(6"-36") MXR Bearings IOM

(6"-36") MXR Bearings IOM
Installation, Operation,
and Maintenance Manual
AF (6"-36") MXR Bearings
Table of Contents
Table of Contents
Introduction and Safety .......................................................................................................... 4
Introduction ............................................................................................................................. 4
Safety ...................................................................................................................................... 4
Safety terminology and symbols ............................................................................................. 4
Environmental safety .............................................................................................................. 5
Environmental safety .............................................................................................................. 6
User safety .............................................................................................................................. 6
Precautions before work ......................................................................................................... 7
Precautions during work ......................................................................................................... 7
Safety regulations for Ex-approved products in potentially explosive atmospheres ................ 7
Product approval standards .................................................................................................... 8
Product warranty ..................................................................................................................... 8
Transportation and Storage .................................................................................................
Inspect the delivery ...............................................................................................................
Inspect the package ...........................................................................................................
Inspect the unit ...................................................................................................................
Transportation guidelines ......................................................................................................
Pump handling ...................................................................................................................
Lifting methods ...................................................................................................................
Storage guidelines ................................................................................................................
Pump storage requirements ...............................................................................................
Uncrating / De-Skidding ........................................................................................................
10
10
10
10
10
10
10
11
11
12
Product Description .............................................................................................................. 13
General Description .............................................................................................................. 13
Nameplate information .......................................................................................................... 15
Installation .............................................................................................................................
Preinstallation .......................................................................................................................
Foundation Requirements ..................................................................................................
Sub-base Leveling ..............................................................................................................
Spring Mounted Base .........................................................................................................
Remove Spring from Spring Pocket ...................................................................................
Pipe support design requirements ........................................................................................
Install the pump to the piping ................................................................................................
Connection of Piping .............................................................................................................
Drive Alignment Procedures .................................................................................................
V-Belt Drive (Sheaves) .......................................................................................................
Gear Drive (Couplings) .......................................................................................................
Impeller Alignment ................................................................................................................
Align the impeller (Type 1) ....................................................................................................
Align the impeller (Type 2) ....................................................................................................
Rotation Check .....................................................................................................................
Impeller alignment worksheet ...............................................................................................
17
17
17
18
20
23
24
25
27
28
29
31
34
35
36
36
38
Commissioning, Startup, Operation, and Shutdown .........................................................
Preparation for start-up .........................................................................................................
Start the Pump ......................................................................................................................
Operation ..............................................................................................................................
Shut down the pump .............................................................................................................
Final Alignment .....................................................................................................................
39
39
43
45
47
47
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
1
Table of Contents
Maintenance ...........................................................................................................................
Preventative Maintenance ....................................................................................................
Maintenance schedule ..........................................................................................................
Bearing Maintenance ............................................................................................................
Oil Lubricated Bearings ......................................................................................................
Grease lubricated bearings (6-18 inch sizes only) ..............................................................
Shaft-seal maintenance ........................................................................................................
Mechanical-seal maintenance ............................................................................................
Packed stuffing-box maintenance ......................................................................................
Packed Stuffing Box ..............................................................................................................
Labyrinth Seals .....................................................................................................................
Connection of Sealing Liquid ................................................................................................
48
48
48
49
49
50
51
51
51
52
53
53
Disassembly .......................................................................................................................... 55
Pump Disassembly Precautions ........................................................................................... 55
Disassembly precautions ...................................................................................................... 55
Remove the coupling guard .................................................................................................. 56
Tools required ....................................................................................................................... 57
Disassemble the guard / drive (v-belt configuration) ............................................................. 57
Disassemble the back-pullout / elbow ................................................................................... 61
Disassemble the back-pullout elbow with casing .................................................................. 61
Remove the liner (option) ...................................................................................................... 62
Remove the standard impeller .............................................................................................. 62
Remove the sealed impeller .................................................................................................. 62
Remove mechanical seal with optional adapter .................................................................... 63
Disassemble the packed box ................................................................................................ 64
Remove the drip pan ............................................................................................................. 64
Disassemble the bearing housing ......................................................................................... 65
Remove the bearing (1MXR-3MXR configuration) ................................................................ 67
Remove the bearing (4MXR-6MXR configuration) ................................................................ 68
Disassemble the cooling coil (optional) sight glass / breather and plugs .............................. 69
Pre-assembly inspections ....................................................................................................
Inspect the elbow / casing / liner (options) ............................................................................
Inspect impeller vane ............................................................................................................
Inspect the shaft ....................................................................................................................
Inspect the shaft sleeve ........................................................................................................
Inspect the mechanical seal / restrictor bushing ...................................................................
Inspect the stuffing box .........................................................................................................
Inspect the bearing housing ..................................................................................................
Inspect the bearings ..............................................................................................................
Labyrinth seals and O-rings ..................................................................................................
Critical axial flow dimensions and tolerances ........................................................................
70
70
70
71
71
72
72
72
73
73
73
Reassembly ........................................................................................................................... 75
Reassemble the cooling coil (optional) sight glass / breather and plugs ............................... 75
Reassemble the rotating element (1MXR-3MXR configurations) .......................................... 75
Reassemble the rotating element (4MXR-6MXR configurations) .......................................... 76
Reassemble the bearing housing .......................................................................................... 77
Reassemble the drip pan ...................................................................................................... 79
Reassemble the packed box ................................................................................................. 80
Reassemble the mechanical seal with optional adapter ....................................................... 81
Reassemble the standard impeller ........................................................................................ 81
Reassemble the sealed impeller ........................................................................................... 82
Reassemble the back-pullout elbow ..................................................................................... 82
Reassemble the back-pullout elbow with casing ................................................................... 83
Reassemble the back-pullout liner (option) ........................................................................... 83
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Table of Contents
Reassemble the drive / guard (v-belt configuration) .............................................................. 83
Reassemble the drive / guard (direct connect configuration) ................................................ 85
Troubleshooting .................................................................................................................... 88
Pump Troubleshooting .......................................................................................................... 88
Parts Listings and Cross-Sectionals ................................................................................... 93
Cross sectional drawing (shown with optional restrictor bushing adapter) ............................ 93
Parts list and materials of construction .................................................................................. 94
AF options ............................................................................................................................. 98
MXR bearing configurations .................................................................................................. 99
AF with separate casing ...................................................................................................... 100
Appendix .............................................................................................................................. 101
Bearing alignment ............................................................................................................... 101
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
3
Introduction and Safety
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could
cause death, serious personal injury, or damage to the equipment. This includes any modification to
the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• Do not change the service application without the approval of an authorized ITT representative.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe
proper decontamination procedures in order to eliminate the possible exposure to any hazardous or
toxic fluids. Wear the proper personal protective equipment. Potential hazards include, but are not
limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. You must handle
and dispose of pumped fluid in compliance with the applicable environmental regulations.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
4
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Introduction and Safety
Hazard levels
Hazard level
DANGER:
Indication
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE:
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area
Always keep the pump station clean to avoid and/or discover emissions.
Recycling guidelines
Always recycle according to these guidelines:
1. If the unit or parts are accepted by an authorized recycling company, then follow local
recycling laws and regulations.
2. If the unit or parts are not accepted by an authorized recycling company, then return them
to the nearest ITT representative.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the pumped fluid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
5
Introduction and Safety
Reference for electrical installation
For electrical installation requirements, consult your local electric utility.
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the manufacturer if it has been contaminated by any nuclear radiation. Inform
ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other sections of this manual.
6
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Introduction and Safety
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with
the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Safety regulations for Ex-approved products in potentially
explosive atmospheres
Guidelines for compliance
WARNING:
This manual clearly identifies accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply
heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this
manual.
If there are any questions regarding these requirements, the intended use, or if the equipment
requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
7
Introduction and Safety
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
•
All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
•
All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.
•
Any maintenance for Ex-approved products must conform to international and national
standards (for example IEC/EN 60079-17).
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the
nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
Product approval standards
Regular standards
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved
products.
8
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Introduction and Safety
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However,
should the need arise for a warranty claim, then contact your ITT representative.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
9
Transportation and Storage
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation guidelines
Pump handling
WARNING:
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or
subject it to shock loads as this can damage the internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the
pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
• All lifting must be done in compliance with all applicable regulations/standards.
• Assembled units and their components are heavy. Failure to properly lift and support this equipment
can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically
identified lifting points. Lifting devices such as hoist rings, shackles, slings and spreaders must be
rated, selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear
steel-toed shoes at all times.
10
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Transportation and Storage
Examples
Figure 1: Example of proper lifting method from sub-base
Figure 2: Example of proper lifting method of motor
Storage guidelines
Pump storage requirements
Storage requirements depend on the amount of time that you store the unit. The normal
packaging is designed only to protect the unit during shipping.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
11
Transportation and Storage
Length of time in storage
Upon receipt/short-term (less than six months)
Long-term (more than six months)
Storage requirements
• Store in a covered and dry location.
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
Uncrating / De-Skidding
Care should be taken when uncrating or de-skidding pumps. If shipment is not delivered in
proper order, and in accordance with the bill of lading, note the damage or shortage on both the
receipt and freight bill. Make any claims to the transportation company promptly. Instruction
books and sheets are included in the shipment - DO NOT DISCARD.
12
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Product Description
Product Description
General Description
The AF pump generates flow by the thrust or lift action of rotating axial vanes of the impeller.
Axial flow pumps generate high flow rates and low head which are ideal for re-circulation,
evaporator, and generator cooling systems. The AF has an elbow that directs the flow through
the suction and out the discharge end of the pump. It can be used in the top or end suction
configuration depending on the customer’s needs.
Refer to original factory documentation for the arrangement of your pump. The model AF is
based on (6) power ends and (12) hydraulic pump sizes. The first (3) power ends have ball
bearings, the others have taper and spherical roller bearings. Groupings are as follows:
Table 1: Pump Description
Power End
1MXR
2MXR
3MXR
4MXR
5MXR
6MXR
Inboard Bearing
Ball
Ball
Ball
Sphrcl Roller
Sphrcl Roller
Sphrcl Roller
Outboard Bearing
(2) Ang. Contact
(2) Ang. Contact
(2) Ang. Contact
Taper Roller
Taper Roller
Taper Roller
Pump Size
6", 8", 10"
12", 14"
16", 18"
20", 24"
700mm, 30"
36"
Elbow
The elbow is cast with 150# flat face suction and discharge flanges, it comes with an opening in
the rear for a back-pullout. The back-pullout consists of the bearing housing, shaft, and
impeller. The elbow has cast feet for mounting to a sub-base or it can be mounted directly in
the piping. It also comes with an optional elbow liner.
Elbow or Casing Liner (Optional)
An optional liner provides erosion and corrosion protection for longer elbow or casing life. It
may also come with a serrated inside diameter for pumping stringy material.
Back Pullout
The back-pullout is based on the (6) power ends listed previously. It consists of a bearing
housing, bearings, stuffing box cover, locknuts,
lockwashers, labyrinth oil seals, shaft, shaft sleeve (w/packing), oil slinger (20" ~36"), impeller,
keys, shaft washer, and a front and back foot.
Stuffing Box Cover
The cast stuffing box cover is used to close the rear of the elbow and provide a mounting
surface for a mechanical seal or stuffing box and gland. Inside it has a machined flat face with a
(3) or (4) bolt pattern to accept a stuffing box or standard cartridge mechanical seal. When
used with a mechanical seal it has a cast in 5 deg. taper bore opening to assist in ejecting
particles from the seal area. The cover comes with adjusting ears that allow for centering on the
shaft and also to center the impeller in the elbow.
Mechanical Seal Adapter (Optional)
An optional adapter is used when the mechanical seal requires a restrictor bushing. The
restrictor bushing is supplied with the mechanical seal.
Optional
Packed Stuffing Box / Sleeve
The stuffing box is cast and is separate from the elbow and stuffing box cover. It comes with a
replaceable wear sleeve that is keyed to the shaft. Included are 5 rings of packing and a lantern
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
13
Product Description
ring to seal the shaft area. Two flush ports provide packing lubrication. A gland is used for
packing adjustment. The stuffing box can also be modified to accept a mechanical seal if
required.
Casing
A sacrificial wear casing is provided on the 700mm and 36" sizes. Adjusting lugs are used to
center the casing relative to the impeller. The casing has 150# flanges for mounting to the
elbow and comes with an optional liner.
Impeller
The impeller is cast with (4) fixed vanes. It is machined with internal steps for easy assembly
onto the shaft. It comes configured for 0 or +5 degree, clockwise or counterclockwise rotation,
and top or end suction. The impeller is held in place with a shaft washer and bolts. The 700mm
and 36" impellers come with cover plates and o-rings, to seal them from the pumpage. The seal
prevents corrosion and allows for easy impeller replacement. The impeller is dynamically
balanced (double plane) per ISO 1940 to a quality grade G-16.
Shaft
The shaft is cantilevered into the pump elbow to eliminate the need for internal bearings. It is
designed to have small deflections, high critical speeds, and corrosion resistance. The shafts
are stepped for easy assembly with the impeller.
Bearings
The inboard radial bearing absorbs radial loads and aligns the pump shaft. It is either a ball or
spherical roller bearing, depending on pump size. The outboard thrust bearing absorbs thrust
loads and comes as either back-to-back angular contacts or a single taper roller bearing,
depending on pump size. Lubrication is by flood oil or grease, depending on customer
requirements.
Oil Cooling (Optional)
An oil cooling option is available on 12" and larger sizes. A coiled tube mounted inside the
bearing housing circulates water to cool the oil bath. It is attached to the bottom of the bearing
housing by a removable bottom plate and gasket. It is generally used when process
temperatures cause excessive heat build up in the bearing housing and or bearings.
Configuration and Drives
Most AF pumps are V-belt driven to allow for varying speeds. V-belts can be configured for side
by side, overhead, under-slung, or vertical operation. The pumps can also be configured with
gear reducers and or jack shafts for direct connect operation.
Maximum Sphere Size
The maximum solid size that the AF can pass depends on the pump size. The following are the
maximum sphere sizes for each pump:
Table 2: Maximum Sphere Size
Pump Size
Sphere Size
6"
1.5"
8"
2.0"
10"
2.5"
12"
3.0"
14"
3.5"
16"
4.0"
14
Pump Size
18"
20"
24"
700mm
30"
36"
Sphere Size
4.5"
5.0"
6.0"
6.0"
7.5"
9.0"
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Product Description
Nameplate information
Important information for ordering
Every pump has nameplates that provide information about the pump. The nameplates are
located on the bearing housing.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the bearing housing for most of the information. See Parts List for
item numbers.
Nameplate on the casing using English units
Nameplate field
S/N
MODEL
SIZE
STD. DIM.
HYRO PRESS PSI
FLOW
R.P.M.
MAX. DES. WORKING PRESS.,PSI
HEAD
MAT'L.
IMP. DIA.
CONT./ITEM NO.
MAX. DIA.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Explanation
Serial number of the pump
Pump model
Size of the pump
Standard ANSI dimensional code
Hydrostatic pressure at 100°F, in PSI
Rated pump flow in GPM
Rated pump speed, revolutions per minute
Maximum working pressure at temperature °F, in
PSI
Rated pump head, in feet
Material of which the pump is constructed
Impeller diameter, in inches
Customer contract or item number
Maximum impeller diameter, in inches
15
Product Description
Nameplate on the casing using Metric units
Nameplate field
S/N
MODEL
SIZE
STD. DIM.
HYRO PRESS
FLOW
R.P.M.
MAX. DES. WORKING PRESS. @°C
HEAD
MAT'L.
IMP. DIA.
CONT./ITEM NO.
MAX. DIA.
16
Explanation
Serial number of the pump
Pump model
Size of the pump
Standard ANSI dimensional code
Hydrostatic pressure at 38° C, in kg/cm2
Rated pump flow in m3/hr
Rated pump speed, revolutions per minute
Maximum working pressure at temperature °C, in
kg/cm2
Rated pump head, in m
Material of which the pump is constructed
Impeller diameter, in inches
Customer contract or item number
Maximum impeller diameter, in inches
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
Installation
Preinstallation
AF units are usually shipped completely assembled. Check all bolts and nuts on the entire unit
and make sure they are securely tightened.
If necessary install and adjust drive components per manufacturer’s recommendations
Equipment that will operate in a potentially explosive environment must be installed in
accordance with the following instructions.
All equipment being installed must be properly grounded to prevent unexpected static
electric discharge. If not, a static electric discharge may occur when the pump is drained and
disassembled for maintenance purposes.
Foundation Requirements
AF pump shall be located in a clean, dry area free from flooding. The area should provide
adequate space for operation, maintenance, inspection and repair, considering complete
disassembly and handling of equipment. The pump should have a supply of clean liquid for
packing or mechanical seal lubrication. The pump shall be positioned to provide the most
efficient pipeline system.
The AF pumps covered by these instructions may be designed to hang in the piping system,
furnished with spring loaded sub-base bolts, or have a sub-base designed to be anchor bolted
and grouted to the foundation.
The foundation must be substantial enough to absorb any vibration and form a permanent, rigid
support for the pumping unit to the degree that there shall not be any adverse movement or
settling over a long period of time.
Foundations for anchor bolted and grouted sub-bases are typically concrete with anchor bolts
cast in to secure the pump.
The most commonly used foundation bolts are the sleeve-type.
Sleeve-type bolts
Figure 3: Sleeve type bolts
1.
2.
3.
4.
5.
6.
Baseplate
Shims or wedges
Foundation
Sleeve
Dam
Bolt
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
17
Installation
J-type bolts
Figure 4: J-type bolts
1.
2.
3.
4.
5.
Baseplate
Shims or wedges
Foundation
Dam
Bolt
Sub-base Leveling
Grouted Base
When the unit is received with the pump and driver mounted to the sub-base, it should be
placed on the foundation and the coupling halves or V-belts disconnected (see Figure titled
Sub-base, top view). The coupling should not be reconnected until all realignment operations
have been completed. A recommended coupling alignment procedure is included in the
following sections.
Figure 5: Sub-base, top view
Figure 6: Sub-base, side view
1. The sub-base should be supported on rectangular metal blocks or on metal wedges having
a slight taper. There should be support blocks or wedges on both sides of each foundation
18
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
2.
3.
4.
5.
bolt. A gap of about 3/4" (19mm) to 1-1/2" (38mm) should be allowed between the subbase and the foundation for grouting, see Figure titled Sub-base, side view.
Adjust the metal supports or wedges until the shafts of the pump and driver and sub-base
are level. Check the coupling faces, as well as the suction and discharge flanges of the
pump, for horizontal and vertical position by means of a level. Check also for any internal
rubbing in the pump. Correct, if necessary, by adjusting the supports or wedges under the
sub-base as required. In most cases, factory alignment will be regained by shimming under
the sub-base alone. Provisions must be made to support the discharge piping independently from the pump to prevent excessive loads and maintain pump-driver alignment.
The sub-base should be level to within .125" (3 mm) over the length of the base and .0875"
(1.5 mm) over the width of the base. Bases anchored with conventional foundation bolts
use shims on both sides of the anchor bolts to level the base. The bolts which secure the
pump sub-base to the foundation should be 1/8" (3mm) – 1/4" (6mm) less in diameter than
the holes in the sub-base (hole size is shown on the certified installation drawing).
Clean outside areas of sub-base that will contact grout. Do not use oil-based cleaners
because grout will not bond to it. Refer to grout manufacturer's instructions.
Build a dam around foundation and thoroughly wet the foundation.
Figure 7: Build dam around foundation
1.
2.
3.
4.
5.
6.
Baseplate
Shims or wedges
Foundation
Sleeve
Dam
Bolt
6. Pour grout through the grout holes in the sub-base, up to level of dam. Remove air bubbles
from grout as it is poured by puddling, using a vibrator, or pumping the grout into place.
Non-shrink grout is recommended.
7. Allow grout to set.
8. Allow grout to set.
9. Allow grout to set at least 48 hours.
10. Tighten foundation bolts.
Figure 8: Tighten foundation bolts
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
19
Installation
Spring Mounted Base
The Figure: V-belt Driven AF pump on spring mounted sub-base, shows a V-belt driven AF
pump on a spring mounted sub-base. Sub-bases supported by spring pockets assure that the
pump remains level, regardless of vertical movement due to thermal pipe expansion during
operation.
1. Spring pockets
Figure 9: V-belt Driven AF pump on spring mounted sub-base
The following is a brief description of the spring pocket components and their function (see
Figure: Spring pocket components). The adjusting screw is used to compress or relax the
spring. Turning the screw causes the adjusting screw nut assembly to move vertically and
change the amount of force the spring exerts against the spring retainer, which is fastened to
the sub-base. The stop nut is to limit the vertical up motion of the sub-base in case part of the
load is removed from the pump unit when the system is cold. The jam nut keeps the stop nut
from turning during normal operation when the sub-base has been pushed down from the
thermal expansion. The adjusting screw holder is a bearing surface for the end of the adjusting
screw and serves to hold the end of the screw in a fixed location.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
1.
2.
3.
4.
5.
Adjusting screw
Jam nut
Stop nut
Spring retainer
Bolts and nuts
6.
7.
8.
9.
10.
Spring
Spring holder (welded to sub-base)
Adjusting screw nut assembly
Lubricate with oil
Adjusting screw holder
Figure 10: Spring pocket components
The adjusting screw was lubricated at the factory but should be re-lubricated with heavy
protective grease during the pump installation. The springs and other parts should be coated
with an agent to protect the surface from corrosion, and a heavy lubricant should be applied to
the adjusting screw holder pocket.
The following steps are used to set the springs and level the sub-base:
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
21
Installation
1. Place blocks under the sub-base, near each spring holder, and position the sub-base level
on the blocks. A small gap(approx. 1/16" or 1.6 mm) should exist between the flange of the
vertical pipe and the pump elbow with the gasket in place (see Figure: Blocks placed under
sub-base).
2. Install several flange bolts to help maintain alignment of the flanges.
Figure 11: Blocks placed under sub-base
WARNING:
Do not tighten bolts.
3. Position the adjusting screw holders, while the adjusting screw end is seated in the hole, in
the direction of the horizontal thermal expansion. This will allow the required horizontal
motion without having the adjusting screw nut assembly hit the walls of the spring holder.
Make sure there is sufficient clearance between the adjusting screw holder and the bottom
of the sub-base for vertical thermal expansion, this clearance is usually shown on the pump
installation drawing.
NOTICE: Each spring carries a share of the unit load but generally do not carry equal
loads. Each holder has a small "window" to check the spring coil spacing, which is an
indication of the relative load on the spring. The installation drawing may indicate the
approximate number of turns required for each spring location, especially if the unit uses
more than (4) springs. If necessary refer to Table: Spring rate information.
Table 3: Spring rate information
Spring Size
Wire Size
1
2
3
4
5
.812"
.750"
.532"
1.00"
.375"
Spring Rate
1140 #/in.
760 #/in.
560 #/in.
1000 #/in.
133 #/in.
Adjusting Screw Load Change per
Size
Full Turn
1-1/2”-6 UNC
190 #
1-1/2”-6 UNC
127 #
1-1/2”-6 UNC
93 #
2”-4-1/2 UNC
222 #
¾”-10 UNC
13 #
4. Turn the adjusting screws until the bottom of the sub-base just clears each block. Next
adjust each screw evenly until the pump flange and gasket are less than 1/32" (0.8 mm)
away from the pipe flange. Careful adjustment is necessary to keep the pump level and
22
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
obtain better weight distribution on the springs. After the springs have been loaded and
adjusted, the base should be off the support blocks and level.
5. Check the alignment of the impeller and the pump elbow. If necessary, correct the
alignment by adjusting the springs or by using shims.
NOTICE: If the flange gap is over 1/32" (0.8 mm) , turn the adjusting screws a uniform
amount to close the gap. For a gap of 1/32" (0.8 mm) or less, omit this step.
6. Tighten the vertical pipe flange bolts, recheck the alignment and connect the horizontal
pipe flange to the elbow. The pump unit should be level and there should not be any
rubbing of the impeller in the elbow when the shaft is turned by hand.
7. Run each stop nut down to make light contact with the spring retainer. Lock in place by
turning the jam nut down tight against the stop nut.
8. Inspect each spring holder to check the gap between the coils of the spring. There must be
enough total gap to accommodate the downward thermal expansion of the system without
having them compressed solid.
NOTICE: Pumps with oil lubrication should be checked for oil level while thermal expansion
is taking place. It may be necessary to add oil to the bearing housing to provide the proper
oil level to the higher bearing. A line parallel with the sub-base deck through the proper oil
level line will show the correct level at the highest end of the bearing housing. A horizontal
line back from that point will establish the proper level mark on the sight gauge.
The system should be operated at normal temperature before the adjusting screw holders
are grouted in place. Some customers operate their units with the adjusting screw holders
ungrouted.
If it becomes necessary to remove a spring assembly from a spring pocket, for safety the
following steps should be strictly adhered to:
Remove Spring from Spring Pocket
If it becomes necessary to remove a spring assembly from a spring pocket, for safety the
following steps should be strictly adhered to:
1. Make sure the spring is relaxed. If the spring cannot be relaxed with the adjusting screw,
the safest method is to pry off the Plexiglas cover and cut the coils using a torch.
2. Remove the bolts or cap screws, which fasten the spring retainer to the holder and lift out
the entire assembly.
3. When the pump is connected to the system and a spring is removed, there should be
support under the sub-base near the spring location until the spring has been replaced and
adjusted. Distortion of the sub-base will affect the pump alignment, and the weight of the
components is more likely to cause distortion when the pump is connected to the rigid pipe
system.
4. If a spring is replaced while the system is hot, the stop nut should not be set until the
system is cold. The springs must be allowed to push the base back to its cold position.
An optional grease filled spring pocket is shown in Figure: Grease filled spring pocket
assembly. The difference between the standard pocket and the grease filled pocket is the
addition of a grease fitting and grease seal. Adjustment and setting of the grease filled
pocket are identical.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
23
Installation
1.
2.
3.
4.
5.
6.
7.
Grease fitting
Adjusting screw
Jam nut
Stop nut
Spring retainer
Bolts and nuts
Spring
8.
9.
10.
11.
12.
13.
Spring holder (welded to sub-base)
Seal washer
Grease seal
Adjusting screw nut assembly
Lubricate with oil
Adjusting screw holder
Figure 12: Grease filled spring pocket assembly
Pipe support design requirements
1. Piping supports must meet Hydraulic Institute, ASME/ANSI, DIN requirements, in conjunction with standard construction practices.
2. Piping shall be stiff enough to prevent unwanted pump vibrations.
3. Thermal expansion of the piping must be accounted for by the piping/system designer.
4. Refer to the installation/dimensional drawing for pump weights.
5. Refer to pump flange load drawing for allowable loads.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
6. Follow the power transmission manufacturer’s recommendations for angular limits and
thermal movement of the pump relative to pump driver.
NOTICE:
Future access to the pump impeller and shaft will require removal of a section of the horizontal
pipe. The piping shall have a spool piece for this purpose
1 Spool piece
.
2 Upper flange
.
3 Lower flange
.
Figure 13: Spool piece in horizontal pump
Install the pump to the piping
1. Connect the elbow upper flange to the vertical pipe run and tighten the flange bolts.
2. Check the impeller clearance in the elbow/casing to be sure it is well centered using the
criteria that the minimum gap at the vane O.D. is at least ½ the maximum gap. See the
Impeller alignment worksheet (page 38) of this IOM.
3. Connect the horizontal pipe or spool piece to the elbow lower flange and tighten the flange
bolts.
4. Check pump for level. Pump should be less than 1/2 degree (0.1"/ft) from horizontal so
bearings are not starved of oil. Be sure thermal expansion does not cause this angle to be
exceeded.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
25
Installation
1.
2.
Must be less than 1/2 degree
Exagerated for effect
Figure 14: Check pump for level
5. With the under-slung arrangement install the motor after the pump is connected to the
piping. Be sure motor shaft is parallel to the pump shaft in the horizontal and vertical plane.
Figure 15: Motor shaft parallel to pump shaft
6. If pump unit is direct drive utilizing a drive shaft, refer to the drive shaft manufacturer’s
installation manual for mounting instructions.
NOTICE:
Pipe flanges must be parallel with the pump flange before the bolts are tightened. If the
flanges are not parallel, forcing them parallel by tightening the bolts will cause excessive
strain on the pump
26
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
Connection of Piping
General
WARNING:
Never draw piping into place by forcing at the flanged connections of the pump. This may impose
dangerous strains on the unit and cause misalignment between pump and driver. Pipe strain will
adversely effect the operation of the pump resulting in physical injury and damage to the equipment.
Guidelines for piping are given in the “Hydraulic Institutes Standards” available from: Hydraulic Institute,
30200 Detroit Road, Cleveland OH 44145-1967 and must be reviewed prior to pump installation.
1. All piping must be supported independently of, and line up with the pump flanges.
2. Piping runs should be as short as possible to minimize friction losses.
3. DO NOT connect piping to the pump until the pump and driver hold-down bolts have been
tightened.
4. It is suggested that expansion loops or joints be properly installed in suction and /or
discharge lines when handling liquids at elevated temperatures, so linear expansion of
piping will not draw pump out of alignment.
5. The piping should be arranged to allow pump flushing prior to removal of the unit on
services handling corrosive liquids.
6. Carefully clean all pipe parts, valves and fittings, and pump branches prior to assembly.
Suction and Discharge Piping
WARNING:
Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR) as shown on
the published performance curve of the pump.
(Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction
piping)
Properly installed suction piping is a necessity for trouble-free pump operation. Suction piping
should be flushed BEFORE connection to the pump.
1. Use of elbows close to the pump suction flange should be avoided. There should be a
minimum of 2 pipe diameters of straight pipe between the elbow and suction inlet. Where
used, elbows should be long radius.
2. Use suction pipe one or two sizes larger than the pump suction, with a reducer at the
suction flange. Suction piping should never be of smaller diameter than the pump suction.
3. To prevent suction cavitation, horizontal reducers should be eccentric with the sloping side
down and concentric for vertical applications.
4. Pump must never be throttled on suction side.
5. Separate suction lines are recommended when more than one pump is operating from the
same source of supply.
6. A removable spool piece of a minimum of 1 ft at the connection adjacent to the impeller is
recommended to allow impeller alignment measurements during service activities.
Suction lift conditions
1. Suction pipe must be free from air pockets.
2. Suction piping must slope upwards to pump.
3. All joints must be airtight.
Suction head/Flooded suction conditions
1. An isolation valve should be installed in the suction line at least two pipe diameters from the
suction to permit closing of the line for pump inspection and maintenance.
2. Keep suction pipe free from air pockets.
3. Piping should be level or slope gradually downward from the source of supply.
4. No portion of the piping should extend below pump suction flange.
5. The size of entrance from supply should be one or two sizes larger than the suction pipe.
6. The suction pipe must be adequately submerged below the liquid surface to prevent
vortices and air entrainment at the supply.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
27
Installation
Discharge piping
1. Isolation and check valves should be installed in discharge line. Locate the check valve
between isolation valve and pump, this will permit inspection of the check valve. The
isolation valve is required for priming, regulation of flow, and for inspection and
maintenance of pump. The check valve prevents pump or seal damage due to reverse flow
through the pump when the driver is turned off.
2. Increasers, if used, should be placed between pump and check valves.
3. Cushioning devices should be used to protect the pump from surges and water hammer if
quick-closing valves are installed in system.
Final piping check
1. Rotate shaft several times by hand to be sure that there is no binding and all parts are free.
2. Check alignment, per Impeller alignment worksheet (page 38) to determine absence of
pipe strain. If pipe strain exists, correct the piping.
NOTICE: Prior to starting pump, ensure all flush and cooling systems are operating.
Drive Alignment Procedures
Alignment procedures must be followed to prevent unintended contact of rotating parts.
Follow coupling manufacturer’s installation and operation procedures.
WARNING:
Before beginning any alignment procedure, make sure driver power is locked out. Failure to lock out
driver power will result in serious physical injury.
Lock out driver power to prevent electric shock, accidental start-up and physical injury.
The AF pump comes with two drive variations, V-belt and gear driven. Accurate alignment of
both systems is essential to long pump life and reduced pump problems.
The points at which alignment are checked and adjusted are:
• Initial Alignment is done prior to operation when the pump and the driver are at ambient
temperature.
• Final Alignment is done after operation when the pump and driver are at operating
temperature.
Alignment is achieved by adding or removing shims from under the feet of the driver and
gearbox and shifting equipment horizontally by adjusting bolts as needed.
NOTICE:
Proper alignment is the responsibility of the installer and user of the unit.
Trouble free operation can be accomplished by following these procedures.
Initial Alignment (Cold Alignment)
• Before Grouting Sub-base - To ensure alignment can be attained. After Grouting Subbase - To ensure no changes have occurred during the mounting process.
• After Spring Setting – To ensure no changes have occurred during the leveling process.
After Connecting Piping - To ensure pipe strains have not altered alignment. If changes have
occurred, alter piping to remove pipe strains on pump flanges.
• Final Alignment (Hot Alignment)
• After First Run - To obtain correct alignment when both pump and driver are at
operating temperature. Thereafter, alignment should be checked periodically in accordance with plant operating procedures.
28
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
NOTICE:
Alignment check must be made if process temperature changes, piping changes, and or pump
service is performed.
V-Belt Drive (Sheaves)
Well designed and properly installed V-belt drives are capable of running for years. AF pumps
come in several different belt drive configurations i.e. side by side, overhead, underslung or “Z”
mount. Installation and alignment procedures are similar for all configurations. Remove the
guard or guards by referring to the assembly/disassembly instructions. There are a few items
that should be checked during installation and alignment.
Sheave Alignment - Alignment must be maintained for full power transmission, minimum
vibration, and long drive life. A dial indicator can be used to check runout on the periphery and
face of each sheave. A straight edge can be used to check parallel and angular alignment of
the pump and drive sheaves, see Figure: Sheave alignment.
1. Parallel misalignment
2. Angular misalignment
3. Perfect alignment
Figure 16: Sheave alignment
1. Belt Installation - When installing new belts, shorten center distance between sheaves so
that belts can be placed on the sheave without the use of force. Never 'roll' or "Pry" the
belts into place, as this could damage the belt cords.
2. Check Belt Fit - Regardless of the belt section used, the belt should never be allowed to
bottom in the groove. This will cause the belts to lose their wedging action and slippage can
occur. Sheaves or belts that permit such a condition to occur should be changed.
3. Maintain Proper Belt Tension - Proper tension is essential for long belt life. Improper
tension could cause belt fatigue and/or hot bearings.
4. Impeller Alignment after Belt Tensioning – If the impeller was aligned prior to belt
tensioning a check should be made to determine that it is still centered. An off center
impeller may rub and cause unnecessary pump damage. Belt Tension will usually cause
impeller misalignment opposite the motor. Be sure to align or re-align in accordance with
the Impeller Alignment (page 34).
The general method of tensioning belts is given below, and should satisfy most drive
requirements.
General Method:
1. Reduce the center distance so that the belts may be placed over the sheaves and in the
grooves without forcing them over the sides of the grooves. Arrange the belts so that both
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
29
Installation
belt spans have a proximately the same sag between the sheaves. Apply tension to the
belts by increasing the center distance until the belts are snug, see Figure: Belt tensioning.
1. Too tight
2. Slight bow
3. Too loose
Figure 17: Belt tension
WARNING:
Do not operate the pump without the proper drive guard in place. Failure to observe this warning could
result in personal injury to operating personnel
2. Operate the drive a few minutes to seat the belts in the sheave grooves. Observe the
operation of the drive under its highest load condition (usually starting). A Slight bowing of
the slack side of the drive indicates proper tension. If the slack side remains taut during the
peak load, the drive is too tight. Excessive bowing or slippage indicates insufficient tension.
If the belts squeal as the motor begins operation or at some subsequent peak load, they
are not tight enough to deliver the torque demanded by the drive machine. The drive should
be stopped and the belts tightened.
3. Check the tension on a new drive frequently during the first day by observing the slack side
span. After a few days of operation the belts will seat themselves in the sheave grooves
and it may become necessary to readjust so that the drive again shows a slight bow in the
slack side.
Other methods of determining proper belt tension can be obtained from the drive
manufacturer.
4. Use Belt Guards - Belt guards protect personnel from danger and the drive from
contamination. Inspect periodically to assure that belts do not rub against guard.
5. Keep Belts Clean - Dirt and grease reduce belt life. An occasional wiping with a dry cloth
to remove any build-up of a foreign material can extend the life of the belt. Should oil or
grease splatter onto the belts, clean with soap and water.
Belt dressing affects performance only temporarily and is never recommended. Maintaining a
clean drive is a better practice.
If any questions arise pertaining to the drive limitations, consult the manufacturer.
30
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
Gear Drive (Couplings)
NOTICE:
The coupling used in an ATEX classified environment must be properly certified.
Remove the guard or guards by referring to the assembly/disassembly instructions. Disconnect
motor/gearbox and the pump/gearbox coupling halves before proceeding with the alignment.
First, align the pump/gearbox coupling then the motor/gearbox coupling. Check both coupling
connections for parallel and angular alignment by either the Dial Indicator or Straight-Edge
Method outlined below. Good alignment is achieved when the dial indicator readings, for both
parallel and angular misalignment, are .003" (.076mm) Total Indicated Reading (T.I.R.) or less
when the pump and driver are at operating temperature (Final Alignment). Figure: Proper
coupling alignment, describes what to look for.
1. Angular misalignment
2. Parallel misalignment
3. Perfect alignment
Figure 18: Proper coupling alignment
1. Mount two dial indicators off one half of the coupling (X) so they contact the other coupling
half (Y).
1. (Motor End) (Gear box end)
2. (Gearbox end) (Pump end)
Figure 19: Using a dial indicator to check coupling alignment
2. Check setting of indicators by rotating coupling half (X) to ensure indicators stay in contact
with coupling half (Y) but do not bottom out. Adjust indicators accordingly.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
31
Installation
3. To ensure accuracy of indicator readings, always rotate both coupling halves together so
indicators contact the same point on coupling half (Y). This will eliminate any measurement
problems due to runout on coupling half (Y).
4. Take indicator measurements with hold-down bolts tightened. Loosen hold down bolts prior
to making alignment corrections.
5. Take care not to damage indicators when moving driver during alignment corrections.
Keep this instruction manual handy for reference. Further information can be obtained by
contacting Goulds Pumps, 240 Fall St., Seneca Falls, New York 13148 or your local
representative.
Alignment Procedure
On gear driven AF pumps angular and parallel misalignment are corrected in the vertical
direction by means of shims under the motor or gearbox mounting feet, and in the horizontal
direction by adjusting bolts that slide the motor or gearbox in the proper direction.
After each adjustment, it is necessary to recheck the alignment of the coupling halves.
Adjustment in one direction may disturb adjustments already made in another direction. It
should not be necessary to adjust the pump in any way.
Angular Alignments
Couplings are in angular alignment when indicator "A" (Angular Indicator), (page ) (page ),
does not vary by more than .003" (.076mm) as measured at four points on the coupling
periphery 90° apart at operating temperature. Outlined below are two acceptable methods to
achieve the desired alignment.
METHOD 1 - Dial Indicator Method
For steps 1 through 5 refer to Figure: Directions for viewing coupling (view from front end of
pump).
1. Zero indicator “A” at position 1 of coupling half (Y). Mark this position on both flanges.
2. Rotate both flanges 180° to position 3. Observe needle and record reading.
3. Negative Reading - The coupling halves are further apart at position 3 than position 1.
Positive Reading - The coupling halves are closer at position 3 than position 1.
Figure 20: Directions for viewing coupling (view from front end of pump)
32
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
4. Correct any misalignment by shimming the under the motor or gearbox feet to attain the
proper alignment.
When using positions 2 and 4 in steps 1-3, correct any misalignment by sliding the motor
back and forth to attain the proper alignment.
5. Repeat steps 1-4 substituting position 2 for position 1 and position 4 for position 3. Use the
same marks made on the coupling from position 1 and be sure to turn the coupling halves
together.
METHOD 2 - Feeler Gauge Method
For the following steps refer to Figure: Directions for viewing coupling (view from front end of
pump).
1. Insert a feeler gauge at position 1 at the periphery of the couplings. Mark this position on
both flanges.
2. Record the largest gauge size that fits snugly between the two flanges.
3. Rotate both flanges to position 3 - 180°
4. Insert a feeler gauge at the periphery of the couplings at position 3.
5. Record the largest gauge size that fits snugly between the two flanges.
6. Calculate the difference between the readings at positions 1 and 3. The difference should
not be greater than .003" (.076mm).
7. Correct any misalignment by shimming under the motor or gearbox feet to attain the proper
alignment.
When using positions 2 and 4 in steps 1 - 6, correct any misalignment by sliding the motor
or gearbox back and forth to attain the proper alignment.
8. Repeat steps 1-6 substituting positions 2 and 4 for position 1 and 3 respectively. Use the
same marks made on the coupling from position 1 and be sure to turn the coupling halves
together.
Parallel Alignment
The unit is in parallel alignment when indicator “P” (Parallel Indicator) does not vary by more
than .003” (.076mm) as measured at four points on the coupling periphery 90° apart at
operating temperature. There are two methods outlined below that are acceptable to achieve
the desired alignment.
NOTICE: Equal amounts of shims must be added to or removed from each driver foot.
Otherwise the vertical angular alignment will be affected.
METHOD I - Dial Indicator Method
For the following steps, refer to Figure: Directions for viewing coupling (view from front end of
pump).
1. Zero the indicator “P” at position 1 of coupling half (Y). Mark this position on both flanges.
2. Rotate both flanges 180° to position 3. Observe needle and record reading.
3. Negative Reading - Coupling half (Y) is shifted toward position 1.
If the value is greater than .003” (.076mm), correct the misalignment by evenly (at equal
amounts on both sides) shimming the motor higher. When using positions 2 and 4 in steps
1 - 2, correct any misalignment by sliding the motor evenly toward position 2.
Positive Reading - Coupling half (Y) is shifted toward position 3.
If the value is greater than .003" (.076mm), correct the misalignment by evenly (at equal
amounts on both sides) shimming the motor or gearbox lower. When using positions 2 and
4 in steps 1 - 2, correct any misalignment by sliding the motor or gearbox evenly toward
position 4.
4. Repeat steps 1-3 until indicator “P” reads .003" (.076mm) or less.
5. Once the ideal alignment is reached, repeat steps 1-4 substituting position 2 for position 1
and position 4 for position 3.
METHOD 2 - Straight-Edge Method
For the following steps refer to Figure: Directions for viewing coupling (view from front end of
pump).
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
33
Installation
1. Place a straight edge across the two coupling flanges at position 1 and mark the spot on
both flanges.
2. Adjust the motor or gearbox so that the straight-edge rests evenly on both flanges (within
.003" .076mm).
3. Rotate both flanges 90° to positions 2 and repeat steps one and two.
4. The unit will be in parallel alignment when the straight edge rests evenly (within .003”
.076mm) on the coupling periphery at both positions along the periphery.
NOTICE: Care must be taken to have the straight edge parallel to the axis of the shafts
Complete Alignment
A unit is in complete alignment when both indicators "A" (angular) and "P" (parallel) do not vary
by more than .003" (.076 mm) as measured at four points 90° apart.
Vertical Correction (Top-to-Bottom)
1. Zero indicators “A” and “P” at top dead center (12 o'clock) of coupling half (Y).
2. Rotate indicator to bottom dead center (6 o'clock). Observe the needles and record the
readings.
3. Make corrections as outlined previously.
Horizontal Correction (Side-to-Side)
1. Zero indicators "A" and "P" on the left side of coupling half (Y), 90° from top dead center (9
o'clock).
2. Rotate indicators through, top dead center to the right side, 180° from the start (3 o'clock),
Observe the needle, measure and record the reading.
3. Make corrections as outlined previously.
4. Recheck both vertical and horizontal readings to ensure adjustment of one did not disturb
the other. Correct as necessary.
Factors that may disturb alignment
The unit should be checked periodically for alignment. If the unit does not stay in line after
being properly installed, the following are possible causes:
1. Settling or spring of the foundation.
2. Wear of bearings.
3. Pipe strains distorting or shifting the machine.
4. Shifting of the sub-base due to heat created from an adjacent heat source.
5. Shifting of the building structure due to variable loading or other causes.
6. Loose nuts or bolts on the pump or driver assembly.
NOTICE: With experience, the installer will understand the interaction between angular and
parallel and will make corrections appropriately.
Impeller Alignment
Improper impeller adjustment could cause contact between the rotating and stationary
parts, resulting in a spark and heat generation.
The impeller clearance setting procedure must be followed. Improperly setting the
clearance or not following any of the proper procedures can result in sparks, unexpected heat
generation and equipment damage.
The AF impeller has been aligned at the factory but should be checked prior to pump operation.
The impeller requires several thousandths of and inch of clearance to prevent rubbing due to
the action of hydraulic forces when the pump is operating. Many corrosion-resistant alloys will
gall and build up if rubbing occurs, therefore, pumps using these alloys need to be free from
any rubbing.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
Turn the shaft by hand, if the impeller rubs the inside of the casing it must be realigned. The
following steps are used to align the impeller.
There are (2) types of impeller adjustment for the AF pump. Type 1 has adjusting lugs on the
stuffing box cover, Type 2 has adjusting lugs on the elbow. Type 1 moves the back-pullout
relative to the elbow. Type 2 moves the casing relative to the impeller to set the clearance (see
figures for type 1 adjustment and type 2 adjustment).
NOTICE: Impeller rubbing is often caused by pipe strain or belt tension. Pipe strain must be
eliminated prior to impeller alignment. The impeller should aligned after proper belt tensioning.
Clearance measurement
The alignment worksheet Figure: Impeller alignment worksheet, is used to align the impeller of
the AF pump. The measurement procedure is as follows:
Make sure the cap screws fastening the casing to the elbow are tight, so an accurate
measurement of the impeller clearances can be made prior to adjustment.
Mark each blade 1, 2, 3 and 4 and then align the impeller blades as shown on the impeller
alignment worksheet (approx. 2, 4, 8, and 10 o’clock)
Rotate the shaft and measure the gap between each blade and the casing at all four clock
positions indicated on the worksheet. The value of interest is the largest value of feeler gage
thickness that will slide easily the whole length of the vane tip.
Add the measurements for all positions together and divide by the number of measurements.
This will give the average measurement.
Divide the average measurement by 2. This will give the minimum clearance.
If any blade has a clearance in any position smaller than the calculated minimum clearance the
prop is not sufficiently centered and should be adjusted.
Align the impeller (Type 1)
1. Loosen the bolts that attach the bearing housing to the elbow.
2. Use the adjusting bolts closest to the elbow to adjust the impeller clearance.
The (2) upper adjusting bolts are used to raise and lower the impeller. The upper and lower
adjusting bolts on either side are used to center the impeller left to right in the elbow.
1.
2.
3.
Type adjustment
Box alignment
Impeller alignment
Figure 21: Type 1 adjustment
3. Move the back pullout relative to the elbow until the impeller is centered.
At this point it is recommended that the Impeller Alignment Worksheet be filled out and filed
with the pump maintenance records for future reference.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
35
Installation
4. Tighten the bolts between the bearing housing and elbow and re-check the clearance to be
sure the adjustments have centered the impeller.
If the impeller is centered the bearing housing may be taper pinned to the elbow to maintain
alignment.
Align the impeller (Type 2)
1. Loosen the bolts that attach the casing to the elbow.
2. Use the adjusting bolts attached to the elbow to adjust the impeller clearance.
The (2) adjusting bolts are used to raise and lower the casing and shift the casing left to
right relative to the impeller.
1.
2.
3.
4.
Box alignment
Not used
Type 2 adjustment
Impeller alignment
Figure 22: Type two impeller alignment
3. Move the casing relative to the impeller until the impeller is centered. At this point it is
recommended that the Impeller.
Alignment Worksheet should be filled out and filed with the pump maintenance records for
future reference.
4. Tighten the bolts between the casing and the elbow and re-check the clearance to be sure
the adjustments have centered the impeller.
If the impeller is centered the casing may be taper pinned to the elbow to maintain
alignment.
Rotation Check
Before the V-belts or couplings are installed, the motor should be wired and the direction of
rotation checked. A rotation arrow is located on the bearing housing (134C).
Serious damage could occur if the pump is run the wrong direction.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Installation
NOTICE:
When installing in a potentially explosive environment, make sure that the motor is properly
certified.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
37
Installation
Impeller alignment worksheet
38
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Preparation for start-up
NOTICE:
When installing in a potentially explosive environment, ensure that the motor is properly
certified.
Damage occurs from:
Checking rotation
1. Increased vibration levels-affects bearings, stuffing box or seal chamber and mechanical
seal
2. Increased radial loads Stresses on shaft and bearings
3. Heat build up-Vaporization causing rotating parts to score or seize
4. Cavitation-Damage to internal surfaces of pump
CAUTION:
Serious damage may result if pump is run in the wrong direction.
WARNING:
Lock out power to prevent accidental start-up and physical injury.
A check must be made to be sure motor rotation coincides with the pump rotation direction.
Depending on your pump arrangement (V-belt or gear-drive) use one of the following methods
to check motor rotation.
Direct connect
1.
2.
3.
4.
5.
Lock out power to the driver.
Remove the pump coupling guard.
Make sure the coupling halves are securely fastened to shafts.
Unlock driver power.
Make sure everyone is clear. Jog the driver just long enough to determine direction of
rotation of the output shaft of the gearbox. Rotation must correspond to an arrow on
bearing housing.
6. Lock out power to driver.
7. Replace the pump coupling guard.
NOTICE:
The coupling guard used in an ATEX classified environment must be constructed from a
non-sparking material.
V-Belt
1. Lock out power to the driver.
2. Remove the V-belt guard.
3. Make sure the sheaves are securely fastened to shafts.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
39
Commissioning, Startup, Operation, and Shutdown
4. Unlock driver power.
5. Make sure everyone is clear. Jog the driver just long enough to determine direction of
rotation. Rotation must correspond to an arrow on bearing housing.
6. Lock out power to driver.
7. Replace the V-belt guard.
Check Impeller Clearance
Check impeller clearance before installing the pump. The impeller must not rub when the shaft
is turned by hand, therefore it is recommended that the Figure: Impeller Alignment Worksheet,
is filled out and filed with the pump maintenance records for future reference.
Check for free turning
Before the pump is started, rotate the pump by hand to be sure it turns freely, and does not rub
or bind.
Bearings
The bearing assembly uses spherical roller bearings to carry the radial load, and a spherical
roller thrust bearing to carry the axial thrust load from the impeller. The bearing housing has a
horizontal split along the centerline for ease of assembly and inspection.
Bearing lubrication
Before start up, the pump should be checked for proper lubrication. AF pumps are flood-oil or
grease lubricated. Lubrication method is usually dependent on the pump operating conditions.
The following paragraphs describe both methods of lubrication.
Flood oil
WARNING: Bearings must be lubricated properly in order to prevent excess heat generation, sparks and
premature failure.
Oil lubricated bearings use an oil bath for lubrication. Oil lubricated bearing assemblies are
shipped without oil. ADD OIL TO THE HOUSING UNTIL IT IS AT THE CENTERLINE OF THE
SIGHT GLASS. Oil must be added to the bearing housing before starting. If the unit has an
external oil lube system, fill the bearing housing and the reservoir to satisfy the system
requirements.
Run the pump for 1 minute to fill the oil galleys and in and around each bearing. Check the oil
level indicator and add oil accordingly. Monitor the oil level indicator for the first 24 hours of
operation and maintain fill level.
Change the oil after the first 200 hours of operation. For normal operating conditions, change
the oil at least four (4) times a year. If the bearing assembly is exposed to dirty or moist
conditions, the oil should be changed more often.
If the level of oil in the bearing housing (134C) is too high, excessive heat may be generated
due to churning. If the level is too low, excessive heat may be generated due to inadequate
lubrication. A liquid level switch connected to the oil sump can be used to warn of a dangerous
oil level condition.
Observe the oil level requirements shown on the assembly drawing furnished with the pump. If
excessive heat is experienced within these levels, consult the factory. Be sure that the shaft
centerline is horizontal through the bearing housing.
Grease
Bearings are hand-packed at the factory and have sufficient grease for at least 24 hours of
operation after startup. The bearings will run hotter than normal for the first few hours until the
grease is worked out of the ball path and the bearings have “run- in”. Adding more grease
during this period may increase the bearing temperature. After the first re-greasing, a small
amount of grease should be added at each fitting every 500 hours of operation or 3 weeks of
continuous operation.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Oil Type
Use an industrial quality lubrication oil such as Mobil DTE series, Exxon Teresstic, or similar of
ISO VG68. ISO VG46 may be used in ambient temperatures below 40°F (4°C).
In any case the operating temperature viscosity must be a minimum of 150SSU.
An oil with a higher viscosity than required will increase the bearing operating temperature
because of the extra viscous drag, but never to the point where the viscosity becomes lower
than required from the increased heat generation. It is therefore better for the bearings to have
an oil that is too heavy rather than too light.
Change the oil after the first 200 hours of operation. For normal operating conditions, change
the oil at least four (4) times a year. If the bearing assembly is exposed to dirty or moist
conditions, the oil should be changed more often.
Oil level control
If the level of oil in the bearing housing (134C) is too high, excessive heat may be generated
due to churning. If the level is too low, excessive heat may be generated due to inadequate
lubrication. A liquid level switch connected to the oil sump can be used to warn of a dangerous
oil level condition.
Observe the oil level requirements shown on the assembly drawing furnished with the pump. If
excessive heat is experienced within these levels, consult the factory. Be sure that the shaft
centerline is horizontal through the bearing housing
Normal bearing temperature
The running temperature for a bearing assembly depends on many factors such as speed,
bearing loads, lubrication, ambient air temperatures, and condition of bearings. Temperatures
higher than the human hand can tolerate are very satisfactory for temperature and should not
be cause for alarm. Sudden change in temperature without any change in speed or loading can
mean a lubrication difficulty or the approach of bearing failure.
Temperatures higher than the human hand can tolerate are very satisfactory for good bearing
operation and should not cause any alarm.
For a given speed and loading, the bearing housing temperature will stabilize at some
temperature, usually below 200°F (93°C)., which will be the normal temperature for the
installation. Higher temperatures than this normal temperature, without any change in speed or
loading can mean a lubrication difficulty or the approach of bearing failure.
Installing bearing
Long bearing life is dependent on careful handling of the bearing when it is out of the housing
and during the installation procedure. Dirt and rough handling are prime enemies of precision
bearings. Bearings should be pressed, not “hammered” into place. If heat is used to facilitate
the installation, a hot oil bath is the best method.
CAUTION:
Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause physical injury.
Thrust bearing orientation
All 6" thru 36" AF pumps use a bidirectional thrust bearing arrangement capable of taking all
thrust loads in either direction for either top or end suction configuration. See Bearing alignment
(page 101) for the correct bearing installation. Pump Description table in General Description
(page 13), shows sizes vs. bearing arrangement style utilized.
Shaft sealing
A packed stuffing box or mechanical seal is used to seal the AF pump shaft. Both methods are
described below.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
41
Commissioning, Startup, Operation, and Shutdown
Packed stuffing box
The original equipment packing is a suitable grade for the service intended. To pack the
standard stuffing box use the following procedure: For the special (6) ring packing arrangement
see the appendix 1.
1. Stuffing box and shaft sleeve must be clean and free of grit.
For a given speed and loading, the bearing housing temperature will stabilize at some
temperature, usually below 200°F (93°C)., which will be the normal temperature for the
installation.
2. Form packing over shaft or mandrel of same diameter. Carefully cut to packing length.
Discard rings cut too short.
3. Pre-form each ring by coiling 1-1/2 turns.
4. To install packing rings, do not pull straight. Expand the coil as a coil spring, see Figure:
Packing rings, for the correct and incorrect method of installing packing.
Correct
Incorrect
Figure 23: Packing rings
5.
6.
7.
8.
9.
10.
11.
Expand the first coil as shown and insert into stuffing box. Tamp packing to stuffing box
shoulder firmly with the gland. Note, where the cut is positioned.
Install the first lantern ring into the stuffing box. Failure to property locate the lantern ring
with the flush port will result in insufficient packing lubrication.
Install the second and third coil as required by sectional drawing, staggering the cut 90° to
120°.
Install the second lantern ring into stuffing box, carefully noting its proper position on the
sectional drawing.
Install the third and fourth coil as required by sectional drawing, staggering the cut 90° to
120°.
After packing and lantern rings are properly installed, insert gland into stuffing box. Tighten
gland nuts finger tight only. The shaft should turn freely.
Turn lubricant supply on, start pump, and adjust the gland as described in Section III-E
Stuffing Box Adjustment.
Periodic maintenance is absolutely required for all packed pumps. Normal shaft run-out
should be under .005" (.13mm) to avoid pounding of stuffing box packing. With excessive
shaft run-out, shaft straightening or replacement is necessary.
Gland adjustment
Adjust the stuffing box if packing is used. When the pump is first started, there should be
considerable leakage by the gland to cool the packing. Gradually tighten the gland nuts on flat
at a time while observing the leakage and stuffing box temperature. Packing requires time to
"run-in" and extra coolant (leakage) while it is being "run-in". If the leakage is reduced too
quickly, the packing will overheat and may be destroyed. The shaft sleeve may also be
damaged.
Leakage
Normal leakage for a properly adjusted box, depending on shaft size and speed, varies from a
few drops a second to a small trickle out of the gland.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Mechanical seal
The mechanical seal used in an ATEX classified environment must be properly certified.
The mechanical seal must always be properly flushed. Failure to do so will result in excess
heat generation and seal failure
Most mechanical seals are installed and adjusted at the factory. A common seal type used on
the AF pump is the cartridge type. Cartridge seals are preset at the seal manufacturer’s facility
and require no field settings. Due to size and design, some installed mechanical seals are
supplied with holding clips. These clips keep the sealing faces apart to avoid damage during
transport. The clips must be removed before the shaft is to be rotated. Pumps with retained
seal faces will be specifically marked and instructions from the seal manufacturer for clip
removal will be provided.
If the seal has been installed in the pump at the Goulds Pumps factory, these clips have
already been removed. For other types of mechanical seals, refer to the seal manufacturer’s
instructions for installation and setting.
Mechanical seals have a stationary and a rotating sealing face. Commonly, these sealing rings
are of carbon and ceramic material, brittle in nature, and easily damaged. As the sealing rings
seat with the operation of the pump, a compatible wear pattern develops between the mating
surfaces.
To disassemble the mechanical seal after the wear pattern is established would necessitate the
replacement of the rotating element and stationary sealing elements. Do not replace only one
component.
To ensure the life and sealing characteristics of the mechanical seal, lubricating liquid must be
circulated through the seal gland. Clear, grit-free liquid is necessary. Goulds Pumps strongly
recommends the stocking of replacement sealing elements.
WARNING:
Do not make shaft adjustments on mechanical seal installations without consulting seal instructions and
the pump assembly drawing. Damage to the mechanical seal may result.
Dynamic seals are not allowed in an ATEX classified environment.
Start the Pump
Priming the pump
Pumps that are not self-priming must be fully primed at all times during operation.
DANGER:
All openings (e.g. pipe connections, flanges) must be sealed off with proper fitting and material prior to
filling pump. Failure to plug all openings will result in personal injury.
WARNING:
Foreign objects in the pumped liquid or piping system can block the flow and cause excess heat
generation, sparks and premature failure. Make sure that the pump and systems are free of foreign
objects before and during operation.
WARNING:
If pump becomes plugged, shut down pump and unplug prior to restarting.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
43
Commissioning, Startup, Operation, and Shutdown
CAUTION:
1. Foreign objects in the pumped liquid or piping system can block the flow and cause excess heat
generation, sparks and premature failure. Make sure that the pump and systems are free of foreign
objects before and during operation.
2. All equipment and personal safety related devices and controls must be installed and operating
properly.
3. To prevent premature pump failure at initial start up due to dirt or debris in the pipe system, ensure
the system has been adequately cleaned and flushed.
4. Variable speed drivers should be brought to rated speed as quickly as possible.
5. Variable speed drivers should not be adjusted or checked for speed governor or overspeed trip
settings while coupled to the pump at initial start up If settings have not been verified, uncouple the
unit and refer to driver manufacturers instructions for assistance.
6. Pumpage tempertatures in excess of 200°F (93°C) will require warmup of pump prior to operation.
Circulate a small amount of pumpage through the pump until the casing temperature is within 100°F
(38°C) of the pumpage temperature and evenly heated.
7.
8.
When starting pump, immediately observe pressure gauges. If discharge pressure is not quickly
attained, stop driver, re-prime and attempt to restart.
Never start the pump until it has been properly primed. Check the pump impeller for submergence.
The pump must be full of liquid with specified submergence head above the impeller. Do not run the
pump dry, as this might damage pump and seal components.
Lubricating liquid must be flowing to the stuffing box before pump is started.
Flush flows
Prior to starting pump, ensure all flush and cooling systems are operating.
Packing or mechanical seals are used to seal the rotating shaft. Generally, a clear liquid such
as water is used to lubricate and cool the sealing elements. The lubricating liquid pressure
must be 10 -15 psi higher than the pressure inside the elbow to prevent pumpage from entering
the sealing elements. The lubricating liquid must be clean and free of grit. Shaft scoring,
packing destruction, and mechanical seal face damage will result from contaminated lubricant.
The stuffing box may be on the suction or the discharge side of the impeller, depending on the
direction of flow through the elbow ordered by the customer. If the pressure inside the elbow is
unknown, it should be measured with a pressure gauge when the pump is operating. The
standard stuffing box is furnished with (2) N.P.T. holes for piping the lubricating liquid. The
lubricating liquid is piped into one of them. Some users simply plug the other hole. For
additional cooling of the sealing elements, an outlet pipe with a valve can be installed to allow
more liquid to flow through the stuffing box.
For special (6) row packing arrangement see appendix 1 at the end of this manual for flush
pressures and flow rates.
(Mechanical seals have no leakage and usually require a lubricant flow through the stuffing box
for cooling). The lubricating flow should be regulated by the valve in the outlet pipe rather than
by throttling the flow in the supply pipe.
Driver
Start driver.
CAUTION:
Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver,
reprime, and attempt to restart the pump.
Set desired flow
If your system is equipped with a variable frequency drive (VFD) or a variable speed V-belt
drive, you may at this point want to set your speed for the desired flow.
CAUTION:
Observe the pump for vibration levels, bearing temperature, and excessive noise. If normal levels are
exceeded, shut down the pump and resolve the issue.
44
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Operation
General considerations
Service temperature in an ATEX classified environment is limited by the table in the ATEX
identification section.
1. Do not operate pump below hydraulic minimum flow. For hydraulic minimum flow, refer to
technical manual and pump performance curve.
2. Do not operate pump below hydraulic or thermal minimum flow. For hydraulic minimum
flows refer to technical manual and pump performance curves. To calculate thermal
minimum flow, refer to HI Centrifugal Pump Design and Application ANSI/HI 1.3-2000.
3. Do not operate pump past maximum flow. For maximum flow refer to pump performance
curve.
4. Observe the pump for vibration levels, bearing temperature, and excessive noise. If normal
levels are exceeded, shut down the pump and resolve the issue.
5. Make sure to operate the pump at or near the rated conditions. Failure to do so can result in
pump damage from cavitation or recirculation.
6. Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from
the suction side since this can result in decreased performance, unexpected heat
generation, and equipment damage.
7. Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR)
as shown on the published performance curve of the pump.
8. NPSHa must always exceed NPSHr as shown on Goulds performane curves received with
order.
9. Reference Hydraulic Institute for NPSH and pipe friction values needed to evaluate suction
piping.
10. Most axial flow pumps are in evaporator circulation service and since the evaporator
performance and the amount of product depends on the rate of liquid circulation, care
should be taken to maintain these pumps in good operating condition.
When production drops off, it is usually due to lower circulation rate. An approximation of
this rate can be made by several methods:
1. Temperature drop across the heat exchanger.
2. Visual inspection of flow in evaporator body.
3. Testing the circulating pump.
11. Items (1) and (2) above are covered by the evaporator manufacturer.
12. While field conditions preclude absolute accuracy, a check of pump performance will give
reasonably close results. This can be done by installing a mercury manometer at pipe taps
located at least-one pipe diameter away from the suction and discharge flanges of the
pump. If-gauges are used, the pressure differential times 2.31 divided by the specific
gravity of the slurry indicates the TDH against which the pump is actually operating. If a
manometer is used, then inches of mercury times 1.0455 divided by specific gravity equals
TDH, providing water is in both legs of the manometer and connecting lines.
13. Check the pump speed and determine flow rate (gpm) from the pump curve. This curve will
also give efficiency from which the hp requirement can be determined. A double check is to
take motor ammeter readings, convert to hp, figure 90% drive efficiency, and use it against
the pump curve to get GPM. This is only an approximate check, as the hp curve on some
applications is rather flat, but is probably within 7-1/2%. It is important to take and record
these readings when the equipment is new, so that later readings can be judged on a
relative basis.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
45
Commissioning, Startup, Operation, and Shutdown
Operating at reduced capacity
WARNING:
Do not operate the pump below the minimum rated flows or with the suction or discharge valves closed.
These conditions can create an explosive hazard due to vaporization of pumped fluid and can quickly lead
to pump failure and physical injury.
Driver may overload if the pumpage specific gravity (density) is greater than originally
assumed, or the actual flow is much less than the rated flow.
The pump and system must be free of foreign objects. If pump becomes plugged, shut down
and unplug prior to restarting pump.
Listed below are some causes for circulation loss. Keep in mind that operation at reduced
capacities can cause damage to the pump.
1. Increase in TDH against which pump operates could be caused by:
1. Heat exchanger tubes partially plugged.
2. Too many heat exchanger tubes blanked off
3. Improperly sized or partially plugged strainer.
2. Viscosity of slurry higher than it should be.
3. Pump speed low. V-belt drive may be slipping and operating pump below design speed.
4. Pump throttled on suction side. This could be caused by:
1. rubber lining pulling away from the suction pipe and partially collapsing,
2. large solids dropping into the suction, or
3. by an improperly sized or-plugged strainer in the suction pipe.
5. Pump partially plugged by large solid jammed between two impeller blades. This will also
cause rough operation with excessive vibration.
6. Incorrect pump rotation. When changing motors for any reason or after any electrical
system changes or modifications, always check motors for correct direction of rotation.
7. Worn pump impeller and/or casing. On a new pump, clearance between tip of impeller
blade and casing is carefully determined. As this clearance increases, pump performance
decreases.
It is not practical to predict performance at any given clearance without running a test at this
clearance. On small pumps, this effect is magnified as the percentage of impeller blade area
lost from wear and corrosion is higher.
Other pump conditions and possible causes are:
High HP demand
1. Increased head or viscosity
2. Pump speed too high
3. Specific-gravity of slurry higher-than normal
4. Packing gland pulled up too tight
5. Impeller rubbing in casing
Noisy or rough operation
1. Throttled suction or plugging
2. Impeller rubbing in casing
Damage occurs from:
1. Increased vibration levels - Affects bearings, stuffing box seal chamber, and mechanical
seals.
2. Heat build up - Vaporization causing rotating parts to score or seize.
3. Cavitation - Damage to internal surfaces of pump.
4. Loose impeller
5. Broken impeller blade
6. Bearings not properly lubricated
7. Bent shaft
8. 8. Impeller out of balance.
Operating under freezing conditions
46
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage
the pump. Liquid inside pump should be drained.
Shut down the pump
1. Turn off power to pump motor.
2. In case of necessary maintenance or pump inspection, lock driver to prevent accidental
rotation.
WARNING:
When handling hazardous and/or toxic fluids, skin and eye protection are required. If pump is being
drained, precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of
in conformance with applicable environmental regulation.
Final Alignment
1. Run the pump under actual conditions for a sufficient length of time to bring the pump and
driver up to operating temperature.
2. Check alignment per alignment procedure outlined earlier.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
47
Maintenance
Maintenance
Preventative Maintenance
A routine maintenance program can extend the life of your pump. Well maintained equipment
will last longer and require fewer repairs. You should keep maintenance records, this will help
pinpoint causes of problems.
Condition monitoring
For additional safety precautions, and where noted in this manual, condition monitoring
devices should be used.
• Pressure gauges
• Temperature detectors
• Flow meters
• Bearing monitors
• Level indicators
• Leak detectors
• Motor load readings
• PumpSmart control system
For assistance in selecting the proper instrumentation and its use, please contact your ITT/
Goulds representative.
Maintenance schedule
NOTICE:
The preventive maintenance section must be adhered to in order to keep the applicable
ATEX classification of the equipment. Failure to follow these procedures will void the ATEX
classification for the equipment.
Inspection intervals should be shortened appropriately if the pumpage is abrasive and/or
corrosive, or if the environment is classified as potentially explosive.
NOTICE:
When handling hazardous and / or toxic fluids, proper personal protective equipment should be
worn. If pump is being drained, precaution must be taken to prevent physical injury. Pumpage
must be handled and dispersed of in conformance with applicable environment regulations.
Maintenance inspections
A maintenance schedule includes these types of inspections:
• Routine maintenance
• Routine inspections
• Three-month inspections
• Annual inspections
Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if
the environment is classified as potentially explosive.
Routine inspections
Perform these tasks whenever you check the pump during routine inspections:
• Check for unusual noise, vibration, and bearing temperatures.
• Check the pump and piping for leaks.
• Analyze the vibration.
48
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Maintenance
Three-month inspections
Perform these tasks every three months:
• Check that the foundation and the hold-down bolts are tight.
• Check the packing if the pump has been left idle, and replace as required.
• Change the oil every three months (2000 operating hours) at minimum.
• Change the oil more often if there are adverse atmospheric or other conditions that
might contaminate or break down the oil.
• If any rubbing noise has been noticed, re-align the impeller.
Annual inspections
Perform these inspections one time each year:
• Check the pump capacity.
• Check the pump pressure.
• Check the pump power.
If the pump performance does not satisfy your process requirements, and the process
requirements have not changed, then perform these steps:
1. Disassemble the pump.
2. Inspect it.
3. Replace worn parts.
Bearing Maintenance
Operation of the unit without proper lubrication will cause bearing failure, and pump
seizure.
Throughout this section on bearing lubrication, different pumpage temperatures are listed.
If the equipment is ATEX certified and the listed temperature exceeds the applicable value
shown in the table under ATEX identification, then that temperature is not valid. Should this
situation occur, please consult with your ITT/Goulds representative.
Oil Lubricated Bearings
1. Remove the bearing housing breather (113A) and add oil until oil level is at the center of the
sight glass.
2. If the unit has an external oil lube system, fill the bearing housing and the reservoir to
satisfy the system requirements.
3. Replace the breather.
Refer to Oil Volume table for required oil volume.
Table 4: Axial Flow Pump Approximate Oil Volume
Pump Size
Quarts
6"
1
8"
1
10"
1
12"
4
14"
4
16"
8
18"
8
20"
19
24"
19
700mm
19
30"
19
Litres
0.95
0.95
0.95
3.80
3.80
7.60
7.60
18.10
18.10
18.10
18.10
Approximate values only. Always fill using sight glass to verify level. Oil level should be at
the center of the sight glass. See comments in this section.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
49
Maintenance
Bearings must be lubricated properly in order to prevent excess heat generation,
sparks and premature failure.
4. Run the pump for 1 minute to fill the oil galleys and in and around each bearing. Check the
sight glass and add oil accordingly. Monitor the oil level indicator for the first 24 hours of
operation and maintain fill level.
Grease lubricated bearings (6-18 inch sizes only)
The bearings are pre-lubricated at the factory. Re-grease bearings every 500 operating hours
or after every 3 weeks of continuous operation.
Regrease procedure
NOTICE:
When re-greasing there is danger of impurities entering the bearing housing. The grease
container, the grease device, and fittings, must be clean.
1. Wipe dirt from the grease fittings.
2. Fill both grease cavities through the grease fittings (193A and 193B) found on the bearing
housing (134C). Use recommended grease and fill until slight resistance is felt in the
grease gun.
3. Wipe excess grease from fittings.
4. Ensure the bearing housing labyrinth seals are still seated in place and have not been
pushed from their seats by grease pressure.
Figure 24: Fill bearing grease cavities
NOTICE:
The bearing temperature usually rises after re-greasing due to an excess supply of grease.
Temperature will return to normal after pump has run and purged excess from the bearings,
usually two to four hours.
For most operating conditions a lithium complex soap based grease of NLGI consistency No. 2
is recommended. This grease is acceptable for bearing temperatures of -15°F to 350°F (-26°C
to 177°C). If another brand is desired, it should be checked with the supplier for being
equivalent to the above.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Maintenance
Table 5: Lubricating grease requirements
Lubricant brand
Pumpage temp. below 350°F
(177°C)
NLGl Grade
2
Mobil
Mobilux #2
Mobil
Mobilith AW2
Humble
Lidok #2
Exxon
Unirex N2
Shell
Alvania #2
Sunoco
Multipurpose EP
SKF
LGMT 2
Texaco Regal
Starfak #2
Pumpage temp. above 350°F
(177°C)
3
---Mobilith AW3
---Unirex N3
------LGMT 3
----
Bearing temperatures are generally about 20°F (18°C) higher than bearing housing outer
surface temperature.
CAUTION:
Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different thickeners. For
example, never mix a lithium-based grease with a polyurea-based grease. Doing so may result in
decreased performance.
Pumpage temperatures above 350°F (177°C) should be lubricated by a high temperature.
Mineral oil grease. Mineral oil greases should have oxidation stabilizers and a consistency of
NLGI 3.
Shaft-seal maintenance
Mechanical-seal maintenance
WARNING:
The mechanical seal used in an Ex-classified environment must be properly certified. Prior to startup,
make sure that all areas that could leak pumped fluid to the work environment are closed.
CAUTION:
Never operate the pump without liquid supplied to mechanical seal. If you run a mechanical seal dry,
even for a few seconds, this can cause seal damage. Physical injury can occur if a mechanical seal fails.
Cartridge-type mechanical seals
Cartridge-type mechanical seals are commonly used. Cartridge seals are preset by the seal
manufacturer and require no field settings. Cartridge seals installed by the user require
disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the
seal has been installed in the pump by ITT, these clips have already been disengaged.
Other mechanical seal types
For other types of mechanical seals, refer to the instructions provided by the seal manufacturer
for installation and setting.
Before you start the pump
Check the seal and all flush piping.
Packed stuffing-box maintenance
WARNING:
• Never attempt to replace the packing until the driver is properly locked out and the coupling spacer is
removed.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
51
Maintenance
Adjustment of gland
Adjust the gland if the leakage rate is greater than or less than the specified rate.
Evenly adjust each of the two gland bolts with a one-quarter (1/4) turn until the desired leakage
rate is obtained. Tighten the bolts to decrease the rate. Loosen the bolts to increase the rate.
Tightening of packing
NOTICE: Never over-tighten packing to the point where less than one drop per second is
observed. Over-tightening can cause excessive wear and power consumption during operation.
If you cannot tighten the packing to obtain less than the specified leakage rate, then replace the
packing.
Packed Stuffing Box
If the axial flow pump has a standard stuffing box to seal the rotating shaft the packing rings
were installed at the factory, but at some point during the life of the pump they must be
replaced. The following steps are used to replace the standard packing:
1. Drain the system or isolate the pumpage from the pump before replacing the packing.
2. Remove the nuts from the gland studs that hold the gland in place.
3. Use a packing puller remove the first (3) rows of packing from the box.
4. Use threaded rods or a packing puller to remove the lantern ring from the box.
5. Use a packing puller remove the final (2) rings of packing from the box.
6. Clean the stuffing box of any grit or build-up. Clean the shaft sleeve prior to replacing the
packing. If the sleeve is damaged now is the time to replace it.
7. Install the packing and lantern ring in the reverse order of removal, 2 rings of packing,
lantern ring, 3 rings of packing, and the gland. Firmly seat each ring. Stagger joints in each
ring 90°. Make sure center of lantern ring lines up with flush tap in the stuffing box.
8. Die formed packing rings are used when re-packing a box. Care must be used during their
installation. To install packing, twist the ring sideways just enough to get it around the shaft.
Do not attempt to pull rings straight out, see Figure: Packing rings.
Correct
Incorrect
Figure 25: Packing rings
9. Insert the lantern ring with tapped extractor holes facing outward from the box, be sure it is
aligned with the flush ports in the stuffing box.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Maintenance
Figure 26: Insert lantern ring
10. Install the gland nuts finger tight. Then with the lubricating supply on and the pump
running, gradually tighten the gland nuts one flat at a time, while observing the leakage and
stuffing box temperature. Packing requires time to run-in.
11. Allow a minimum of ½ hour between adjustments. If the leakage is reduced quickly, the
packing will overheat and may be destroyed. The shaft sleeve may also become damaged.
The normal leakage for a properly adjusted stuffing box, depending on the shaft size and
speed, varies from a few drops per second to a small trickle out of the gland.
Labyrinth Seals
Labyrinth seals are found on the inboard and outboard end caps of the bearing housing to
prevent contaminants from entering the bearing housing.
On some older models lip seals were used. These were assisted by cast slingers that fling
contaminant fluids away prior to reaching the lip seals. Lip seals do not require any
preventative maintenance but should be replaced during any rebuild operations. They can be
cleaned occasionally from the outside by removing the slingers.
Connection of Sealing Liquid
If stuffing box pressure is above atmospheric pressure and the pumpage is clean, normal gland
leakage of 40-60 drops per minute is usually sufficient to lubricate and cool packing and sealing
liquid is not required.
NOTICE: If stuffing box is below atmospheric pressure or pumpage is not clean, an external
flush should be used to lubricate and cool packing.
An external sealing liquid is required when:
1. Abrasive particles in the pumpage could score the shaft sleeve.
2. Stuffing box pressure is below atmospheric pressure due to pump running when suction
source is under vacuum. Under these conditions, packing will not be cooled and lubricated
and air will be drawn into the pump. If an outside source of clean compatible liquid is
required, The piping should be connected to the stuffing box flush port inlet.
3. If an outside source of clean liquid is required:
1. The pressure should be 15-20 psi (1.1-1.4 kg/cm2) above suction pressure.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
53
Maintenance
2. Under extreme temperature and pressure a pipe should also be connected to the flush
port outlet.
NOTICE: Most packing requires lubrication. Failure to lubricate packing may shorten the
life of the packing and pump.
4. An external drip pan (799G) drain is provided to carry away normal gland leakage.
1. Drip pan
Figure 27: External drip pan drain
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Disassembly
Pump Disassembly Precautions
NOTICE:
Make sure that all replacement parts are available before you disassemble the pump for
overhaul.
WARNING:
Lock out power to prevent accidental start-up and physical injury.
1.
2.
3.
4.
Shut all valves controlling flow "to and from" the pump.
Drain liquid from piping, flush the pump if necessary.
Disconnect all auxiliary piping and tubing.
If the pump is oil lubricated drain all oil from the bearing housing before attempting to move
the pump.
5. Depending on the drive arrangement, either direct connect or V-belt, follow steps as
applicable.
Disassembly precautions
WARNING:
• Chemical hazard. You must individually decontaminate each component according to all federal,
state, local, and company environmental regulations.
• A build up of gases within the pump, sealing system, or process-piping system can result in an
explosive environment within the pump. Make sure that the process piping system, pump, and
sealing system are properly vented prior to operation.
• Burn Hazard. Coupling may be hot. Use proper protection when handling.
• Burn Hazard. use proper protection when handling bearings.
• Worn parts may have sharp edges. Wear heavy work gloves while handling.
• Chemical Hazard. A small amount of liquid may be left in the pump.
• Process fluid leaks can result in an explosive atmosphere. Follow all pump and seal assembly
procedures.
• Make sure that the pump is isolated from the system and that pressure is relieved before you
disassemble the pump, remove plugs, open vent or drain valves, or disconnect the piping.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear
steel-toed shoes at all times.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe
proper decontamination procedures in order to eliminate the possible exposure to any hazardous or
toxic fluids. Wear the proper personal protective equipment. Potential hazards include, but are not
limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. You must handle
and dispose of pumped fluid in compliance with the applicable environmental regulations.
CAUTION:
• You must keep the shop area clean and free of any substances that can contaminate the magnets,
such as ferrous metals.
• The magnets in this unit are extremely powerful. Beware of serious injury to fingers and hands.
Keep magnetic drive components and magnetic tools apart by a minimum of 3 ft (1 m).
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
55
Disassembly
NOTICE:
Use a bench with a non-magnetic work surface such as wood or brass when you work on the
pump.
Remove the coupling guard
1. Remove the nut, bolt, and washers from the slotted hole in the center of the coupling guard.
2. Slide the driver half of the coupling guard toward the pump.
1. Driver
2. Slide to remove
3. Remove the nut, bolt, and washers from the driver half of the coupling guard.
4. Remove the driver-side end plate.
1. End plate
2. Coupling guard half
3. Driver
5. Remove the driver half of the coupling guard:
a) Slightly spread the bottom apart.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
b) Lift upwards.
6. Remove the remaining nut, bolt, and washers from the pump half of the coupling guard.
It is not necessary to remove the end plate from the pump side of the bearing housing. You
can access the bearing-housing tap bolts without removing this end plate if maintenance of
internal pump parts is necessary.
7. Remove the pump half of the coupling guard:
a) Slightly spread the bottom apart.
b) Lift upwards.
Tools required
In order to disassemble the pump, you need these tools:
• Allen wrenches
• Bearing puller
• Brass drift punch
• Cleaning agents and solvents
• Feeler gauges
• Induction heater
• Lifting sling
• Micrometer
• Torque wrench with sockets
• Wrenches
• Safety glasses, leather gloves
• Spanner wrench
• Crane or hoist
• Lifting eyebolt (dependent on pump size)
Disassemble the guard / drive (v-belt configuration)
Direct drive configuration
1. Remove the pump coupling guard screws and guard (501).
Figure 28: Pump guard removal
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
57
Disassembly
2. Remove the fasteners that hold the coupling cover halves together, remove each half and
set it aside for re-assembly. Do not remove the hubs from the gear drive and pump shafts.
1. Coupling covers
Figure 29: Coupling cover removal
3. Remove the pump to sub-base bolts (372V) and wrap lifting straps or chains around the
bearing housing (134C) and elbow (315A).
Use care when lifting the pump from the sub-base. Be sure all lifting devices are rated for
the pump weight. If any shims are found under the bearing housing feet match mark and
retain them for re-assembly.
V-belt configuration
4. Remove the V-belt guard screws and the guard cover (500) from guard base.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Figure 30: Guard cover removal
5. Relieve the belt tension by adjusting the slide base toward the pump then remove the belts.
1.
2.
Remove belts
Shift slide base
Figure 31: Belt removal
6. Remove the pump to sub-base bolts (372V) and wrap lifting straps or chains around the
bearing housing (134C) and elbow (315A).
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
59
Disassembly
Figure 32: Pump lifting
7. Using a crane, lift the pump vertically from the sub-base.
Be careful not to damage the pump by striking any beams or walls that may be near the
pump.
8. If any shims are found under the bearing housing feet retain them for re-assembly later.
9. Depending on the drive type, remove the hub fasteners that hold the coupling or pump
sheave to the shaft (122).
10. Remove either a coupling half or pump sheave and key (400).
If the coupling half is interference fit, heat may be necessary to remove it from the shaft.
Drive instructions are included with the data package. Follow the manufacturer’s
instructions for coupling or sheave removal.
Figure 33: Coupling half or pump sheave removal
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Disassemble the back-pullout / elbow
1.
2.
3.
4.
5.
6.
Set the pump down on a smooth flat surface to stabilize it for disassembly.
Loosen the impeller adjusting bolts (356A) so that they are clear of the rear elbow flange.
Text of third step.
Remove the bolts (789L, 799O) that attach the back-pullout (903A) to the elbow (315A).
With the elbow held in place, slide the back-pullout from the elbow.
Remove the face o-ring (351) between the elbow and the back-pullout, discard and order a
replacement.
Be sure to order the correct o-ring material.
1.
2.
Back-pullout 903A
Rear elbow flange
Figure 34: Back-pullout / elbow disassembly
Disassemble the back-pullout elbow with casing
The 700mm and 36" sizes come with a separate casing.
1. Remove the bolts (799C) and nuts (799D) that secure the casing (100) to the elbow (315A).
2. Remove the casing and discard the mating o-ring or gasket (351A).
3. Loosen the four screws (356A).
4. Remove the bolts (789l & 799O) that secure the back-pullout (903A) to the elbow and
discard the o-ring (351).
1. Back-pullout
Figure 35: Elbow with casing
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
61
Disassembly
Remove the liner (option)
If the elbow (315A) or casing (100) has an optional liner (103A) now is the time to remove it.
1. Jack the liner from its seat using the four tapped holes with screws, in the liner flange.
If the liner has been in service this may require considerable effort due to corrosion.
If the liner is worn or deeply eroded, order a replacement for re-assembly.
1. Jacking screws
Figure 36: Remove the liner (option)
Remove the standard impeller
1. Remove the bolts (198) that hold the shaft washer (199) in place.
2. Remove the shaft washer.
3. To remove the impeller (101), use a wooden mallet and gently tap it to break it loose from
the shaft (122).
4. Pull the impeller from the shaft, retain the shaft key (178).
Figure 37: Standard impeller removal
Remove the sealed impeller
700mm and 36” sizes use an impeller cover (998E) and O-rings to keep pumpage out of the
impeller cavity. The impeller cover must be removed first to get to the shaft washer (199).
1. Remove the bolts (799B) and cover (998E) from the impeller (101).
2. Remove the cover o-ring (412T).
3. Remove the bolts (198) and shaft washer (199).
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
4. To remove the impeller (101), use a wooden mallet and gently tap it to break it loose from
the shaft (122).
5. Pull the impeller off the shaft, retain the shaft key (178), and discard the impeller o-ring
(412A).
6. A pipe plug (358I) located in the center of the cover is used to test the impeller seal after reassembly, do not remove this plug.
Figure 38: Sealed impeller removal
Remove mechanical seal with optional adapter
Be sure all gland flush tubing is disconnected.
1. Remove the seal nuts (353) and pull the seal away from the stuffing box cover (184).
It is unnecessary to remove the gland studs (355) unless they are damaged.
2. If the seal includes a restrictor bushing (496B) and optional adapter (108B) remove these
now.
3. Remove and discard the adapter gasket (211).
4. Remove the stuffing box cover (184) by removing (2) screws (370C) that secure the stuffing
box cover (184) to the bearing housing (134C).
5. Remove the stuffing box cover from the bearing housing.
On larger pumps use a sling or hook and chain to securely support the weight of the stuffing
box cover during removal.
6. Remove the adjusting bolts (356A) and all four adjusting lugs (415).
Be careful not to scuff or scar the pump shaft (122) during removal.
Figure 39: Mechanical seal with optional adapter
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
63
Disassembly
Disassemble the packed box
With a packed box, the gland nuts (353), gland (107), packing (106) and lantern ring (105) must
be removed before the stuffing box cover (184).
1. Remove all flush tubing..
2. Remove the impeller adjusting bolts (365A) and all (4) adjusting lugs (415).
3. Remove the two bolts (370C) that secure the stuffing box cover (184) to the bearing
housing (134C) then remove the stuffing box cover.
On larger pumps use a sling or hook and chain to support the weight of the stuffing box
cover during removal. Be careful not to scuff or scar the pump shaft (122) or sleeve (126)
during removal.
4. Remove the stuffing box (220), bolts (799E) and gasket (351W).
5. Remove the set screw (469D) and key (178D) that secure the shaft sleeve (126) to the
shaft (122).
If the sleeve is immovable use a brass drift to knock it from its seat. Be careful not to mar or
scratch the shaft during the process.
6. Remove and discard the o-rings (412D).
Figure 40: Packed box disassembly
Remove the drip pan
1. Remove the street elbow (799G) from the drip pan nipple.
2. Remove the screws (799H) and washers (799I) that secure the drip pan (179) to the
bearing housing (134C).
3. Pull the drip pan from the bearing housing.
Figure 41: Drip pan removal
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Disassemble the bearing housing
1. Before removing the bearings carefully remove the labyrinth seals from the outboard and
inboard positions (332, 333).
2. Use a sharp edged tool or screwdriver to remove them from the bearing housing.
Be careful not to damage the shaft (122) or seat.
Figure 42: Bearing housing removal
3. Lift the bearing housing up vertically by the drive end using an eyebolt and chain.
Be careful not to damage the impeller end of the shaft.
4. Place the bearing housing on a bench or stand so that the shaft protrudes down through it.
5. Remove the screws (799F & 370Y) that secure the front (239B) and rear feet (239A).
6. Remove the screws (788Z) that secure the thrust bearing retainer (119C) to the bearing
housing.
7. Remove the retainer and discard the gasket/shims (331) or o-ring (412Y).
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
65
Disassembly
Figure 43: Retainer removal
8. Using the eye bolt already threaded into the shaft, pull the rotating assembly from the
bearing housing.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Figure 44: Pull rotating assembly from bearing assembly
9. Once the rotating assembly has been removed place it on a set of wooden V-blocks for
bearing removal.
Remove the bearing (1MXR-3MXR configuration)
1. In order to remove the bearings first pry the tangs of the lock-washer (382) from the locknut (136).
2. Using a spanner wrench remove the lock-nut (136) and lockwasher (382).
This thrust bearing configuration consists of two back to back angular contact bearings.
3. Use a bearing puller to remove both thrust bearings (112C).
4. Use a puller to remove the inboard radial bearing (168C) from the opposite end of the shaft.
Be careful not to damage the shaft.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
67
Disassembly
Figure 45: 1MXR-3MXR rotating element
Remove the bearing (4MXR-6MXR configuration)
1. In order to remove the bearings first pry the tangs of the lock-washer (382) from the locknut (136).
2. Use a spanner wrench to remove the lock-nut (136) and lockwasher (382).
3. Slide off the keyed washer (142B).
This thrust bearing configuration is an indirectly mounted taper roller bearing.
4. Use a bearing puller to remove the thrust bearing (112C).
5. Remove the thrust bearing collar (443X) and oil wheel (248).
The oil wheel has one to three set screws (222N) that hold it to the shaft (122). The collar
and oil wheel must be removed prior to removing the inboard bearing.
6. Use a puller to remove the inboard radial bearing (168C) from the drive end of the shaft.
Be careful not to damage the shaft.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Disassembly
Figure 46: 4MXR-6MXR rotaing element
Disassemble the cooling coil (optional) sight glass / breather and
plugs
1. Loosen and remove the screws (370F) that secure the cover plate (113B) to the bearing
housing (134C) and discard the gasket. (360E).
2. Remove the cover plate and coil. Disconnect the connectors (972G and 972H) from the
cover plate and remove the cooling coil (984A).
Figure 47: Removal of optional cooling coil
3. If necessary remove the breather (113A), pipe plugs (408D, 408, 408A, 251C) and the sight
glass (319).
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
69
Pre-assembly inspections
Pre-assembly inspections
Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics before
you reassemble your pump. Replace any part that does not meet the required criteria.
• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove oil,
grease, and dirt.
NOTICE:
Protect machined surfaces while you clean the parts. Failure to do so may result in
equipment damage.
Inspect the elbow / casing / liner (options)
The elbow and or casing (315A or 100) and liner (103A) should be inspected for excessive
wear or pitting in the impeller and gasket areas. They should be repaired or replaced if wear or
corrosion exceeds the following criteria.
1. Inspect for localized wear or grooving greater than 1/8 in. (3.2mm) deep.
2. Inspect for pitting greater than 1/8 in. (3.2mm) deep.
3. Inspect case gasket seat surface for irregularities.
Inspect impeller vane
1. Inspect impeller vanes for damage (101). Check the vane O.D. for erosion. Check the vane
surfaces, replace if grooved, worn, or eroded deeper than 3/16" (5.0 mm.) Excessive
impeller wear may cause a reduction in performance.
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Pre-assembly inspections
Figure 48: Impeller inspection
2. Inspect the leading and trailing edges of the vanes for pitting, erosion or corrosion damage
replace if grooved, or worn deeper than 3/16" (5.0 mm.)
3. Inspect the root (vane attach point at hub) of each vane for cracks. Impeller vane failure
can cause unbalance in the rotating assembly that will lead to catastrophic failure of the
pump.
4. Inspect the keyway and stepped bores for signs of pitting, wear or corrosion damage.
5. Check the O-ring groove and bolt holes for signs of pitting or corrosion.
Inspect the shaft
1. Check the shaft (122) for straightness, wear, corrosion, and radial run-out. Maximum runout for non-contact portions of the shaft is .003 in. max.
Figure 49: Shaft inspection
2. 2. For all contacting surfaces such as bearing seats, sleeve seats, and impeller mounting
surfaces see critical axial flow table.
Inspect the shaft sleeve
1. The shaft sleeve (126) should be replaced if badly grooved or worn. Localized wear or
grooving greater than 3/32 in. (2.4 mm) deep is cause for replacement.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
71
Pre-assembly inspections
Inspect the mechanical seal / restrictor bushing
1. Refer to the mechanical seal (383) vendor’s manual for inspection instructions.
2. The restrictor bushing, (496B) if necessary should be replaced during re-assembly.
Inspect the stuffing box
1. Check the stuffing box (220) for localized wear or grooving greater than 1/16 in. (1.6 mm)
deep.
2. Check for pitting greater than 1/16 in. (3.2mm) deep.
3. Inspect stuffing box gasket seat surface for any irregularities.
Figure 50: Inspect the stuffing box
Inspect the bearing housing
1. Inspect the bearing housing (134C) bores for signs of scarring or galling from the outer
race.
2. Refer to Critical bore dimensions table for the critical bore dimensions for the housings. The
bores should not be eggy and should be concentric
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AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Pre-assembly inspections
1 Outer housing bore
.
2 Inboard housing bore
.
Figure 51: Bearing housing inspection
Inspect the bearings
1. Inspect the bearings (112C and 168C) for contamination and damage.
The condition of the bearing will provide useful information on operating conditions in the
bearing housing.
2. Note the lubrication condition and residue.
3. Investigate bearing damage to determine the cause.
4. If cause is not normal wear, correct before the pump is returned to service.
DO NOT RE-USE BEARINGS.
Labyrinth seals and O-rings
Although the labyrinth seals (332, 333), O-rings (351, 351A, 351W, 412A, 412D, 412T, 412Y,
496D) and gaskets (331, 351A, 351W, 211) may seem okay during inspection and
examination, DO NOT RE-USE SEALS when rebuilding the pump. Replace them while pump
is disassembled.
Critical axial flow dimensions and tolerances
Pump
Size
6
8
10
12
14
16
18
Inboard Outboard
Housing housing
Bore
bore
Inboard
bearing
seat
Outboard
Mech.
bearing Seal
Seat
seat
Sleeve
Seat
Impeller End
1st Step 2nd Step
1.2495
1.2485
1.3745
1.3735
3.5442
3.5433
3.9379
3.9370
1.9690
1.9686
1.7722
1.7718
1.750
1.748
1.687
1.685
4.7253
4.7244
5.5128
5.5118
2.5597
2.5592
2.5597
2.5592
2.500
2.498
2.437
2.435
5.9076
5.9055
6.6950
6.6929
3.3472
3.3466
3.1502
3.1497
3.250
3.248
3.248
3.247
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
1.9995
1.9985
1.9895
1.9885
2.5935
2.5925
2.6245
2.6235
2.0307
2.0297
1.9995
1.9985
2.6245
2.6235
2.6555
2.6545
73
Pre-assembly inspections
Pump
Size
Inboard
bearing
seat
Outboard
Mech.
bearing Seal
Seat
seat
Sleeve
Seat
Impeller End
1st Step 2nd Step
7.8758
7.8740
8.3780
8.3770
4.7263
4.7254
4.2531
4.2521
5.250
5.248
5.188
5.186
700mm
30
9.8449
9.8431
10.7530
10.7520
5.9071
5.9061
4.7534
4.7524
6.250
6.248
6.187
6.186
3.6240
3.6552
3.6230
3.6542
4.0000
4.0300
3.9985
4.0290
3.999
3.998
36
11.0262
11.0244
12.0030
12.0020
6.6945
6.6935
5.7525
5.7515
7.000
6.998
6.9360
6.9335
4.7180
4.7165
20
24
74
Inboard Outboard
Housing housing
Bore
bore
4.7490
4.7475
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Reassembly
Reassemble the cooling coil (optional) sight glass / breather and
plugs
Re-assembly of the AF is done opposite the order of disassembly with a few exceptions. Be
sure the parts are clean and free of burrs and scratches. Every assembly step should be
double-checked to ensure proper order and technique to prevent having to partially
disassemble the step you just finished.
1. The optional cooling coil is installed by first fastening two modified male connectors (972G)
to the cooling coil cover (113B).
2. Insert the ends of the cooling coil (984A) through the male connectors (972G) and screw
the female connector (972H) to the male compressing the tubing in-between.
3. Attach the cover plate (113B) to the bearing housing (134C) using a new gasket (360E)
and the six screws (370F) w/ O-rings (370F).
Figure 52: Cooling coil reassembly
4. Install the breather (113A), pipe plugs (408, 408A, 408D, 251C) and sight glass (319) in the
locations shown in Cooling coil reassembly figure.
Reassemble the rotating element (1MXR-3MXR configurations)
1. 1. Heat the inboard radial bearing (168C) to 225°F using an induction heater.
2. Slide the bearing onto the impeller end of the shaft (122), push it on until it rests flush and
square against the shaft shoulder, see figure below and the sectional drawing at the end of
this section.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
75
Reassembly
1.
Outer thrust bearing
2.
Inner thrust bearing
Figure 53: Rotating element reassembly (1MXR-3MXR configurations)
WARNING:
Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause physical injury.
3. Heat the inner thrust bearing (112C) to 225°F. The thrust bearings are mounted back-toback, so before placing the bearing on the shaft (122) be sure that the large diameter face
of the inner race is facing the shaft shoulder.
4. Heat the outer thrust bearing (112C) to 225°F. Slide the bearing onto the shaft with the
small diameter of the inner race facing the inner thrust bearing. Be sure it rests flush and
square against the inner thrust bearing.
5. Before the bearings cool install the bearing lock-washer (382) and lock nut (136). Tighten
until snug. Re-tighten the lock nut (136) several times before the bearing cools completely.
The tapered end of the locknut (136) should face toward the lock washer (382). Be sure
that no clearance exists between the outer and inner thrust bearing (112C). With the nut
secure align the slots with the lock-washer tangs and bend the lock washer tangs into the
nut slots.
6. If the pump is grease lubricated pack the inboard (168C) and outboard bearings (112C)
with suitable grease. Make sure the races are fully packed.
Reassemble the rotating element (4MXR-6MXR configurations)
1. Heat the inboard radial bearing (168C) to 225°F using an induction heater. Slide the
bearing onto the drive end of the shaft (122) push it on until it rests flush and square against
the inboard shoulder.
76
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Figure 54: Rotating element reassembly (4MXR-6MXR configurations)
WARNING:
Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause physical injury.
2. Install the oil wheel (248) by sliding it onto the shaft with the open end facing the inboard
bearing (168C). With the oil wheel up against its shoulder install the set screws (222N) that
hold it to the shaft (122).
3. Heat may be applied to the thrust bearing collar (443X) if necessary to install on the shaft.
Install it with the tapered end facing the oil wheel (248).
4. Heat the thrust bearing (112C) to 225°F. Install one row of roller bearings and the inner
race on the shaft (122). Be sure to slide the bearing on the shaft until it is flush and square
up against the thrust bearing collar (443X).
5. While the thrust bearing is still hot install the outer row of rollers and the outer race. Install
the keyed washer (142B), lock-washer (382) with its tang in the groove on the shaft (122)
and the lock nut (136) with tapered end toward the lock washer (382). Tighten the whole
unit until snug. Re-tighten the lock nut (136) several times before the bearing cools
completely. Be sure no clearance exists between the inner race, collar (443X) and shaft
shoulder (122). With the locknut secure align the slots with the tangs of the lock-washer
and bend the lock washer tangs into the nut slots.
6. If the pump is grease lubricated pack the inboard (168C) and outboard bearings (112C)
with suitable grease. Make sure the races are fully packed.
Reassemble the bearing housing
1. Thread an eyebolt into the end of the shaft (122), lift and lower the rotating element into the
bearing housing (134C), see Fig. 59. A collar similar to that shown on pg. 69 should be
used to prevent misalignment of the inboard radial bearing.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
77
Reassembly
1. Rotating element
Figure 55: bearing housing insertion
2. Using screws (799F & 370Y), install the front (239B) and rear feet (239A).
3. Install the thrust bearing retainer (119C), O-ring (412Y) (4MXR ~ 6MXR) or gaskets (331)
(1MXR~ 3MXR).
See the assembly drawing for proper shimming of gasketed pumps. Install the screws
(788Z) that secure the thrust bearing retainer (119C) to the bearing housing (134C).
78
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Figure 56: Reassemble the bearing housing
4. Install the outboard and inboard labyrinth seals (132) and (133).
The drains should be located at the bottom and face inward when mounted.
Figure 57: Labyrinth seal reassembly
Reassemble the drip pan
1. Tilt the drip pan (179) so the attachment ears clear the bearing housing (134C) flange and
the nipple protrudes through the cast hole in the bottom of the bearing housing.
2. Secure the drip pan to the bearing housing ribs using the two screws (799H) and washers
(799I).
3. Thread the street elbow (799G) into nipple on the bottom of the drip pan.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
79
Reassembly
Figure 58: Drip pan reassembly
Reassemble the packed box
1. Place the sleeve key (178D) into the shaft (122) key seat. Slip the O-ring (412D) into the
shaft sleeve (126) then slide the sleeve onto the shaft until the keyways are lined up.
2. Install the set screw (469D) and tighten it to lock the sleeve in place.
Be careful not to mar or scratch the sleeve or shaft during the process.
3. Attach the stuffing box (220) and gasket (351W) to the stuffing box cover (184) using
screws (799E).
If removed re-install the four studs (355). On larger pumps use a sling or hook and chain to
support the weight of the stuffing box cover during installation.
4. Mount the stuffing box cover (184) to the register of the bearing housing (134C).
Be careful not to scuff or scar the pump shaft (122) or sleeve (126) during installation.
5. Secure the stuffing box cover (184) to the bearing housing (134C) using bolts (370C).
6. Pack the stuffing box initially with two rings of packing (106) staggering the joints for each
row. Insert the lantern ring (105) being sure that the lantern ring lines up with the flush
ports.
If the lantern ring has taps for removal make sure they face out of the box.
7. Insert three more rings of packing (106), gland (107), and gland nuts (353), tighten the nuts
only hand tight.
8. Install all flush tubing that may have been removed during disassembly.
Figure 59: Packed box reassembly
80
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Reassemble the mechanical seal with optional adapter
The loose mechanical seal (383, 108) components and gaskets (211) are slid onto the shaft
(122) first before the stuffing box cover (184) can be installed. If the seal includes a restrictor
bushing (496B) an optional adapter (108B) will be included with the pump.
1. On large pumps use a sling or hook and chain to securely support the weight of the stuffing
box cover during installation.
2. Mount the stuffing box cover on the bearing housing (134C) register.
3. Secure the stuffing box cover (184) to the bearing housing (134C) using two bolts (370C).
Be careful not to scuff or mar the pump shaft (122) during installation.
4. Install the four adjusting lugs (415) and impeller adjusting bolts (356A).
5. Use the upper adjusting screws (356A) closest to the bearing housing to center the stuffing
box cover on the shaft.
The seal manufacturers instructions should be followed to correctly install and align the
mechanical seal.
6. Lastly, install the seal gland nuts (353) and secure the seal to the stuffing box cover (184).
Be sure all gland quench or flush tubing is connected.
Figure 60: Mechanical seal with optional adapter reassembly
Reassemble the standard impeller
If your model has a standard impeller, follow the steps below:
1. Install the shaft key (178).
2. Slide the impeller (101) onto the shaft (122) and if necessary use a wooden mallet to set it
in place against the shaft shoulder.
3. Install the shaft washer (199) and fasteners (198), tighten to lock the impeller (101) in
place, see Fig. 65.
Figure 61: Standard impeller reassembly
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
81
Reassembly
Reassemble the sealed impeller
If you have a sealed impeller, follow the steps below:
1. 700mm and 36” sizes use an impeller cover and O-rings to keep pumpage out of the
impeller cavity. First, install the shaft key (178) on the shaft. Using some silicone stick the
impeller O-ring (412A) to the back side of the impeller (101).
2. Slide the impeller (101) onto the shaft (122). If necessary use a wooden mallet to set it in
place against the shaft shoulder.
3. Install the shaft washer (199) and bolts (198).
4. Place the O-ring (412T) on the cover and fasten the cover (998E) to the impeller (101)
using bolts (370M).
Some impeller covers have a pipe test plug (408H) located on the face of the cover to test
the cavity seal after re-assembly.
5. Re-install this plug (358I).
Figure 62: Sealed impeller reassembly
Reassemble the back-pullout elbow
1.
2.
3.
4.
5.
Set the pump down on a smooth flat surface to stabilize it for assembly.
Loosen the impeller adjusting bolts (356A) so that they are clear of the rear elbow flange.
Loosen the impeller adjusting bolts (356A) so that they are clear of the rear elbow flange.
With the elbow held in place, slide the back-pullout into the elbow (315A).
Install the bolts (789L and 799O) that secure the back-pullout to the elbow (315A).
Be sure to use the correct O-ring material for the pumpage.
1.
Back pull-out
2.
Rear elbow flange
Figure 63: Elbow reassembly
82
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Reassemble the back-pullout elbow with casing
1. The 700mm & 36" size pumps come with a separate casing (100). Loosen the adjusting
screws (356A) so that they are clear of the elbow flange.
2. Insert O-ring (351) into the elbow groove and hold in place with a small amount of grease.
Be sure to use the correct O-ring material for the pumpage.
3. With the elbow fixed, slide the back-pullout into the elbow (315A) and install bolts (789L
and 799O).
4. Insert the O-ring or gasket (351A) between the casing (100) and elbow (315A).
5. Attach the casing (100) to the elbow (315A) using the bolts (799C) and nuts (799D).
6. With casing (100) slightly loose adjust casing to center the impeller.
1. Back-pullout
Figure 64: Elbow with casing reassembly
Reassemble the back-pullout liner (option)
1. If the elbow (100) or casing (100) has an optional liner (103A) now is the time to install it.
The liner may require some effort to install try using a wooden mallet if resistance is
noticed. The liner is sealed when it is compressed against the pipe flange and requires no
gasket. If a replacement is necessary be sure to order the correct material for the pumpage.
Figure 65: Liner (option) reassembly
Reassemble the drive / guard (v-belt configuration)
1. Using a crane, lift the pump into place on the sub-base.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
83
Reassembly
Be careful not to damage the pump by striking any beams or walls that may be near the
pump.
2. If any shims were found under the bearing housing feet during disassembly replace them at
this time.
3. Install the pump to sub-base bolts (500A) and remove the lifting straps or chains from
around the bearing housing (134) and elbow (100).
Figure 66: Pump to sub-base reassembly
4. Install V-belts and re-apply tension by adjusting the slide base away from the pump.
5. Adjust and check the tension per the drive manufacturers instructions.
1.
Install belts
2.
Shift slide base
Figure 67: V-belt installation
6. Fasten the guard base (501) to the sub-base using screws (502). Install the guard cover
(500) using screws (502).
84
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
Figure 68: Guard base to sub-base reassembly
7. Check impeller alignment and re-align if necessary according to instructions for (impeller
alignment).
Reassemble the drive / guard (direct connect configuration)
1. Using a crane, lift the pump into place on the sub-base.
Be careful not to damage the pump by striking any beams or walls that may be near the
pump.
2. If any shims were found under the bearing housing feet during disassembly replace them at
this time.
3. Install the pump to sub-base bolts (500A) and remove the lifting straps or chains from
around the bearing housing (134) and elbow (100).
Figure 69: Direct drive - pump to sub-base reassembly
4. Align the gear box and pump coupling halves as described in sub-base installation section.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
85
Reassembly
If the motor and gear box were moved during disassembly re-align they must be re-aligned
also.
5. Wrap the coupling cover around the coupling halves and install the fasteners that hold the
coupling cover together.
Figure 70: Coupling cover reassembly
6. Bolt the two halves of the coupling guard (500) together and install over the coupling.
7. Fasten the guard to the sub-base using screws (502).
Figure 71: Coupling guard reassembly
8. Check impeller alignment and re-align if necessary according to instructions impeller
alignment.
9. Fill pump with proper lubricant. Refer to preventative maintenance for requirements.
10. Connect all auxiliary piping and tubing
11. Fill system piping so pump impeller is submerged, flush the pump if necessary.
12. Open all valves controlling flow “to and from” the pump.
13. Un-lock driver power and jog the pump motor to be sure the pump rotates with no binding
or rubs. If all is proper, continue with pump start-up.
86
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Reassembly
WARNING:
With power unlocked be careful so as to prevent accidental start-up and physical injury.
WARNING:
Operator should be aware of pumpage and safety precautions to prevent physical injury.
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
87
Troubleshooting
Troubleshooting
Pump Troubleshooting
Table 6: Pump Troubleshooting
Symptom
Cause
Remedy
Pump not primed or prime lost,
Fill system piping completely so
liquid level does not completely fill the impeller is submerged
elbow
Suction inlet clogged
Remove obstructions from pump
inlet
Impeller clogged with foreign ma- Back flush pump or manually
terial
clean impeller
Suction and /or discharge valve
Open valves to remove shut-off
closed or clogged
condition
Change rotation to concur with
No liquid delivered or intermittent Wrong direction of rotation
direction indicated by the arrow on
flow
the bearing housing
Suction piping incorrect
Replace or modify suction piping
Insufficient NPSH available
Increase liquid level or lower
pump
Air leak in suction line
Test suction piping for leaks
Speed (rpm) too low
New drive or gear box to obtain
higher pump speed
Excess air entrapped in liquid
Install vent in piping or eliminate
air source
Impeller partly clogged
Back flush pump or manually
clean impeller
Insufficient suction head
Fill system piping so the liquid
level is above the pump impeller
centerline
Pump not primed or prime lost,
Fill system piping completely so
pump does not completely fill el- the impeller is submerged
bow
Suction and/or discharge valve
Open valves to remove partially
closed or clogged
blocked condition
Suction piping incorrect
Replace or modify suction piping
Excessive air entrapped in liquid Install vent in piping or eliminate
air source
Pump not producing rated flow or
head
Speed (rpm) too low
New drive or gear box to obtain
higher pump speed
Incorrect rotation
Check motor wiring
Incorrect impeller or impeller diCheck vane angles and/ or impelameter
ler clearances
System head too high
Check system curve calculations,
reduce system resistance
Instruments give erroneous read- Check and calibrate instruments,
ings
replace if necessary
Worn or broken impeller, bent
Inspect and replace if necessary
vanes
Pump assembled incorrectly
Compare pump assembly to instruction manual
88
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Troubleshooting
Symptom
Wear of internal wetted parts is
accelerated
Cause
Insufficient NPSH available
Chemicals in liquid other than
specified
Pump assembled incorrectly
Higher solids concentration than
specified
Excessive leakage from stuffing
box
Packing gland improperly adjusted
Stuffing box improperly packed
Worn mechanical seal parts
Overheating mechanical seal
Shaft sleeve scored
Packing has short life
Pump run off design point
Shaft/shaft sleeve worn
Packing gland not properly adjusted
Packing not properly installed
Pump not assembled correctly
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Remedy
Increase liquid level or lower
pump
Analyze pumpage and correct or
change pump wet end materials to
suit pumpage composition
Compare pump assembly to instruction manual
Analyze pumpage and correct or
change pump wet end materials to
harder composition
Tighten gland nuts
Check packing and re-pack box
Replace worn parts
Check lubrication and cooling
lines
Re-machine or replace as required
Check head and flow, AF’s should
normally be run between 75% and
125% of BEP
Replace shaft or shaft sleeve if
necessary
Replace packing and readjust
gland as specified in the operating
manual
Check packing manufacturer's instructions
Compare pump assembly to instruction manual
89
Troubleshooting
Symptom
Cause
Lubricant level
Bearings run hot and or fail on a
regular basis
90
Remedy
Be sure the oil level is at center
line of sight glass
Improper lubricant
Check lubricant for suitability
Not lubricated enough
Increase frequency of grease lubrication
Broken or bent impeller vanes
Check impeller dimensions and
vane layout
Excessive shaft misalignment
Check shaft run-out and consult
factory
Inadequate lubricant cooling
Check pumpage temperature and
add oil cooling system if necessary
Axial thrust or radial load higher
Calculate bearing life for make
than bearing rating
and model bearing
Improper coupling lubrication
Check coupling lubrication schedule in manufacturers installation,
operation, maintenance manual
Coupling out of balance
Check pump and drive component
vibration levels, rebalance
coupling if necessary
Suction pressure too high
Check liquid levels and static suction pressure
Bearing incorrectly installed
Check bearing orientation to sectional drawing
Impeller out of balance
Check pump vibrations, if necessary rebalance impeller
Excessive shaft deflection
Check shaft diameter, sag and
deflection, consult factory
Pump run off design point
Check head and flow, AF’s should
normally be run between 75% and
125% of BEP
Lubricant contamination
Inspect oil or grease for contaminants
Piping not properly anchored
Check to see if excessive pipe
strain is being transferred to pump
flanges
Pump and/or driver not secured to Check fasteners, if loose check
sub-base
alignment and re-tighten
Specific gravity higher than spec- Analyze pumpage and compare to
ified
specified gravity
Viscosity higher than specified
Analyze pumpage and compare to
specified viscosity
Pump assembled incorrectly
Compare pump assembly to instruction manual
Partly clogged impeller causing
Back flush pump or manually
Imbalance
clean impeller
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Troubleshooting
Symptom
Cause
Pump is noisy or vibrates at high- Broken or bent impeller or shaft
er than normal levels
Pump foundation not rigid or subbase not completely secured
Impeller out of balance
Motor not secure
Improper coupling lubrication
Bearing incorrectly installed
Coupling out of balance
Pump operating speed too close
to system’s natural frequency
Impeller partly clogged
Impeller clearances too tight
Pump assembled incorrectly
Pump run off design point
Excessive shaft deflection
Worn bearings
Suction or discharge piping not
anchored or properly supported
Suction and/or discharge valve
closed or clogged
Excessive shaft misalignment
Pump assembled incorrectly
Pump is cavitating, insufficient
NPSH available
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Remedy
Replace as required
Tighten hold down bolts on subbase Check foundation rigidity
Check impeller balance
Check motor fasteners
Check coupling lubrication schedule in manufacturers installation,
operation, maintenance manual
Check bearing orientation to sectional drawing
Check pump and drive component
vibration levels, rebalance
coupling if necessary
Change speed to be +/- 20% of
the pumps natural frequency
Back flush pump or manually
clean impeller
Check impeller clearances adjust
if necessary
Compare pump assembly to instruction manual
Check head and flow, AF’s should
normally be run between 75% and
125% of BEP
Check shaft diameter, sag and
deflection, consult factory
Replace
Anchor per Hydraulic Institute
Strandards Manual recommendation
Open valves to remove partially
blocked condition
Check shaft run-out and consult
factory
Compare pump assembly to instruction manual
System problem, increase liquid
level or lower pump
91
Troubleshooting
Symptom
High rate of mechanical seal failure
Motor requires excessive power
92
Cause
Insufficient NPSH available
Remedy
Increase liquid level or lower
pump
Excessive shaft misalignment
Check shaft run-out and consult
factory
Suction pressure too high
Check liquid levels and static suction pressure
Bearing installed incorrectly
Check bearing orientation to sectional drawing
Impeller out of balance
Check pump vibrations, if necessary rebalance impeller
Overheating of seal faces
Check flush flow with mfgr’s recommendation, increase if necessary
Excessive shaft deflection
Check shaft diameter, sag and
deflection, consult factory
Lack of seal flush to seal faces
Check shaft diameter, sag and
deflection, consult factory
Incorrect seal installation
Check seal materials vs. pumpage to determine compatibility
Pump is run dry
Fill system piping completely so
the impeller is submerged
Pump run off design point
Check head and flow, AF’s should
normally be run between 75% and
125% of BEP
Shaft/shaft sleeve worn
Replace shaft or shaft sleeve if
necessary
Coupling out of balance
Check pump and drive component
vibration levels, rebalance
coupling if necessary
Sub-base not installed correctly
Compare pump sub-base installation to instruction manual
Bearing failing
Replace if necessary
Piping not properly anchored
Check to see if excessive pipe
strain is being transferred to pump
flanges
Pump and/or driver not secured to Check fasteners, if loose check
sub-base
alignment and re-tighten
Specific gravity higher than spec- Analyze pumpage and compare to
ified
specified gravity
Viscosity higher than specified
Analyze pumpage and compare to
specified viscosity
Pump assembled incorrectly
Compare pump assembly to instruction manual
Head higher than rating. Reduced Check for fouling in the piping or
flow
obstruction in discharge
Liquid heavier than expected
Check specific gravity and viscosity
Incorrect rotation
Jog motor and check rotation
Pump run off design point
Check measured head and flow to
specified head and flow
Stuffing box packing too tight
Readjust packing. Replace if worn
Rotating parts binding, internal
Check internal wearing parts for
clearances too tight
proper clearances
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
Parts Listings and Cross-Sectionals
Cross sectional drawing (shown with optional restrictor bushing
adapter)
Figure 72: Cross sectional (shown with optional restrictor bushing)
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
93
Parts Listings and Cross-Sectionals
Parts list and materials of construction
Table 7: Parts list and materials of costruction
Standard Materials of Construction
Part
Item Name
Cast
304
316
Alloy Duplex 904L Monel Inconel Nicket Titaniu
Iron
20
SS
m
100
Elbow
1002
1284
1245
1283
1247
1233
1119
1273
1601
1220
101 Impeller
105 Lantern
Teflon
rig
106 Packing
Dependent on pumpage
107
Gland 1002
1284
1245
1283
1247
1233
1119
1273
1601
1220
Out112C board
Steel
bearing
113A
Oil
Steel
breather
Thrust
109 bearing
1000
retainer
122
Shaft
2206
2228
2229
2230
3279
2369
2150
2266
2155
2156
126
Shaft
1002
1284
1245
1283
1247
1233
1119
1273
1601
1220
sleeve
Bearing 1000
134 housing
136 Bearing
Steel
locknut
Keyed
142B washer
Steel
168C Inboard
Steel
bearing
178 Impeller
key
2213
2228
2229
2230
2248
2369
2150
2266
2155
2156
178D Sleeve
key
179
Drip
316 standard, other options available
pan
Stuffing
184
box
1002
1284
1245
1283
1247
1233
1119
1273
1601
1220
cover
198 Impeller 2210
2228
2229
2230
2248
2369
2150
2266
2155
2156
screw
199 Impeller 3201
2228
3211
2230
3270
2369
2150
2266
2155
2156
lockplate
220 Stuffing 1002
1284
1245
1283
1247
1233
1119
1273
1601
1220
box
222A
Set
2213
2228
2229
2230
2248
2369
2150
2266
2155
2156
screw,
sleeve
222B
Set
Steel
screw,
oil
wheel
239B Frame
Steel
foot, inboard
239A Frame
Steel
foot,
outboard
248
Oil
Iron
wheel
94
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
Item
Part
Name
251C
Plug,
oiler
Elbow
w/casing
Liner,
elbow
Laby
seal,
outboard
Laby
seal, inboard
Gasket,
stuffing
box
Gasket,
elbow
casing
Gland
stud
Gland
nuts
Nuts,
casing
Ajusting
bolts
Oil fill
plug
Cover,
oil cooling
Gasket,
oil cooling
HHCS,
oil cooling
HHCS
casing
HHCS
bearing
housing
/ elbow
HHCS
foot,
front
HHCS
SB coverframe
HHCS
SB cover-bearing
housing
HHCS
impeller
Frame
foot,
rear
315A
315B
332A
332B
351
351A
353
355
357G
356A
358U
360W
361
370F
370G
370J
370K
370H
370L
370M
370Q
Cast
Iron
304
316
1002
1284
1245
Standard Materials of Construction
Alloy Duplex 904L Monel Inconel Nicket Titaniu
20
SS
m
Steel
1283
1247
1233
1119
1273
1601
1220
Carbon filled teflon
Carbon filled teflon
5202
5303
5309
2229
2210
2228
2229
2230
2248
2369
2150
2266
2155
2156
2150
2266
255
2156
2150
2266
2155
2156
Steel
Steel
Steel
5302
Steel
2210
2228
2229
2230
2248
2369
Steel
Steel
Steel
2210
2228
2229
2230
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
2248
2369
Steel
95
Parts Listings and Cross-Sectionals
Item
Part
Name
370S
End
cover
screws
HHCS
adj. lug
HHCS
adj.
screw
Frame
foot
screws
Lock
washer
Mechanical seal
Drip
pan
screws
Couplin
g key
Plug,
drain
Sensor
plugs
Plug,
impeller
O-ring,
sleeve
Spacer
O-ring,
stuffing
box
cover
O-ring,
end
cover
O-ring,
impeller
cap
O-ring,
impeller
nose
Gasket,
bearing
housing
Drip
pan elbow
HHCS,
SBX/
SBXCV
R
Adjusting bar
Male
connector
Femail
connector
Cooling
coil
370U
370V
370Y
382
383
388Z
400
408
408A
408H
412F
443X
496
496A
496B
496C
540C
555D
600Z
787H
9727
9728
9841
96
Cast
Iron
304
316
2210
2228
2229
Standard Materials of Construction
Alloy Duplex 904L Monel Inconel Nicket Titaniu
20
SS
m
Steel
2230
2248
2369
2150
2266
2155
2156
2150
2266
2155
2156
Steel
Steel
As specified
Stainless
Steel
Steel
Steel
2210
2228
2229
2230
2248
2369
5302
5303
5309
5302
Steel
5303
5309
BUNA-N
5302
5303
5309
5302
Stainless steel standard, other options availblrle
2210
2228
2229
2230
2248
2369
2150
2266
2155
2156
Steel
Steel
Steel
2229
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
Item
Part
Name
Cast
Iron
304
316
Adjusting lug,
casing 2210
9985 Impeller
cover
2228
2229
Standard Materials of Construction
Alloy Duplex 904L Monel Inconel Nicket Titaniu
20
SS
m
9879
2230
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
2248
2369
2150
2266
2155
2156
97
Parts Listings and Cross-Sectionals
AF options
Figure 73: AF options
98
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Parts Listings and Cross-Sectionals
MXR bearing configurations
Figure 74: MXR bearing configurations
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
99
Parts Listings and Cross-Sectionals
AF with separate casing
Figure 75: AF with separate casing
100
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
Appendix
Appendix
Bearing alignment
Figure 76: Bearing alignment collar detail
AF (6"-36") MXR Bearings Installation, Operation, and Maintenance Manual
101
Visit our website for the latest version of this
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240 Fall Street
Seneca Falls, NY 13148
USA
Tel. 1-800-446-8537
Fax 1-315-568-2418
© 2015 ITT Corporation
The original instruction is in English. All non-English instructions are translations of the original instruction.
Form en-US.2015-04.IOM.AF.636MXR.Bearings
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