheet 1, Part 1. GH = Gap difference (right minus left) taken from Sheet 1, Part 1. LI = Distance from driver coupling hub to inboard driver foot. L0 = Distance from driver coupling hub to outboard driver foot.
LOCATION
PUMP SHAFT (FIXED)
3. Record vertical offset from Sheet 1, Part 2- and vertical move obtained from c a l c u l a t i o n s in the " I N B O A R D , and OUTBOARD DRIVER PEDESTAL SHIFT" c o l u m n s . Also record the required direction of shift (raise or lower). 4. Record horizontal offset from Sheet 1, Part 2 and horizontal m o v e obtained from calculations in the "INBOARD, and OUTBOARD DRIVER PEDESTAL SHIFT" o o l u m n s . Also record the required d i r e c t i o n of shift (right or left).
5. Total the move requirements (watch move direction)". This will yield the required horizontal m o v e (right or left) and the vertical move (raise or lower) required at each mounting foot.
HORIZONTAL MOVE J The d i a l indicators as shown in figure are required to accurately measure
the m o v e in the horizontal direction. Move the driver' by bumping with soft h a m m e r / m a l l e t or using the Jackscrews (if provided). The amount of hori-zontal relocation required is the total of the horihori-zontal move calculation (bottom of Sheet 2).
VERTICAL MOVE
Before m o v i n g the equipment vertically, it is important that the vertical thermal expansion be taken into consideration. The preceeding vertical move c a l c u l a t i o n s are based on pump and driver shafts being set on the same p l a n e . Refer to General Arrangement Notes and/or driver instructions for r e c o m m e n d e d cold vertical setting (if thermal expansion is a f a c t o r ) .
£'9 TOP VIEW
C O U P L I N G
DIRECTION OF SHIFT DRIVER
(MOVABLE)
DIAL INDICATORS AT DRIVER FEET
The shims between the e q u i p m e n t feet and mounting surface should be clean and dry. This is especially critical for purcps in service for some time and need to be r e a l i g n e d . W a t e r , d i r t and rust may change the height of the shim pack over a period of t i m e . Shims should be made large enough to support the weight of the equipment on its mounting foot. Do not use many thin shims as this may result in a spongy mounting.
Move the equipment vertically by adding or removing the calculated thickness of shims. Torque equipment hold down bolting to required values.
It is recommended, the completed "ALIGNMENT DATA SHEET" be retained as part of your, permanent maintenance file.
CHECK COUPLING ALIGNMENT
The angular and offset coupling alignment must be rechecked. 1. Coupling faces are to be parallel within .001" TIK.
2. Coupling outside diameters are to be aligned within .003" TIR, 3. "Bump" the motor and check motor rotation,
ASSEMBLE AND LUBRICATE COUPLING
1. Assemble and l u b r i c a t e coupling per the manufacturer's instructions included in "Section 8"_of thi3 manual,
2. Install coupling guard, DOWEL PUMP AND DRIVER
A. Cold Pumps (Below 200 Degrees F.)
Pump hold down b o l t s are to be. torqued to the proper value and dowel pins are put in two (2) feet (diagonally opposite).
B. Hot Pumps
Pumps handling liquid-s of 200 Degrees F. and over are designed to permit the casing to expand with temperature away from coupling end of pump.
The units that come under this classification must have the pump supports or feet dowelled to the b a s e p l a t e at the coupling e n d . This maintains the coupling gap at the desired amount.
RECOMMENDED SHIM DESIGN
NOTE
The pump feet at the opposite end are held from moving vertically by the use of a self locking n u t . The clearance between the base of the nut and the top of the pump foot should be .002".
The h o r i z o n t a l m o v e m e n t is controlled by a "Gib Block" running parallel to the l e n g t h of the pump at each of the outboard feet. The "Gib Blocks" are bolted and dowelled to the baseplate at the time of mounting at the factory. A .010" gap is maintained between the "Gib Block" and pump foot,
IMPORTANT
The self locking n u t s which hold the pump from moving in a vertical motion a r e c l a m p e d tight to the pump foot at time of shhipment. The .002" clear-ance must be established at time of installation.
FLEX LOCK NUT
PUMP FOOT
002" CLEARANCE
GIB BLOCK
C, Pump Driver
Refer to d r i v e r o u t l i n e d r a w i n g a n d / o r driver instructions for dowelling information.
HOT ALIGNMENT CHECK
A hot c h e c k can only be made after the unit has been in operation a suffic-ient l e n g t h of time to assume its NORMAL operating temperature and condi-t i o n s , If condi-the unicondi-t has been p r o p e r l y cold s e condi-t , condi-the offsecondi-t misalignmencondi-t w i l l be within ,003" TIR and the angular misalignment will be within ,001" TIR when in operation. If not make adjustments.
W A R N I N G 8
DO NOT A T T E M P T ANY M A I N T E N A N C E , I N S P E C T I O N , REPAIR OR C L E A N I N G IN THE VICINITY OF ROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN PERSONAL INJURY TO OPERATING PERSONNEL.
M U S T BE IN THE "OFF" P O S I T I O N , L O C K E D A N D T A G G E D TO P R E V E N T INJURY TO
NAME
ALIGNMENT DATA FOR FUMP TEMPERATURE
ALIGNMENT DATA SHEET HORIZONTAL PUMPS
DATE
SHEET 1 OF 2 TIME
SERIAL NUMBER
PART 1 ANGULAR ALIGNMENT CHECK
POSITION 00 90° 100° 270° TOTALS V E TOP.
Open At
R T I C A L BOTTOM R T I C A L Averace DIFF. (T-B) H O•RIGHT SIDE Open At
R I
•LEFT SIDE Average
Z O N DIFF. (R-L)
• Right au,d Left are determi ned when viewing the driver hub from the pump.
PART 2 OFFSET ALIGNMENT CHECK
TOTAL INDICATOR READINGS
VIEW OF DRIVER HALF COUPLING HUB VIEWED" FROM PUK?
Vertical Offset" = Bottom - Top = " = =
Misalignment 2
Horizontal Offset = ' Right - Left = = = Misalignment • 2
RULES TO APPLY TO THE RESULTS BELOW: With Indicator Mounted On The Driver Neg = Driver Coupling Is High & Left Pos = Driver Coupling Is Low & Right
Driver Coupling Is (Circle Correct High Or Low And Right Or Left
One):
ALIGNMENT DATA SHEET
HORIZONTAL PUMPS SHEET 2 OF 2
TOP VIEW ( H O R I Z O N T A L M O V E )
VERTICAL ANGULAR MOVE CALCULATION MOVE DRIVER TO CORRECT ALIGNMENT
Gy X L J Driver Inboard Pedestal Shift
Driver Outboard Pedestal Shift
INBOARD DRIVE) KILS \ PEDESTAL SHIFT DIRECTION OUTBOARD DRIVER MILS PEDESTAL SHIFT DIRECTION OFFSET MOVE • ANGULAR MOVE TOTAL
HORIZONTAL ANGULAR MOVE CALCULATION . HOVE DRIVER TO CORRECT ALIGNMENT
GH x LI Driver Inboard Pedestal Shift =
Driver Outboard Pedestal Shift =
INBOARD DRIVE KILS R PEDESTAL SHIFT DIRECTION OUTBOARD DRIVER KILS PEDESTAL SHIFT DIRECTION OFFSET MOVE ANGULAR MOVE TOTAL 2" 1 3 3 H S I D E VIEW ( V E R T I C A L M O V E )
rvj I
(
3<£T
PIPING •
SUCTION AND DISCHARGE PIPING
These units are furnished for a particular service condition. Changes in the hydraulic system may affect performance adversely. This is especially true if the changes reduce the pressure at the suction or if the liquid temperature is increased. In case of doubt contact the nearest Ingersoll-Rand Office.
Suction and dischrge piping should be of ample size, be installed in direct runs, and have a minimum of bends,
NOTE
PROVISION. MUST BE MADE TO SUPPORT PIPING EXTERNAL TO THE PUMP TO- PREVENT EXCESSIVE NOZZLE LOADS AND MAINTAIN PUMP-DRIVER ALIGNMENT.
Install a check valve and a gate valve in the discharge pipe on the pump. When the pump is stopped, the check valve will protect the pump against excessive pressure and will prevent the pump from running backward. The check valve should be installed between the gate valve and the pump nozzle in order.to permit its inspection. The gate valve is also useful in priming and starting the pump.
Keep the suction pipe short and direct. Use a suction pipe at least one size larger than the pump suction nozzle. Keep the suction pipe free of all air pockets.
IMPORTANT
A SPOOL PIECE S H O U L D BE I N S T A L L E D IN SUCTION L I N E ' S O T H A T THE S U C T I O N SCREEN MAY BE INSTALLED AND REMOVED.
BY PASS LINE
W A R N I N G
OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY PASS MAY BE REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT PUMP DAMAGE. REFER TO LOCAL INGERSOLL-RAND BRANCH TO DETERMINE IF A BY PASS IS REQUIRED. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 25 PERCENT OF THE DESIGN OPERATING POINT OF THE PUMP. Refer to General Ar-rangement Drawing Notes and nameplate rating.
MINIMUM FLOW
W A R N I N G
OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY-PASS LINE IS REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT PUMP DAMAGE. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 210 GPM.
Customer to install a yarway "ARC" valve (Automatic Recirculation Control), furnished by Ingersoll-Rand Company per drawing 62061460 in discharge line between pump discharge and first valve.
Customer to provide a 1.50" by-pass line from y a r w a ynA R C " valve to source of suction. A paddle orifice, furnished by Ingersoll-Rand Company per drawing no. X-150D438JX3,.is to be installed in by-pass line as close to source of suction as possible to prevent vaporization in line.
WARM-UP LINE NOTE
Customer to install 1.00 muffled type orifice furnished by Ingersoll-Rand Company per drawing Y-3HMTA438AX1 in line, by-passing main discharge valve. Direction of flow is from discharge to suction at 20 GPM,
STUFFING BOX
Customer to inject 1/2 GPM cooling water at 10 PSI above suction pressure for each box,
LUBE OIL COOLER
Customer to inject 3,5 GPM of cooling water at 85.Degrees F. and 150 PSI maximum to lube oil cooler inlet.
SUCTION SCREEN i In a new installation,- great care should be taken to prevent dirt, scale and
welding beads from entering the' pump, as it is particularly important to protect the numerous close running fits from abrasive matter present in new piping.
The suction system should be t h o r o u g h l y f l u s h e d before i n s t a l l i n g the suction strainer and making .up suction piping to the pump.
The suction strainer should be installed as close to the pump suction as possible.
THE OPEN AREA OF THE STRAINER SHOULD HAVE A MINIMUM OF A 3 TO 1 RATIO TO THE AREA OF THE PUMP SUCTION.
The Ingersoll-Rand standard for suction strainers consists of a conical shaped steel plate. The plate has 1/16" perforations and is of sufficient size and thickness for the required flow.
Other type strainers may be used as long as they conform to the requirements stated above.
Pressure gauges should be installed on both sides of the screen so that the pressure drop across the screen can be measured.
When the unit is being started, the gages on each side of the screen should be carefully watched. An increase in the differential pressure between the two gauges indicates that the screen is becoming clogged with dirt and scale. At this point, the pump should be shut down, and the screen cleaned and replaced. When the scale and dirt have been removed from the system as indicated by no further pressure from across ther screen, it may be removed. The screen should be used until all foreign material is removed from the system.
COUPLING ALIGNMENT CHECK
Refer to the section entitled "SHAFT/COUPLING ALIGNMENT" and perform a coupling alignment check as outlined. This check is recommended to insure the alignment has not been disturbed during the grouting of the bedplate or while installing suction and discharge piping.
SECTION 3 OPERATION
: TECHNICAL DATA
These pumps are furnished for a particular service condition. Changes in the hydraulic system may affect the pump's performance adversely. This is especially true if the changes reduce the pressure at the suction flange or if the liquid t e m p e r a t u r e is i n c r e a s e d . In case of d o u b t , contact the nearest Ingersoll-Rand Office,
EFFECTS OF SPECIFIC GRAVITY
The capacity and total head in feet of liquid developed by a centrifugal pump are fixed for every point on the curve and are always the same for the same speed. Neither capacity nor total head will be affected by a change in the specific g r a v i t y of the liquid p u m p e d . However, since the developed pressure is PSIG (pounds per square inch) and the brake horsepower to drive the pump are a function of the specific gravity of the liquid, both will be affected in direct proportion by any change in specific gravity. Therefore, a change in -specific gravity will affect the discharge gage pressure. Any c h a n g e s should be n o t e d , in that they may o v e r l o a d the purap'3 d r i v e r . EFFECTS OF VISCOSITY
The pump is designed to deliver rated capacity at rated head for a liquid with a particular viscosity.
When contemplating operation at some viscosity other than for which the pump w a s o r i g i n a l l y d e s i g n e d , the changed c o n d i t i o n s should be r e f e r r e d to Ingersoll-Rand Company for our recommendations,
CHANGING PUMP SPEED
Changing the speed of a centrifugal pump changes the capacity, total head and brake h o r s e p o w e r . The capacity will vary in a direct ratio with the s p e e d , w h e r e a s the total head will vary as the ratio of the speed squared. The brake h o r s e p o w e r will vary as the ratio of the speed cubed .except in c a s e s where the speed change also r e d u c e s the efficiency of the p u m p . NET POSITIVE SUCTION HEAD (NPSH)
Any l i q u i d , hot or c o l d , m u s t be pushed into the impeller of the pump by some absolute p r e s s u r e , such as the atmosphere or the vessel pressure from which the pimp takes its' suction,
The head in feet of liquid necessary to push the required flow into the pump is called the Net Positive Suction Head. This value, more commonly called N P S H , is measured above the vapor pressure of the liquid at the pumping temperature.
There are two kinds of NPSH: the NPSH required by the pump, as shown on the pump curve, is the head needed to cover the losses in the pump suction; the second NPSH is that available in the system taking into account friction l o s s in auction p i p i n g , v a l v e s , f i t t i n g s , e t c . In all c a s e s the NPSH A v a i l a b l e , measured above vapor pressure, must exceed the NPSH Required in order to push the liquid into the pump,
OPERATING PRECAUTIONS
W A I N I N G
DO NOT WIPE DOWN IN THE V I C I N I T Y OF ROTATING PARTS, IF UNUSUAL NOISE OR VIBRATIO.NS OCCUR, SECURE THE PUMP AS SOON AS POSSIBLE.
W A R N I N G
THE UNIT MUST NOT BE O P E R A T E D U N L E S S COUPLING GUARD IS BOLTED IN PLACE. F A I L U R E TO OBSERVE THIS WARNING COULD RESULT IN INJURY TO OPERATING PERSON-NAL.
1. Never operate the pump with suction valve closed.
2. Never operate pump u n l e s s it is c o m p l e t e l y filled w i t h liquid and vented.
3. Never operate the pump unless a liquid source is availble. PRE OPERATIONAL CHECKS
The following s t e p s should be followed at initial start-up and after the equipment has been overhauled:
1. Ensure pump and piping is clean. Before putting the pump into opera-tion,- it should be thoroughly flushed out to remove the rust preventive as w e l l as any foreign matter which may have accumulated during installation. Take all possible care not to contaminate your system,
2. Clean and flush l u b r i c a t i o n s y s t e m . Fill reservoir with oil to the proper l e v e l . Ensure lube system is o p e r a b l e . (Refer to "LUBRICATION" section,)
3. Ensure pump r o t o r is p r o p e r l y aligned within casing (refer to "MAIN-TENANCE" section).
4. Turn pump rotor by hand or w i t h strap wrench to m a k e sure it turns freely.
5. Check Stuffing Box
A. If pump is equipped with a mechanical seal, ensure it is properly assem-bled and tightened (refer to "STUFFING BOX" section).
CAUTION
HOST CARTRIDGE SEALS ARE EQUIPPED WITH A SPACER BETWEEN THE GLAND PLATE AND DRIVE COLLAR. THIS SPACER MUST BE REMOVED BEFORE STARTING UNIT.
B. If pump is equipped with a packed b o x , insure box is properly packed (refer to "STUFFING BOX" section).
6. Ensure coupling is properly aligned and lubricated, and pump and driver is properly dowelled (refer to " S H A F T / C O U P L I N G ALIGNMENT" p r o c e c u r e ) . 7. Ensure coupling guard is in place.
8. Check torque of all bolting and plugs for tightness. INITIAL START UP PROCEDURE
1. Close discharge valve if valve is not already closed.
2. Prepare the driver for start up in accordance with the manufacturer's instructions,
3. Warm-Up Pump
Avoid severe thermal shocks to the pump as a result of sudden liquid temper-ature c h a n g e s , The pump m u s t be p r e h e a t e d prior to s t a r t - u p . Unless otherwise specified the external temperature of the casing must be within
100 Degrees F. of the temperature of the liquid to be pumped at time of start-up. Due to the heavy metal sections, the casing will lag the liquid temperature during such changes, and severe temperature stresses and subse-quent misalignment of machined fits may result. Pre-heating is accomplished by circulating a small amount of hot, fluid through the casing by utilizing vents, drains or by pass from discharge. Preheat pump slowly at a rate not to exceed 100 Degrees F. per hour.
Prime pump and ensure pump suction valve is open. C A U T I O N
I
BEFORE STARTING OR WHILE OPERATING THE PUMP, THE CASING AND SUCTION LINE MUST BE COMLETELY FILLED WITH THE LIQUID BEING PUMPED. THE ROTATING PARTS DEPEND ON THIS 'LIQUID FOR LUBRICATION AND THE PUMP MAY SEIZE IF OPERATED WITHOUT LIQUID.
5. Ensure pump recirculating line (if required) is open, clear and free of obstructions.
6. Check that pump is vented by observing leakage from casing vent and seal piping vent. Close vent when liquid is emitted,
7A. If pump is equipped with a mechanical seal, make sure seal piping is turned on.
7B. If pump is equipped with a packed box; turn on cooling water to lube oil cooler (when s u p p l i e d ) , stuffing box j a c k e t and s m o t h e r i n g g l a n d . 8. Start auxiliary oil pump.
9. Check pump rotation by starting unit momentarily. The direction of rotation is clockwise when facing pump shaft from coupling e n d . Note the pump coasts to a gradual stop.
IF PUMP STOPS A B R U P T L Y WHEN DRIVER IS SHUT D O W N , I N V E S T I G A T E FOR PUMP BINDING. TAKE NECESSARY REMEDIAL ACTION BEFORE RESUMING OPERATION,
10A. Starting the driver (motor driven)
Prepare the d r i v e r for start up in accordance with the m a n u f a c t u r e r ' s instructions.
Start the driver.
10B, Starting the driver (turbine driven)
Prepare the turbine for start up in accordance with the manufacturer´s instructions.
Start the turbine and bring it up to speed quickly.
11. As soon as pump is up to rated speed, slowly open discharge valve. This will avoid a b r u p t c h a n g e s in velocity and p r e v e n t s u r g i n g in the suction line.
12. Check to see that a u x i l i a r y oil pump has shut d o w n . Perform the operating checks.
IN THE INTEREST OF OPERATOR SAFETY THE UNIT MUST NOT BE OPERATED ABOVE THE NAMEPLATE CONDITIONS. SUCH OPERATION COULD RESULT IN UNIT FAILURE CAUSING INJURY TO OPERATING PERSONNEL. CONSULT INSTRUCTION BOOK FOR PROPER OPERA-TION AND MAINTENANCE OF THE PUMP AND ITS SUPPORTING COMPONENTS.
OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY-PASS MAY BE REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT PUMP DAMAGE. REFER TO LOCAL INGERSOLL-RAND BRANCH TO DETERMINE IF A BY-PASS IS REQUIRED. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 25 PERCENT OF THE DESIGN OPERATING POINT OF THE PUMP - REFER TO THE NAMEPLATE RATING.
Immediately after start up, and frequently during running check the follow-ing:
1, Check suction and discharge pressure gauges. C A U T I O N
OPERATING CHECKS
. W A R N I N G
3. Check for excessive leakage at stuffing box gland area,
A. If pump is equipped with a mechanical seal, there should be no visable leakage to the naked eye.
B. If p u m p is equipped with stuffing box packing, leakage should be 1 - 2 ounces per m i n u t e .
4. Check for unusual noises.
5. Check oil pressure at bearing inlets and sight flow indicators. 6. Check for adequate flow of cooling liquids,
7. After unit has been operated a sufficient length of time to reach normal o p e r a t i n g temperature, and conditon, the unit is to be shut down and a "HOT" c o u p l i n g a l i g n m e n t check must be made (refer to "SHAFT/COUPLING ALIGNMENT" procedure).
W A R N I N G
O P E R A T I O N OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE B E A R I N G S , BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT EXPOSING OPERATING PERSONNEL TO PERSONAL INJURY.
NORMAL START UP
The s t a r t i n g p r o c e d u r e to be f o l l o w e d f o r normal start up is the same as t h a t for i n i t i a l starting with the exception that Steps 9 does not have to be repeated.
'SECURING THE PUMP IA. Motor Driven.
De-energize driver circuit. IB, Turbine Driven
S t o p the t u r b i n e d r i v e n p u m p s by m a n u a l l y tripping, the o v e r s p e e d trip. 2. The pump should be shut d o w n r a p i d l y to protect the internal wearing parts which are lubricated by the liquid being pumped.
L u b r i c a t i o n is r e d u c e d w h e n a p u m p is s t o p p e d slowly and s e i z u r e could result.
NOTE
If pump s t o p s a b r u p t l y when d r i v e r is shut d o w n , i n v e s t i g a t e for pump binding, Take necessary remedial action before restarting p u m p .
3. Close, the pump suction and discharge valve.
4. Close valve in by pass line. •3-5
5. Turn off auxiliary oil pump and cooling liquid.
6. If pump is subjected to freezing temperatures the pump must be drained of liquid to prevent damage to pump.
•3-6
TROUBLE SHOOTING
Chart p r e s e n t s the probable troubles that can occur to the pump along with the probable causes and remedies for the troubles.
TROUBLE
TROUBLE SHOOTING CHART
CAUSE REMEDY
Insufficient capacity and/or pressure
Suction pressure or speed too low.
Incorrect direction of rotation.
Open suction valve wide. Check power supply for correct voltage.
Pump loses prime after starting
A. If pump is motor driven;
B. If pump is turbine driven;
Excessive amount of air or vapors in the fluid.
Foreign material in impeller Foreign material in suction line. Mechanical Defects: Impeller damaged. Sheared impeller keys. Broken or damaged coupling,
Insufficient liquid supply.
Refer to motor instruc-tion manual and re-connect motor leads.
Contact turbine manufac-turer.
Check suction system for air leakage and correct. Vent air.
Tighten flange bolts. Dismantle pump and remove any foreign material. Dismantle suction line and and remove foreign material.
Dismantle pump and cor-rect .
Ensure that suction valve is wide open. Check for proper liquid level. Excessive amount of air Check suction system for or vapors in the liquid, air leakage and correct. Clogged impeller, Dismantle pump and
cor-rect.
Pump vibration
Suction pipe clogged. Loose mounting or coupling bolts.
Remove foreign material. Tighten bolts.
TROUBLE, CAUSE Coupling.
Pump vibration (Continued)
Air or gas in
liquid-Foreign material in impeller causing unbalance. Mechanical Defects: Shaft bent. Bearings worn.. Pump overloads driver Speed too high.
A. If pump is motor driven:
B. If pump is turbine driven:
Pump bearings seize or rotating element binds.
Pump stops abruptly
High pump thrust bearing temperature rise
Pump binding at running fits.
Improper lubrication.
Rotor not centered in volutes,
Insufficient oil. Contaminated oil.
High oil temperature.
REMEDY
Check alignment and correct.
Vent air and check suc-tion for leaks. Tighten flange bolts.
Dismantle pump and remove any foreign material.
Dismantle pump and re-place part or parts
caus-ing vibration.
Refer to motor instruc-tion manual and check power supply for correct frequency.
Check steam pressure to turbine.
Dismantle pump and re-place part or parts caus-ing seizures, or bindcaus-ing. Dismantle pump and re-align rotor in casing. Replenish oil with proper grade lubricant.
Check rotor centraliza-tion .
Add oil.
Drain and clean reser-voir .
Refill with clean, oil. Connect cooling liquid to lube oil cooler. Stuffing box gland
(when used) exces-sive leakage
Gland nuts loose.
Packing worn.
Tighten gland nuts.
TROUBLE CAUSE REMEDY Mechanical seal gland
(when used) overheats
Pump is noisy
Insufficient cooling water to seal,
Mechanical seal not properly set. Check for cracked stationary face/rotating face. Cavitation.
Obstruction in seal water piping. Remove and clean.
v,
Refer to- "STUFFING BOX1' pages.
Check that pump is prim-ed, check for high suc-tion temperature, in-crease static head, check for obstruction in suc-tion line.
Tighten or replace defec-tive part.
Loose parts.
• Noise in driver.
Check driver instruction book for trouble-shooting instructions.
Check driver with stetho-scope .
SECTION 4 LUBRICATION
LUBRICATION SYSTEM
W A R N I N G I
OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE BEARINGS, BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT EXPOSING OPERATING PERSONNEL TO PERSONAL INJURY. REFER TO LUBE OIL PIPING DRAWING.
Oil is supplied to the pressure lubrication system by one of the two (2) oil pumps. The main oil pump is mounted on a support head (6-172) which is bolted to the thrust end bearing body and cap (6-021/023).and is driven by the main pump shaft via a Lovejoy coupling (6-185).
A motor driven auxiliary oil pump is furnished to supply oil to the pressure lubrication system during starting and stopping periods. At time of start up, the auxiliary oil pump must be started manually. When the main oil pump supplies the required oil pressure, the auxiliary oil pump will automatical-ly stop by action of an auxiliary oil pump pressure switch mounted in the lubrication system. The auxiliary oil pump will remain in the standby state until such time as the lubricating oil pressure falls to a pre-determined value, at which time the auxiliary oil pump pressure switch will automat-ically start the auxiliarly oil pump.
During operation oil is taken from the oil reservoir by the oil pump and is directed to the oil cooler. From the oil cooler the oil is directed through the oil filter and is then supplied to the pump and driver bearings. A back pressure relief v a l v e m o u n t e d in the lubrication system m a i n t a i n s the required system oil pressure of 15 PSI, The system is additionally equipped with a low pressure, pressure switch which trips the unit when the oil pressure in the lubrication system decreases to a pre-determined value or prevents the starting of the unit until adequate oil pressure is establish-ed. A gravity assisted, sloped oil return line conducts the oil from the pump and driver bearings back to- the system reservoir.
A check valve is mounted in the auxiliary oil pump discharge line to prevent oil from returning to the oil reservoir when the main oil pump is running and the auxiliary oil pump is shut down.
The oil reservoir has a capacity of 35 gallons.
The functions and control pressures of the pressure switches mounted in the lubrication system are as follows: (Refer to your Lube Piping Drawing,) PRESSURE SWITCH NO. 8
Starts the auxiliary oil pump on falling oil pressure (10 PSI) and stops the auxiliary oil pump on rising pressure (20 PSI).
PRESSURE SWITCH NO. 7
Permits the start, of main pump driver at adequate oil pressure (11 PSI), Trips main punp driver on falling oil pressure (8 PSI),
MAKE PERIODIC INSPECTIONS
Remember that oil requires frequent replenishment at normal temperatures and very frequent, replenishment at high temperatures. Oil is always subject to gradual deterioration from use and contamination from dirt and moisture. In time, the accumulated sludge will be harmful to the bearings and cause p r e m a t u r e w e a r . For this r e a s o n , draining and flushing with a safety solvent are necessary at six month intervals.
OIL SPECIFICATIONS
The ideal bearing lubricant is a straight, well refined, neutral mineral oil, preferably of the turbine type. It should not contain acid, chlorine, sulphur or more than a trace of free alkali. It is suggested that the oil conform to the following physical characteristics based on tests by ASTM Standard Methods. ASTM STANDARDS • 4 Oil Characteristics Naphthene Base Paraffin Base Flash Point Saybolt Viscosity 100 Degrees F. 300 Degrees F. Min. 150 (Min.) Seconds 200 (Max.) Seconds 360 Degrees F. Min. 140 (Min.) Seconds 185 (Max.) Seconds Pour Point 5 Degrees F. Max. 35 Degrees F. Max.
In a majority of instances SAE number 10 motor oil will meet the above specifications,
LUBRICANT MUST BE COMPATIBLE WITH ALL PARTS REQUIRING LUBRICATION.
Refer to Lube Piping Drawing and Notes for information pertaining to your system.
OIL TEMPERATURE
Oil' temperature entering the plain/thrust end bearings should be maintained between 60 Degrees F. (16 Degrees C.) and 160 Degrees F. (71 Degrees C). Alarm temperature is 170 Degrees F. (77 Degrees C.) with shut down tempera-ture set at 180 Degrees F. (82 Degrees C.).
If bearing oil temperature exceeds the above mentioned limits, cooling liquid to the lube oil cooler will have to be increased.
IMPORTANT
If necessary, to maintain the minimum bearing oil temperature at start u p , oil in the lube oil reservoir may have to be heated or drained and replaced with warm oil.
CLEANING THE LUBRICATION SYSTEM PRIOR TO OPERATION
Before operating the pump, the lubrication system should be thoroughly cleaned to remove any f o r e i g n matter that m a y h a v e a c c u m u l a t e d during shipment, storage or installation.
To clean the lubrication system proceed as follows:
1, Remove the bearing caps, bearing linings, thrust shoes and drain plugs, (Refer to "MAINTENANCE" section.)
2, Flush out the bearing bodies with kerosene.
3, Wash the bearing linings and thrust shoes with a suitable solvent. Flush the entire lubrication system with flushing oil. Flushing oil should be compatible with lubricating oil that will be used.
5. During flushing operation examine the piping for leaks and correct as necessary. Also check for any obstructions that will interfere with free flow of oil to the bearings.
SECTION 5
STUFFING BOX PACKING
Your pump is shipped without packing in the stuffing boxes. A complete set of packing is shipped in a separate box attached to the pump crate. Pre-serve the wrapper on the packing so that r e p l a c e m e n t s can be o r d e r e d accordingly.
C A U T I O N
STUFFING BOXES THAT ARE PACKED TOO TIGHT OFTEN RESULT IN BURNED PACKING, SCORED SHAFT SLEEVES AND POSSIBLE ROTOR SEIZURE.
Eight (8) rings of 1/2 inch wide preformed packing (4-064) and a seal cage (when used) (4-014) must be installed in each stuffing box (refer to pump "Assembly Drawing" for proper sequence).
This packing is specifically designed to have an initial clearance between the I.D. of. the packing ring and 0.D, of the shaft sleeve. As the packing is gradually compressed by tightening the gland nuts, this clearance is decreased thus reducing the leakage, rate. In this fashion, the leakage can be precisely controlled without having the packing burn, cut off the leakage and damage the shaft sleeve.
Properly packed stuffing boxes are a must for efficient pump operation. Note the directions with the packing and proceed as follows:
LIQUID ESCAPING HERE DOES NOT PROPERLY LUBRICATE GLAND TOO FAR OUT GLAND CORRECTLY POSITIONED IMMEDIATELY AFTER NEW PACKING INSTALLATION SHAFT PACKING SHAFT SLEEVE INCORRECT CORRECT
TYPICAL VIEW OF CORRECT AND INCORRECTLY PACKED STUFFING BOX
PACKING INSTALLATION
1. Install one ring of packing. Note that a clearance should exist between the shaft sleeve and the packing I.D., which insures a proper liquid flow for cooling and lubrication. Intimate contact between packing ring 0,D. and stuffing box I.D. should be o b t a i n e d w i t h o u t forcing p a c k i n g into the stuffing box. If too large, trim the butts slightly to obtain a good fit without overlapping. Press this ring of packing into stuffing box as far as it will go by installing gland halves (4-0165 and bearing down until gland contacts stuffing box. Remove gland halves.
NOTE
The successive packing ring j o i n t s m u s t be staggered a p p r o x i m a t e l y 90 degrees from the proceeding ring.
2. If seal cage (4-014) is used, install and seat the next three (3) rings of packing (4-064), the seal cage (4-014) and the final four (4) rings of packing (4-064). Install gland halves to seat each ring, one at a time, and once again push them as far into the box as they will g o . Remove gland halves,
NOTE
The packing cross-section may be slightly rectangular and, thus, may not allow insertion of all p a c k i n g r i n g s , No force should be e x e r t e d to compress the rings. After the exterior ring is in place, at least 1/8 inch clearance should exist between the face of the exterior ring and the face of the stuffing box,
3. Install the gland halves (4-016) and bolt together. Install the gland washers (4-246A) and nuts (4-279A). With the gland true to the shaft, hand tighten the gland nuts until the gland contacts the last ring of packing. Do not attempt to tighten gland nuts until suction pressure is applied to the pump, Following application of suction pressure to pump, allow liquid to flow freely from stuffing box for a short period of time. This will provide time for the packing to absorb liquid which will provide lubrication during start up and protection against burn out.
4. Operate the unit for a minimum of one half hour, allowing the gland to leak f r e e l y . This is n e c e s s a r y to " b r e a k - i n " the p a c k i n g and p r e v e n t over-heating. After "break-in" gradually reduce gland leakage with the pump in operation. Leakage will decrease when pump, is rotating.
5. If the last ring of packing was left out in Step 2 above, secure pump and install the additional ring at this time, or when convenient. Do not force packing rings into stuffing box at any time.
6. Continue o p e r a t i o n of the pump gradually reducing the leakage. If the flow d e c r e a s e s too r a p i d l y during the procedure, slack off gland nuts to increase f l o w . If leakage is stopped, secure pump for a short period, to a l l o w gland to c o o l . Slack off gland n u t s a p p r o x i m a t e l y 1/2 turn and r e s t a r t . Repeat as n e c e s s a r y , until m i n i m u m required leakage is re-established.
C A U T I O N
WHEN M A K I N G G L A N D A D J U S T M E N T S , NEVER TURN GLAND NUTS MORE THAN ONE OR TWO F L A T S , S U F F I C I E N T TIME SHOULD BE ALLOWED BETWEEN EACH ADJUSTMENT SO THAT C O M P R E S S I O N OF THE PACKING BY THE GLAND CAN BE REFLECTED THROUGH ALL OF THE PACKING RINGS.
7. If l e a k a g e is cut o f f c o m p l e t e l y and smoke issues from stuffing box, secure the pump, remove packing and repack with a new set,
8. Packing m u s t be replaced when gland adjustment can no longer control leakage.
C A U T I O N
PACKING MUST ALWAYS BE REPLACED AS A COMPLETE SET. STUFFING BOX PACKING REMOVAL
1. Remove gland nuts (4-279A), washers (4-246A) and packing gland (4-016). 2. Remove old p a c k i n g ( 4 - 0 6 4 ) and seal cage (4-014) with a packing hook. 3. Saturate a- strong absorbent piece of cloth with solvent. Using a piece of wood push cloth down and around inside of stuffing box until it is clean.
4. Check s h a f t sleeve (4-008) for wear. A small mirror and a flashlight c a n be used to check the condition of the l e n g t h of the shaft s l e e v e . If scoring is .010 inch to ,020 inch deep, the shaft sleeve must be replac-ed.
SECTION 6 MAINTENANCE
