series vsx vsh, vsc®, and vscs® models centrifugal pumps

series vsx vsh, vsc®, and vscs® models centrifugal pumps
Bell & Gossett
Instruction Manual
P5002169
SERIES VSX
VSH, VSC®, AND VSCS® MODELS
CENTRIFUGAL PUMPS
Installation, Operation, Maintenance
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
TABLE OF CONTENTS
MAINTENANCE OF FLOOD DAMAGED PUMPS ....... 20
INTRODUCTION ...................................................................... 1
DESCRIPTION................................................................ 1
PUMP APPLICATION ..................................................... 1
OPERATIONAL LIMITS .................................................. 1
Maximum Suction Pressure...................................... 1
Maximum Working Pressure..................................... 1
SEAL OPERATING LIMITS ............................................ 1
Mechanical Seals...................................................... 1
Packing .................................................................. 1
PUMP IDENTIFICATION ................................................ 2
SAFETY INSTRUCTIONS .............................................. 3
ADDITIONAL SAFETY INSTRUCTIONS........................ 4
Electrical Safety ........................................................ 4
Thermal Safety ......................................................... 4
Mechanical Safety .................................................... 4
TROUBLE SHOOTING .......................................................... 21
GUARDS ................................................................................ 23
ANSI/OSHA COUPLING GUARD
REMOVAL/INSTALLATION................................ 23
Removal ............................................................... 23
Installation .............................................................. 23
BRACKET GUARDS .................................................... 24
SERVICE................................................................................ 25
GENERAL DISASSEMBLY PROCEDURES................ 26
SHUTDOWN................................................................. 26
DISASSEMBLY PROCEDURE TO REMOVE BEARING
FRAMES – ALL PUMPS..................................... 26
DISASSEMBLY PROCEDURE TO REMOVE
STANDARD MECHANICAL SEALS ................... 27
DISASSEMBLY PROCEDURE TO REMOVE STUFFING
BOX AND PACKING........................................... 28
DISASSEMBLY PROCEDURE TO REMOVE
CARTRIDGE SEALS .......................................... 28
DISASSEMBLY PROCEDURE TO REMOVE
COVERPLATES AND SHAFT ASSEMBLY – ALL
PUMPS ............................................................... 29
ASSEMBLY PROCEDURE TO INSTALL
COVERPLATES AND SHAFT ASSEMBLY – ALL
PUMPS ............................................................... 29
ASSEMBLY PROCEDURE TO INSTALL STANDARD
MECHANICAL SEALS........................................ 31
ASSEMBLY PROCEDURE TO INSTALL STUFFING
BOX AND PACKING........................................... 32
ASSEMBLY PROCEDURE TO INSTALL CARTRIDGE
SEALS ................................................................ 32
ASSEMBLY PROCEDURE TO INSTALL BEARING
FRAMES – ALL PUMPS..................................... 33
GENERAL ASSEMBLY INSTRUCTIONS .................... 34
TO CHANGE ROTATION............................................. 35
TO CHANGE STANDARD MECHANICAL SEALS ...... 36
TO CHANGE CARTRIDGE SEALS.............................. 36
TO CHANGE THE PACKING OR SLEEVE.................. 36
ORDERING PARTS ..................................................... 36
DEALER SERVICING................................................... 36
GENERAL INSTRUCTIONS .................................................... 5
PURPOSE OF THE MANUAL ........................................ 5
WARRANTY.................................................................... 5
RECEIVING THE PUMP................................................. 5
TEMPORARY STORAGE............................................... 5
LIFTING THE PUMP....................................................... 5
LOCATION...................................................................... 6
Important .................................................................. 6
FOUNDATION ................................................................ 6
BASE PLATE SETTING.................................................. 7
Optional Grouting...................................................... 7
ROTATION...................................................................... 7
COUPLING ALIGNMENT ............................................... 7
To align using straight edge and calipers ................. 8
To align using dial indicator ...................................... 9
Final Alignment ....................................................... 11
SUCTION AND DISCHARGE PIPING.......................... 11
Suction Piping......................................................... 12
Valves in Suction Piping ......................................... 13
Discharge Piping..................................................... 13
Pressure Gauges.................................................... 14
Pump Insulation ...................................................... 14
PUMP SEALING ........................................................... 14
Mechanical Seals.................................................... 14
Packing ................................................................ 14
VEE-CUT IMPELLER TRIMS ....................................... 15
OPERATION........................................................................... 17
FLUSHING .................................................................... 17
FILLING......................................................................... 17
PRIMING....................................................................... 17
PRE-START CHECKS.................................................. 17
STARTING .................................................................... 18
OPTIONAL CHECKLIST............................................... 18
FREEZE PROTECTION ............................................... 18
FIELD TESTS ............................................................... 18
NOTE: The information contained in this book is intended to
assist operating personnel by providing information about the
characteristics of the purchased equipment.
It does not relieve the user of their responsibility of using
accepted engineering practices in the installation, operation,
and maintenance of this equipment.
For additional questions, contact
MAINTENANCE ..................................................................... 19
GENERAL MAINTENANCE AND PERIODIC
INSPECTION ...................................................... 19
LUBRICATION .............................................................. 19
Pump Bearings ....................................................... 19
Couplings ................................................................ 19
SEAL INFORMATION................................................... 19
Mechanical Seals.................................................... 19
Packing (Non-Asbestos) ......................................... 19
BELL & GOSSETT
(847) 966-3700.
http://www.bellgossett.com
i
ii
INTRODUCTION
SEAL OPERATING LIMITS
DESCRIPTION
The Series VSX centrifugal pumps are framemounted pumps that feature high efficiency,
rugged construction, compact design, footmounted volute, alignment-friendly coupling, and
unitized seals. These features, along with the
vertically split case make installation, operation,
and service easy to perform.
Mechanical Seals
NOTE: For use on closed or open systems
that are relatively free of dirt and/or other
abrasive particles.
Unitized EPR/Car/SiC: 0°F to 300°F
Temperature range; 6.5 to 8.5 pH range
Unitized Viton/Car/SiC: 0°F to 225°F
Temperature range; 6.5 to 8.5 pH range
PUMP APPLICATION
The standard Series VSX centrifugal pump’s
bronze fitted construction makes it ideal for service
with the following liquids: hydronic cooling or
heating, boiler feed water, condensate, pressure
boosting, general pumping, unheated domestic
and fresh water, and benign liquids.
Unitized EPR/Graphite Loaded SiC: 0°F to
300°F Temperature range; 7 to 12.5 pH range
For other applications contact your local Bell &
Gossett representative.
Balanced Viton/Graphite Loaded SiC: 0°F to
225°F Temperature range; 7 to 12.5 pH range
Balanced EPR/Graphite Loaded SiC: 0°F to
300°F Temperature range; 7 to 12.5 pH range
OPERATIONAL LIMITS
Unless special provisions have been made for
your pump by Bell & Gossett, the operational limits
for Series VSX pumps are as follows:
CAUTION: Equipment Damage
To prevent premature seal failure or possible
injury, the unitized seals should not be used as an
alternate or substitute for the balanced seals
installed in a high suction pressure rated VSX
pump.
Maximum Suction Pressure
Table 1 shows the maximum suction
pressures allowed for pump size and seal
type:
Table 1:
Failure to follow these instructions could result in
serious property damage and/or moderate
personal injury.
Maximum Suction Pressures
Unitized Seal Balanced Seal
2” Seal Sizes
4x6x10.5
5x6x10.5
5x6x13.5
6x8x10.5
6x8x13.5
8x10x10.5
175 psi
300 psi
175 psi
300 psi
Packing
NOTE: For use on open or closed systems
that require a large amount of makeup water,
as well as systems that are subjected to
widely varying chemical conditions and solids
buildup.
2.5” Seal Sizes
8x10x13.5
10x12x10.5
10x12x13.5
Braided Graphite PTFE:
0°F to 200°F Temperature range; 7 to 9 pH
range
3” Seal Sizes
12x14x13.5
14x16x13.5
3.5” Seal Sizes
12x14x17.5
160 psi
300 psi
125 psi
300 psi
Maximum Working Pressure
Listed on pump nameplate.
1
PUMP IDENTIFICATION
Bell & Gossett pumps are designated by a series
of numbers such as Series VSX, Model VSH,
VSC, or VSCS. The pump nameplate gives
identification and rating information as shown in
Figures 1 and 2.
Permanent records for this pump are referenced
by the serial number and it must be used with all
correspondence and spare parts orders.
Figure 1:
Figure 2:
Rating Plate
Suction Limitation
2
SAFETY INSTRUCTIONS
SAFETY INSTRUCTION
This safety alert symbol will be used in this manual
and on the pump safety instruction decals to draw
attention to safety related instructions. When used
the safety alert symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTIONS
MAY RESULT IN A SAFETY HAZARD.
Your Series VSX pump should have the following
safety instruction decals located approximately as
shown. If the decals are missing or illegible
contact your local Bell & Gossett representative for
a replacement.
Figure 3:
Safety Instruction Decals
3
ADDITIONAL SAFETY INSTRUCTIONS
Electrical Safety
WARNING: Electrical Shock Hazard
WARNING: Rotating Components
Hazard
Electrical connections to be made by a qualified
electrician in accordance with all applicable codes,
ordinances, and good practices.
Do not operate the pump without all guards in
place.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
WARNING: Excessive System Pressure
WARNING: Electrical Overload Hazard
Hazard
The maximum working pressure of the pump is
listed on the nameplate. Do not exceed this
pressure.
Three-phase motors must have properly sized
heaters to provide overload and under voltage
protection. Single-phase motors have built-in
overload protectors.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage
WARNING: Excessive Pressure Hazard
Volumetric Expansion
The heating of water and other fluids causes
volumetric expansion. The associated forces may
cause failure of system components and release
of high temperature fluids. This will be prevented
by installing properly sized and located
compression tanks and pressure relief valves.
Thermal Safety
WARNING: Extreme Temperature Hazard
If pump, motor, or piping are operating at
extremely high or low temperatures, guarding or
insulation is required.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Mechanical Safety
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
4
GENERAL INSTRUCTIONS
LIFTING THE PUMP
PURPOSE OF THE MANUAL
This manual is furnished to acquaint you with
some of the practical ways to install, operate, and
maintain this pump. Read it completely before any
installation, operation, or maintenance on your unit
and keep it handy for future reference.
WARNING: Falling Objects Hazard
Eyebolts or lifting lugs, if provided, are for lifting
only the components to which they are attached.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Equipment cannot operate well without proper
care. To keep this unit at top efficiency, follow the
recommended
installation
and
servicing
procedures outlined in this manual.
If lifting of the entire pump is required, do so with
the slings placed under the base rails as shown in
Figure 4. The pump unit should be unloaded and
handled by lifting equally at four or more points on
the base plate.
WARRANTY
Refer to your local representative for warranty
coverage.
RECEIVING THE PUMP
Check the pump for shortages and damage
immediately upon arrival. (An absolute must!)
Prompt reporting of any damage to the carrier’s
agent, with notations made on the freight bill, will
expedite satisfactory adjustment by the carrier.
Care must be taken to size the equipment for
unbalanced loads that may exist if the motor is not
mounted on the base at the time of lifting. The
motor may or may not be mounted at the factory.
Some pump, base, and driver assemblies may not
be safe to lift as a complete assembly. Damage to
the base plate may occur. If the driver has been
mounted on the base plate at the factory, it is safe
to lift the entire assembly. If the driver has not
been mounted at the factory, do not lift the entire
assembly consisting of the pump, base, and
driver. Instead lift the pump and base plate to its
final location without the driver. Then mount the
driver.
Pumps and drivers are normally shipped from the
factory mounted on a base plate and painted with
primer and one finish coat. Couplings may either
be completely assembled or have the coupling
hubs mounted on the shafts and the connecting
members removed. When the connecting
members are removed, they will be packaged in a
separate container and shipped with the pump or
attached to the base plate.
Shafts are in alignment when the unit is shipped;
however, due to shipping, the pumps may arrive
misaligned. Alignment must be established during
installation. Bell & Gossett has determined that
proper and correct alignment can only be made by
accepted
erection
practices.
(See
the
Foundation, Baseplate Setting, and Coupling
Alignment sections.)
TEMPORARY STORAGE
If the pump is not to be installed and operated
soon after arrival, store it in a clean, dry place
having slow, moderate changes in ambient
temperature. Rotate the shaft periodically to
coat the bearings with lubricant, to retard
oxidation and corrosion, and to reduce the
possibility of false brinelling of the bearings.
Figure 4:
5
Sample Lifting Diagram
Important
Do not install and operate Bell & Gossett
Pumps, 3D Valves, Suction Diffusers, etc., in
closed systems unless the system is
constructed with properly sized safety
devices and control devices. Such devices
include the use of properly sized and located
pressure relief valves, compression tanks,
pressure controls, temperature controls, and
flow controls as appropriate. If the system
does not include these devices, consult the
responsible engineer or architect before
making pumps operational.
LOCATION
Locate the pump so there is sufficient room for
inspection, maintenance, and service. If the use of
a hoist or tackle is needed, allow ample head
room. For outdoor installations, it is advisable to
shelter the pump unit.
WARNING: Falling Objects Hazard
Eyebolts or lifting lugs, if provided are for lifting
only the components to which they are attached.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
FOUNDATION
The concrete foundation or isolation pad must be
substantial enough to absorb vibration (Hydraulic
Institute Standards recommends that the
foundation weigh at least five times the weight of
the pump unit). It must form a permanent and rigid
support for the base plate and should be built to
suit local conditions. This is important in
maintaining the alignment of the flexibly coupled
unit. Do not use the base as the isolation pad.
The best pump location for sound and vibration
absorption is on a concrete floor with subsoil
underneath. If the pump location is overhead,
special precautions should be undertaken to
reduce possible sound transmission. Consult a
sound specialist.
If the pump is not on a closed system, it should be
placed as near as possible to the source of the
liquid supply, and located to permit installation with
the fewest number of bends or elbows in the
suction pipe.
Figure 5:
Foundation bolts of the proper size should be
embedded in the concrete with either of the
methods shown in Figure 6. See Table 2 for
anchor bolt hole and anchor bolt sizes. Allow the
foundation to cure for several days before
proceeding with the pump installation.
Pump Location
The installation must be evaluated to
determine that the Net Positive Suction Head
Available (NPSHA) meets or exceeds the Net
Positive Suction Head Required (NPSHR), as
stated by the pump performance curve.
Figure 6:
The pump must be primed before starting.
Whenever possible, the pump should be
located below the fluid level to facilitate
priming and ensure a steady flow of liquid.
This condition provides a positive suction
head on the pump. It may also be possible to
prime the pump by pressurizing the suction
vessel.
Foundation
Table 2:
Anchor Bolt/Hole Sizes
Diameter of Anchor
Diameter of Anchor
Bolt Hole
Bolt
1.125”
1.000”
1.375”
1.250”
6
BASE PLATE SETTING
Place the pump unit on its concrete foundation,
supporting it with steel wedges or shims. The
wedges or shims should be machined and be put
on both sides of each anchor bolt to provide a
means for leveling the base. The wedge or shim
width should be equal to or greater than the base
rail width. The length of the wedge or shim should
be at least four times the diameter of the anchor
bolt. It is acceptable to place additional shims
between the existing anchor bolts.
Use an anchor bolt for each anchor bolt hole
provided, and plain, flat Type-W washers at each
anchor bolt.
Figure 7:
Setting Base Plate
CAUTION: Equipment Damage
ROTATION
The Series VSX pump is available in both rightand left-hand rotation. An arrow cast into the pump
body shows the direction of rotation.
Use an anchor bolt and plain, flat Type-W washer
at each anchor bolt hole. Otherwise, shifting of the
pump unit may occur.
Failure to follow these instructions could result in
serious property damage and/or moderate
personal injury.
COUPLING ALIGNMENT
All alignment should be done by moving or
shimming the motor only. Adjustments in one
direction may alter alignment in another.
Therefore, check alignment in all directions after a
correction is made. All measurements should be
taken with the pump and motor bolts tightened.
Final alignment check should be made after the
unit has attained its final operating temperature.
It is very important that the pump base be set level
to avoid any mechanical difficulties with the motor
or pump. This pump was properly aligned (if
furnished with a motor) at the factory. However,
since all pump bases are flexible, they may spring
and twist during shipment. Do not pipe the pump
until it is realigned. After piping is completed and
after the pump is installed and bolted down, align it
again. It may be necessary to re-adjust the
alignment from time to time while the unit and
foundation are new.
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Optional Grouting
It is permissible to grout the base after the
pump unit has been leveled, securely bolted
to the floor, and properly aligned. A good
grade of non-shrinking grout should be used
inside the pump base.
1. Check the pump and motor shafts and
remove any paint, burrs, rust, etc. Slide
the hubs (and bushings, QD or TaperLock style) on the shafts with keys.
2. When high speed rings are used for
spacer couplings, loosely install one ring
on each half element.
7
3. Hold one half element on the hubs to
determine the appropriate hub spacing. If
using spacer elements with high speed
rings, hold both half elements on the hubs
to make sure the hubs do not interfere
with the rings. The hubs may be installed
with the hub extension facing in or out.
Make sure the shaft extends into the hubs
at least .8 times the diameter of the shaft.
4. Lightly fasten the hubs to the shafts to
prevent them from moving during
alignment.
5. The hubs should be aligned to at least the
values shown in Figure 10 for allowable
misalignments. Alignment may be done
with lasers, dial indicators, or with a
straight edge and calipers.
Figure 8:
Checking Alignment with
Straight Edge
Figure 9:
Checking Alignment with Calipers
To align using straight edge and calipers
Angular misalignment may be checked by
using a caliper to gauge the distance
between the two hubs at various points
around the circumference. Do not rotate the
shafts. Reposition the equipment until the
difference between the minimum and
maximum distance values is within the
permissible value.
Angular misalignment may also be checked
by inserting feeler gauges between the
coupling faces at various points around the
circumference. Do not rotate the shafts.
Reposition the equipment until the difference
between the minimum and maximum
distance values is within the permissible
value.
Parallel alignment may be checked by placing
a straight edge across the two hubs and
measuring the maximum offset at various
points around the periphery of the hubs. Do
not rotate the shafts. Reposition equipment
until the offset is within the permissible value.
8
Table 3:
Hub
Size
1
WE2
WE3
WE4
WE5
WE10
WE20
WE30
WE40
WE50
WE60
WE70
WE80
0.032
0.040
0.045
0.055
0.064
0.078
0.095
0.116
0.142
0.153
0.161
0.196
Angular Inch Gap
Degrees
2
3
4
0.065
0.081
0.091
0.109
0.127
0.156
0.189
0.231
0.284
0.305
0.323
0.393
0.097
0.121
0.136
0.164
0.191
0.234
0.284
0.347
0.425
0.129
0.162
0.181
0.218
0.218
Figure 10: Maximum Allowable Misalignment for Wood’s Duraflex®1 Couplings
Example: A WE10 coupling with a 3° angular
misalignment will have a .191” difference in
measurements between L1 and L2. (See Figure
9.)
To align using dial indicator
Angular misalignment may be checked by
mounting the dial indicator base to one
coupling half, or shaft, and positioning the dial
indicator button on the front face or rear face
of the opposite coupling half. Scribe index
lines on coupling halves as shown in Figure
11. Set the dial to zero. Rotate both coupling
halves together, making sure the index lines
remain matched. Reposition the equipment
until the offset is within the permissible value.
Figure 11: Checking Alignment with
Dial Indicators
6. Recheck the hubs to be certain both
angular and parallel alignments are still
within the values given in Figure 10.
Parallel misalignment may be checked by
mounting the dial indicator base to one
coupling half, or shaft, and positioning the dial
indicator button on the outside diameter of
the opposite coupling half. Set the dial to
zero. Rotate both coupling halves together,
making sure the index lines remain matched.
Reposition the equipment until the offset is
within the permissible value.
1
7. Loosen the set screw on the pump hub.
Loosely install one half element opposite
the hub set screws. Torque both hub set
screws to the value shown in Table 4. For
QD or Taper-Lock hubs, follow the
instructions supplied with the bushings.
Loosely install the other half element onto
the hubs. Install capscrews on the highspeed rings. If the capscrews and the
holes in the elements do not line up
Duraflex is a registered trademark of T.B. Wood’s, Inc.
9
properly due to hub misalignment, rotate
the shafts slightly. Torque all element and
high speed ring capscrews to the values
shown in Table 4. If possible, recheck
angular and parallel alignments.
WARNING: Flying Objects Hazard
Coupling capscrews and set screws are to be
installed using torque wrench or other torque
measuring device. Hardware not installed per
the listed torque values may become loose
and dislodge from coupling assembly.
Figure 13: Woods Duraflex Coupling
– Typical Spacer
Failure to follow these instructions could
result in serious personal injury or death, or
property damage.
Table 4:
Fastener Torque Values and
Maximum RPM for Woods Duraflex
Couplings
8. Capscrews supplied with the coupling
have a thread lock coating that aids in
resisting loosening from vibration. The
capscrews should not be reused more
than four times or if the coating is absent.
Replacement capscrews are to be
purchased through your local Bell &
Gossett representative.
Basic
Size
WE2
WE3
WE4
WE5
WE10
WE20
WE30
WE40
WE50
WE60
WE70
WE80
WARNING: Flying Objects Hazard
Capscrews with damaged or absent thread
lock coating should be not be used.
Otherwise the required counterforce will not
be achieved and hardware may become
loose and dislodge from coupling assembly.
Failure to follow these instructions could
result in serious personal injury or death, or
property damage.
Figure 12: Woods Duraflex Coupling
– Typical Non-spacer
10
Element
& Ring
Capscrew
Torque
(ft-lb)
17
30
75
Standard
Hubs Set
screw
Torque
(ft-lb)
Standard
Spacer
7
7
14
23
23
50
50
100
100
167
167
167
7500
7500
7500
7500
7500
6600
5800
5000
4200
3800
3600
2000
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
Maximum RPM
Where flanged joints are used, ensure that inside
diameters match properly.
Final Alignment
Final alignment cannot be accomplished until
the pump as been operated initially for a
sufficient length of time to attain operating
temperature.
When
normal
operating
temperature has been attained, secure the
pump to re-check alignment and compensate
for temperature accordingly. (See the section
entitled Coupling Alignment.)
Remove burrs and sharp edges when making up
joints.
Do not “spring” piping when making any
connections. Coupling and bearing wear will result
if the suction or discharge lines are forced into
position.
When considerable temperature changes are
anticipated, equipment for absorbing expansion
should be installed in the system in such a way as
to avoid strain on the pump.
NOTE: Elastomeric couplings are specifically
designed to accommodate angular shaft
misalignment, as well as parallel offset of the
pump and motor shafts. However, the amount
of the offset and/or misalignment is
dependent on the style of flexible coupling
applied.
Left
unchecked,
coupling
misalignment has a significant impact on the
overall life of the mechanical seals and the
bearings of the pump.
When using an isolation pad, flexible piping should
also be used on both the suction and discharge
sides of the pump.
The pipeline should have isolation valves around
the pump and have a drain valve in the suction
pipe.
WARNING: Rotating Components
Hazard
Do not operate pump without all guards in place.
See Technical Bulletin B-876 or BX-876, Table 5
for allowable static flange loading for vertical
flange configuration. (Models VSC and VSCS)
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
A Bell & Gossett Triple Duty Valve installed in the
discharge line will serve as a check valve to
protect the pump from water hammer, as a gate
valve
for
servicing,
and
for
throttling.
SUCTION AND DISCHARGE PIPING
When installing piping, refer to the Hydraulics
Institute Standards and observe the following
precautions:
Piping should always be run to the pump.
Do not move pump to the pipe. This could make
final alignment impossible.
Both the suction and discharge piping should be
supported independently near the pump and
properly aligned so that no strain is transmitted to
the pump when the flange bolts are tightened. Use
pipe hangers or other supports at necessary
intervals to provide support. When expansion
joints are used in the piping system they must be
installed beyond the piping supports closest to the
pump. Tie bolts should be used with expansion
joints to prevent pipe strain. Do not install
expansion joints next to the pump or in any way
that would cause a strain on the pump resulting
from system pressure changes.
Install the piping as straight as possible, avoiding
unnecessary bends. Where necessary, use 45° or
long sweep 90° fittings to decrease friction losses.
Make sure that all piping joints are leak tight.
11
Suction Piping
When installing the suction piping, refer to the
Hydraulics Institute Standards and observe
the following precautions. (See Figure 14.)
The sizing and installation of the suction
piping is extremely important. It must be
selected and installed so that pressure losses
are minimized and sufficient liquid will flow
into the pump when started and operated.
Many NPSH (Net Positive Suction Head)
problems can be directly attributed to
improper suction piping systems.
Friction losses caused by undersized suction
piping can increase the fluid’s velocity into the
pump. Refer to the Hydraulic Institute
Standards for inlet pipe sizing and velocity
requirements.
Elbows in the suction piping for horizontal
double suction pumps should be installed per
the Hydraulics Institute Standards as there is
always an uneven turbulent flow around an
elbow. When it is in a position other than the
vertical (in relation to the pump suction
nozzle) it causes more liquid to enter one
side of the impeller than the other. (See
Figure 15.) This results in high unequalized
thrust loads that will overheat the bearings
and cause rapid wear, in addition to affecting
hydraulic performance.
For pipe reducers on the inlet side, no more
than one pipe diameter reduction in a single
reducer should be used.
Figure 14: Suction Pipe Installations
(Piping supports not shown)
12
Figure 15: Unbalanced Loading of a Double Suction Impeller
Due to Uneven Flow Around an Elbow Adjacent to the Pump
Check valves are placed in the discharge
piping in normal applications. Before using a
check valve in the suction piping, consider
the added pressure drop to the pump,
potential water hammer, and the chance of
allowing the entire pump volute to be
exposed to the discharge pressure.
When operating on a suction lift, the suction
pipe should slope upward to the pump
nozzle. A horizontal suction line must have a
gradual rise to the pump. Any high point in
the pipe can become filled with air and thus
prevent proper operation of the pump.
To facilitate cleaning the pump’s liquid
passage without dismantling the pump, a
short section of pipe (Dutchman or spool
piece), designed so that it can be readily
dropped out of the line, can be installed
adjacent to the suction flange. With this
arrangement, any matter clogging the
impeller is accessible by removing the spool
piece (or pipe section).
When foot valves are used, or where there
are other possibilities of “water hammer,”
close the discharge valve slowly before
shutting down the pump.
The pump must never be throttled by the use
of a valve on the suction side of the pump.
Suction valves should be used only to isolate
the pump for maintenance purposes, and
should always be installed in positions to
avoid air pockets.
Valves in Suction Piping
When installing valves in the suction piping,
observe the following precautions:
Discharge Piping
The maximum velocity in the discharge piping
should not exceed 15 feet per second. If a
check valve is present in the outlet piping,
this value shall be reduced. System losses,
life-cycle costs, and process considerations
will usually drive the size of discharge piping
and fittings. Some high energy pumps are
sensitive to flow disturbing devices mounted
close to the pump outlet. Consult Bell &
Gossett when in doubt of the minimum
required straight pipe length.
Suction piping valves should be placed right
before the run of recommended straight pipe.
If the pump is operating under static suction
lift conditions, a foot valve may be installed in
the suction line to avoid the necessity of
priming each time the pump is started. This
valve should be of the flapper type, rather
than the multiple spring type, sized to avoid
excessive friction in the suction line. The foot
valve and pipe should be sized to maximize
NPSHa to the pump by minimizing suction
line losses.
13
Pressure Gauges
Properly sized pressure gauges should be
installed in both the suction and discharge
nozzles in the gauge taps. The gauges will
enable the operator to easily observe the
operation of the pump, and also determine if
the pump is operating in conformance with
the performance curve. If cavitation, vapor
binding, or other unstable operation should
occur, widely fluctuating discharge pressure
will be noted.
may cause severe abrasion or corrosion of
the shaft sleeve, and rapid packing
deterioration; they can even plug the stuffing
box flushing and lubrication system. The
stuffing box must be supplied at all times with
a source of clean, clear liquid to flush and
lubricate the packing.
Pump Insulation
On applications where pumps are insulated,
the pump bearing brackets should not be
insulated since this would tend to trap heat
inside the housing. This could lead to
increased
bearing
temperatures
and
premature bearing failures.
Standard pumps are normally packed before
shipment. If the pump is installed within 60
days after shipment, the packing will be in
good condition with a sufficient supply of
lubrication. If the pump is stored for a longer
period, it may be necessary to repack the
stuffing box. In all cases, however, inspect
the packing before the pump is started.
If the pump system pressure conditions vary
during the day, packing adjustment becomes
difficult. Consideration should be given to
using a mechanical seal.
NOTE: Packing adjustment is covered in the
section entitled Maintenance.
On some applications, it is possible to use internal
liquid lubrication (pumped liquid) to lubricate
packing. Only when all of the following conditions
prevail, can this be done:
1. Liquid is clean, free from sediment and
chemical precipitation and is compatible
with seal materials.
2. Temperature is above 32°F and below
160°F.
3. Suction pressure is below 75 psig.
4. Lubrication (pumped liquid) has lubricating
qualities.
Figure 16: Pump Insulation
5. Liquid is non-toxic and non-volatile.
PUMP SEALING
When the liquid being pumped contains solids or
is otherwise not compatible with packing materials,
an outside supply of flush liquid should be
furnished. In general, external-flush liquid (from an
outside source) is required when any of the above
conditions cannot be met.
Mechanical Seals
Mechanical seals are preferred over packing
on some applications because of better
sealing qualities and longer serviceability.
When a seal is properly installed, it will last
longer than packing on similar applications.
The change from packing to an alternate
arrangement may be made in the field by
competent service personnel. Conversion
parts may be ordered from your local Bell &
Gossett representative.
The standard stuffing box consists of rings of
packing (See the Assembly and Disassembly
Procedures section for the number of rings), a
lantern ring, and a gland. A shaft sleeve that
extends through the box and under the gland is
provided to protect the shaft.
Packing
Contaminants in the pumped liquid must not
enter the stuffing box. These contaminants
A tapped hole is supplied in the stuffing box
directly over the lantern ring to introduce a clean,
cooling medium. The stuffing box must, at all
14
impeller diameter on the nameplate which is
chosen from the published performance curves.
times, be supplied with flushing liquid at a high
enough pressure to keep the box free from foreign
matter, which would quickly destroy the packing
and score the shaft sleeve.
A vee-cut is required when the impeller diameter
Dref is smaller than the Dshroud values shown in
Table 5.
Only a sufficient volume of flushing liquid to create
a definite direction of flow from the stuffing box
inward to the pump casing is required, but the
pressure is important. Apply seal water at a rate of
approximately .25 GPM at a pressure
approximately 15 to 20 psig above the suction
pressure. (Approximately one (1) drop per
second.)
Dshroud is the trim diameter of the shrouds. This
value, as shown in Table 5, is constant for all veecut diameters for a given pump size.
Dhub is the diameter at the hub (bottom of the veecut).
External flushing liquid should be adjusted to the
point where the packing runs only slightly warm,
with a very slow drip from the stuffing box. Excess
pressure from an external source can be very
destructive to packing. More pressure is required,
however, for abrasive slurries than for clear
liquids. Examination of the leakage will indicate
whether to increase or decrease external
pressure. If slurry is present in the leakage,
increase the pressure until only clear liquid drips
from the box. If the drippage is corrosive or
harmful to personnel, it should be collected and
piped away.
To achieve the performance for a given Dref, trim
Dshroud to the values in Table 5. Then using the
charts in Figure 18, find Dhub for the appropriate
pump size and Dref.
Example: to trim an 8x10x10.5A impeller to a Dref
of 8.000, trim the shrouds to 8.250” (Dshroud) per
Table 5, and trim the bottom of the vee to 7.750”
(Dref) per Figure 18.
Table 5: Required Vee-cuts
Pump Size
Dshroud
6x8x10.5A
8.000 in.
A common error is to open the external piping
valve wide and then control the drippage by
tightening the packing gland. A combination of
both adjustments is essential to arrive at the
optimum condition. The life of packing and sleeve
depends on careful control more than any other
factor.
8x10x10.5A
10x12x10.5A
8.250 in.
9.750 in.
12x14x13.5A
14x16x13.5A
11.125 in.
12.375 in.
VEE-CUT IMPELLER TRIMS
A vast majority of the impeller trims are standard
straight cuts. However, on several pump sizes a
vee-cut is employed for the smaller diameters.
(See Figure 17.) For either type of cut, Dref is the
Figure 17: Straight and Vee-cut Impellers
15
Figure 18: Vee-cut Impeller Diameters
16
OPERATION
PRE-START CHECKS
FLUSHING
New and old systems should be flushed to
eliminate all foreign matter. Heavy scale, welding
splatter and wire or other large foreign matter can
clog the pump impeller. This will reduce the
capacity of the pump causing cavitation, excessive
vibration, and/or damage to close clearance parts
(wear rings, seals, sleeves, etc.).
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
WARNING: Electrical Shock Hazard
FILLING
Vents should be located at the highest point so
entrained gases and air can escape. However, if
the gases are flammable, toxic, or corrosive they
should be vented to an appropriate place to
prevent harm to personnel or other parts of the
system. Pipe hangers and anchors should be
checked to make sure they are properly set to take
the additional weight of the pumpage.
Electrical connections to be made by a qualified
electrician in accordance with all applicable codes,
ordinances, and good practices.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
All drains should be closed when filling the
system. Filling should be done slowly so that
excessive velocities do not cause rotation of the
pumping elements that may cause damage to the
pump or its driver. The adequacy of the anchors
and hangers may be checked by mounting a dial
indicator off of any rigid structure not tied to the
piping and setting the indicator button on the pump
flange in the axial direction of the nozzle. If the
indicator moves, as the filling proceeds, the
anchors and supports are not adequate or set
properly and should be corrected.
Before the initial start of the pump, make the
following inspections:
PRIMING
If the pump is installed with a positive head on the
suction, it can be primed by opening the suction
valve and loosening the vent plug on top of the
casing (do not remove), allowing air to be purged
from the casing.
4. Turn the rotating element by hand to ensure
that it rotates freely.
1. Check the alignment between the pump and
motor. (See the Coupling Alignment section
for alignment requirements.)
2. Check all connections to the motor and
starting device with the wiring diagram. Check
voltage, phase, and frequency on the motor
nameplate with the line circuit.
3. Check the suction and discharge piping and
the pressure gauges for proper operation.
5. Check the stuffing box adjustment, lubrication,
and piping (packing seal only).
6. Check the driver lubrication. Refer to the
driver installation, operation, and maintenance
manual.
If the pump is installed with a suction lift, priming
must be done by other methods such as foot
valves, ejectors, or by manually filling the casing
and suction line.
7. Ensure that the pump bearings are properly
lubricated. See the Pump Bearings
paragraphs in the Lubrication section.
CAUTION: Seal Damage Hazard
8. Ensure that the coupling is properly lubricated,
if required. See the Couplings paragraph in
the Lubrication section.
Do not run pump dry. Seal damage may occur.
Failure to follow these instructions could result in
serious property damage and/or moderate
personal injury.
9. Ensure that the pump is full of liquid and that
all valves are properly set and operational,
with the discharge valve closed and the
suction valve fully open. Purge all air from the
top of the casing.
While venting the air from the pump body, the
pump shaft should be rotated a few times by hand.
17
reference. Also record voltage, amperage per
phase, kilowatts if an indicating wattmeter is
available, and pump speed.
10. Check rotation. Be sure that the driver
operates in the direction indicated by the
arrow on the pump casing as serious damage
can result if pump is operated with incorrect
rotation. Check rotation each time the motor
leads have been disconnected.
4. Temperature: Check and record bearing
temperatures
using
a
thermometer.
Temperature should not exceed 250°F.
WARNING: Rotating Components
Hazard
Do not operate pump without all guards in place.
5. Vibration: The acceptable vibration level of a
centrifugal pump depends on the rigidity of the
pump and the supporting structure. Refer to
the Hydraulic Institute Standards for a
complete description and charts on various
pumps.
Failure to follow these instructions could result in
serious injury or death, or property damage.
STARTING
1. Close drain valves and valve in discharge line.
6. Sound: Field sound levels are difficult to
measure because of background noise from
piping, valves, drivers, gears, etc. Follow
recommendations in the Hydraulic Institute
Standards.
2. Open fully all valves in the suction line.
3. Slowly turn on flush water to the stuffing box.
(If pumped fluid is dirty or if leakage of air is to
be prevented, these lines should be always
left open.)
7. Make all pump output adjustments with the
discharge valves.
CAUTION: Cavitation Damage Hazard
4. Prime the pump.
5. Start the pump driver (turbines and engines
may require warming up; consult the
manufacturer’s instructions).
Do not throttle the suction valve to adjust the
pump output.
Failure to follow these instructions could result in
property damage and/or moderate personal injury.
NOTE: If the pump loses prime during start-up, it
should be shut down and the condition corrected
before the procedure is repeated.
FREEZE PROTECTION
Pumps that are shut down during freezing
conditions should be protected by draining the
pump and removing all liquid from the casing.
6. When the pump is operating at full speed,
open the discharge valve slowly. This should
be done promptly after start-up to prevent
damage to pump by operating at zero flow.
FIELD TESTS
A typical performance curve for a specific pump
can be obtained from your local Bell & Gossett
representative. This can be used in conjunction
with a field test, if one is required. All Bell &
Gossett tests and curves are based on the
Hydraulic Institute Standards. Any field test must
be conducted according to these Standards.
7. Adjust the flush line valves to produce the
recommended pressure for the stuffing box.
OPTIONAL CHECKLIST
1. Driver/Pump Rotation: Check rotation each
time the motor leads have been disconnected.
Be sure that the driver operates in the
direction indicated by the arrow on the pump
casing. Rough operation and extreme
vibration can result if the pump is operated in
the wrong direction.
Unless otherwise specifically agreed, all capacity,
head, and efficiencies are based on shop tests
when handling clear, cold, fresh water at a
temperature not over 85°F.
2. Flow: An accurate measurement of flow rate
(volume/time) is difficult in the field. Venturi
meters, flow nozzles, orifice plates, or timing
the draw down in the wet well are all possible
methods. Record any reading for future
reference.
3. Pressure: Check and record both suction and
discharge pressure gauge readings for future
18
MAINTENANCE
Using a grease gun, fill the cavities with
Exxon Polyrex EM®2 grease until it is seen
coming out from underneath the lip seals.
GENERAL MAINTENANCE AND PERIODIC
INSPECTION
Operating conditions vary so widely that to
recommend one schedule of preventative
maintenance for all centrifugal pumps is not
possible. Yet, some sort of regular inspection must
be planned and followed. We suggest a
permanent record be kept of the periodic
inspections and maintenance performed on your
pump.
This
recognition
of
maintenance
procedures will keep your pump in good working
condition, and prevent costly breakdowns.
Exxon Polyrex EM® grease is the only
recommended grease. Do not use any other
grease.
CAUTION: Bearing Failure
Do not mix different greases together as they will
tend to separate and fail to properly lubricate the
bearing.
One of the best rules to follow in the proper
maintenance of your centrifugal pump is to keep a
record of actual operating hours. Then, after a
predetermined period of operation has elapsed,
the pump should be given a thorough inspection.
The length of this operating period will vary with
different applications, and can only be determined
from experience. New equipment, however,
should be examined after a relatively short period
of operation. The next inspection period can be
lengthened somewhat. This system can be
followed until a maximum period of operation is
reached which should be considered the operating
schedule between inspections.
Failure to follow these instructions could result in
property damage and/or moderate personal injury.
Normally the maximum desirable operating
temperature for ball bearings should not
exceed 250°F. If the temperature of the
bearing frame rises above the limit, the pump
should be shut down to determine the cause.
Check the temperature using an accurate
measuring device to be sure.
Couplings
Polymer and elastomeric element type
couplings are maintenance free and do not
require lubrication. If other types of couplings
are used, follow maintenance instructions of
the coupling manufacturer.
LUBRICATION
Pump Bearings
Bearing housings are packed with grease at
the factory and ordinarily will require no
attention before starting, provided the pump
has been stored in a clean, dry place prior to
its first operation. The bearings should be
watched for about an hour after the pump has
been started to see that they are operating
properly.
SEAL INFORMATION
Mechanical Seals
Mechanical seals usually require no
maintenance. To protect the seals, do not run
the pump dry. Replace the seals if leakage is
present.
Periodic addition of grease is not required. If
the bearing brackets are removed for
maintenance reasons, thoroughly clean out
the bearing housing and ensure that it is
protected
against
dust
and
other
contaminants.
Packing (Non-Asbestos)
Bell & Gossett does not advocate the use of
asbestos packing material.
On packed pumps the packing is installed
prior to shipment. Before pump is put into
operation check the condition of packing. If
the pump is installed within sixty (60) days
after shipment, the packing will be in good
condition with a sufficient supply of
lubrication. If pump is stored for a longer
period it may be necessary to repack the
Reassemble the pump using new bearings
and lip seals. Use the grease fittings provided
on the underside of the bearing brackets to fill
the bearing cavities.
2
19
Polyrex EM is a registered trademark of Exxon Mobile Corp.
a poor fitting mitered joint. Fit the ring over
the sleeve to ensure proper length. Then
remove and cut all other rings to the first
sample. When the rings are placed around
the sleeve a tight joint should be formed.
Place the first ring in the bottom of the
stuffing box. Then install each succeeding
ring, staggering the joints as described
above, making sure each ring is firmly
seated.
stuffing box. In all cases, however, we
recommend an inspection of the packing
before pump is started.
A soft, well-lubricated packing
stuffing box resistance and
excessive wear on the shaft sleeve.
packing may be purchased through
Bell & Gossett representative.
reduces
prevents
Standard
you local
When a pump with packing is first started it is
advisable to have the packing slightly loose
without causing an air leak. As the pump runs
in, gradually tighten the gland bolts evenly.
The gland should never be drawn to the point
where packing is compressed too tightly and
no leakage occurs. This will cause the
packing to burn, score the shaft sleeve and
prevent liquid from circulating through the
stuffing box cooling the packing. The stuffing
box is improperly packed or adjusted if friction
in the box prevents turning the rotating
element by hand. A properly operated stuffing
box should run lukewarm with a slow drip of
sealing liquid. After the pump has been in
operation for some time, and the packing has
been completely run-in, drippage from the
stuffing box should be at least 40 to 60 drops
per minute. This will indicate proper packing
and shaft sleeve lubrication and cooling.
MAINTENANCE OF FLOOD DAMAGED PUMPS
NOTE: Eccentric run-out of the shaft or
sleeve through the packing could result in
excess leakage. Correcting this defect is very
important.
Electrical connections to be made by a qualified
electrician in accordance will all applicable codes,
ordinances, and good practices.
Make sure the lantern ring is properly located
in the stuffing box under the sealing water
inlet. The function of the lantern ring is to
establish a liquid seal around the shaft,
prevent leakage of air through the stuffing
box and lubricate the packing. If it is not
properly located it serves no purpose.
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
WARNING: Electrical Shock Hazard
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Packing should be checked frequently and
replaced as service indicates; it is impossible
to give any exact predictions. A packing tool
should be used to remove all old packing
from the stuffing box. Never reuse worn
packing or merely add some new rings. Make
sure the stuffing box is thoroughly cleaned
before installing new packing. Also check the
condition of the sleeve for possible wear.
Make replacements where necessary.
Replace bearings and grease if the pump has
been in a flooded condition. The motor should be
evaluated by a qualified motor shop before being
put back into service. Mechanical seals, stuff
boxes, and their packing rings should be cleaned
and inspected. Replace if needed. Couplings that
require lubrication should be replaced.
New packing (non-asbestos) should be
placed carefully into the stuffing box. If
molded rings are used, the rings should be
opened sideways and the joints pushed into
the stuffing box first. The rings are installed
one at a time, each ring seated firmly and the
joints staggered at about a 90° rotation from
each preceding joint.
If coil packing is used, cut one ring to
accurate size with either a butt or mitered
joint. An accurately cut butt joint is superior to
20
TROUBLE SHOOTING
Between regular maintenance inspections, be alert for signs of motor or pump trouble. Common symptoms
are listed below. Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN.
CAUSES
CURES
No Liquid Delivered
1. Lack of prime
Fill pump and suction pipe completely with liquid.
2. Loss of prime
Check for leaks in suction pipe joints and fittings; vent casing to
remove accumulated air.
If no obstruction at inlet, check for pipe friction losses. However,
static lift may be too great. Measure with mercury column or vacuum
gauge while pump operates. If static lift is too high, liquid to be
pumped must be raised or pump lowered.
Check that valves are wide open.
3. Suction lift too high
4. Discharge head too high
5. Speed too low
6. Plugged suction diffuser or
strainer screen
7. Impeller completely plugged
Check whether the properly wired. Frequency may be too low;
motor may have an open phase. Verify that the driver and speed
matches the pump nameplate speed.
Dismantle and clean.
Dismantle pump and clean impeller.
Not Enough Liquid Delivered
8. Air leaks in suction piping
9. Speed too low
10. Discharge head too high
11. Suction lift too high
12. Impeller partially plugged
13. Cavitation; insufficient NPSH A
(depending on installation)
Test flanges for leakage by plugging inlet and putting line under
pressure. A gauge will indicate a leak with a drop of pressure.
See item 5.
Check pipe friction losses. Large piping may correct condition.
Check that valves are fully open.
See item 3.
See item 7.
a. Increase positive suction head on pump.
b. Reduce the temperature of the liquid in the suction pipe.
14. Defective impeller
15. Wrong direction of rotation
16. Wrong direction of impeller
17. Too small impeller diameter
(probable cause if none of the
above)
18. Speed too low
19. Air leaks in suction piping
Inspect impeller, bearings and shaft. Determine the cause and
correct.
Compare the rotation of the motor with the directional arrow on the
pump casing. Correct as required.
Reverse the impeller direction on the shaft.
Check with the factory to see if a larger impeller can be used;
otherwise, cut the pipe losses or increase the speed, or both as
needed. Be careful not to overload the driver.
See item 5.
See item 8.
21
CAUSES
CURES
Not Enough Pressure
20. Mechanical defects
21. Obstruction in liquid passages
22. Air or gases in liquid
23. Too small impeller diameter
(Probable cause if none above)
24. Speed too low
25. Excessive system flow
See items 14 and 15.
Dismantle pump and inspect passages of impeller and casing.
Remove obstruction.
Install an air removal device or repair leaks in system piping.
See item 17.
See item 5.
Balance system.
Pump Operates For Short Time, Then Stops
26. Incomplete priming
27. Suction lift too high
28. Air leaks in suction piping
29. Air or gases in liquid
Free pump, piping and valves of all air. If high points in suction line
prevent this, they need correcting.
See item 3.
See item 8.
See item 22.
Pump Takes Too Much Power
30. Head lower than rating;
thereby pumping too much liquid.
31. Cavitation
32. Mechanical defects.
33. Liquid heavier (in either
viscosity or specific gravity) than
allowed for.
34. Wrong direction of rotation.
35. Casing distorted by excessive
strains from suction or discharge
piping.
36. Shaft bent due to damage –
through shipment, operation, or
overhaul.
37. Mechanical failure of critical
pump parts.
38. Misalignment.
39. Speed may be too high
Machine impeller’s OD to size advised by factory.
See item 13.
See items 14 and 15.
Use larger driver. Consult factory for recommended size. Test liquid
for viscosity and specific gravity.
See item 15.
Check alignment. Examine pump for friction between impeller and
casing. Replace damaged parts.
Check deflection of rotor by turning on bearing journals. Total
indicator run-out should not exceed 0.002” on shaft and 0.004” on
impeller eye outer diameter.
Check bearings and impeller for damage. Any irregularity in these
parts will cause a drag on shaft.
Realign pump and driver.
Check frequency setting on the drive if equipped. Verify that the
driver speed matches the pump nameplate speed.
22
GUARDS
1. Place the bottom inner guard into the bottom
outer guard.
ANSI/OSHA COUPLING GUARD
REMOVAL/INSTALLATION
2. Hold the lower guards under the coupling and
slide the guard support(s) between the base
and lower guards.
WARNING: Extreme Temperature
Hazard
If pump, motor, or piping are operating at
extremely high or low temperatures, guarding or
insulation is required.
3. Install the guard to the support hardware but do
not tighten. Move the support(s) to the proper
location on the base and install the hardware
for support(s) to the base.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
4. Slide the outer guard so it is within .25” from
the motor face.
Removal
(See Figures 19 and 20.)
5. Slide the inner guard so it is within .25” from
the pump bracket face.
1. Remove the two capscrews and hardware
that hold the outer guard’s top and bottom
halves together. Remove the top half of
the outer guard.
6. Tighten the hardware.
2. Remove the two capscrews and hardware
that hold the inner guard’s top and bottom
halves together. Remove the top half of
the inner guard.
3. On some units, it may now be required to
remove the coupling to gain access to the
remaining guard hardware.
4. Remove the capscrews and hardware that
fasten the guards to the guard support.
5. On units supplied with spacer couplings, a
second guard support is supplied
underneath the inner guard. If present,
remove the two capscrews and hardware
fastened to the second guard support.
Figure 19: Coupling Guard
6. Remove the capscrews and hardware that
hold the guard support(s) to the base rail.
Remove the guard support(s) and bottom
guard halves.
Installation
(See Figures 19 and 20.)
23
Figure 20: Installation/Removal Coupling Guard
BRACKET GUARDS
WARNING: Extreme Temperature
Hazard
If pump, motor, or piping are operating at
extremely high or low temperatures, guarding or
insulation is required.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Guarding is also provided to give protection for the
exposed shaft length between the seal gland/stuff
box and the bearing housing. (See Figure 21.)
Three guards are provided for each bracket: two
for the side windows and one for the top window.
Figure 21: Bracket Guard Installed on Inboard
Bearing Bracket
24
SERVICE
Figure 22: Mechanical View
25
maintenance and remove
coupling hub on the pump.
GENERAL DISASSEMBLY PROCEDURES
SHUTDOWN
The following steps will address most normal
shutdowns of the pump, such as maintenance.
Make any further adjustments of process piping,
valves, etc., as required.
the
b. For spacer coupling assemblies:
remove the coupling hub on the
pump.
3. Remove the four capscrews from the bearing
cap.
1. Shut down the pump driver. (Consult
manufacturer’s
instructions
for
special
operations.)
4. Remove the four bearing bracket capscrews.
5. Remove the bearing bracket using jacking
screws. (See Figure 23.) Pry bars may also be
used. (See Figure 24.)
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
2. Close the suction and discharge valves.
3. For pumps equipped with external flush, close
the flush line valves. However, to prevent
contaminating the packing, leave these lines
open, unless the pump is completely drained.
Figure 23: Removing the Outboard Bearing
4. Open the drain valves and casing vents as
required.
Bracket Using Jacking Screws
CAUTION: Extreme Temperature Hazard
Allow pump temperatures to reach acceptable
levels before proceeding. Open the drain valve.
Do not proceed until liquid stops coming out of the
drain valve. If liquid does not stop flowing from the
drain valve, isolation valves are not sealing and
should be repaired before proceeding. After liquid
stops flowing from drain valve, leave the valve
open and continue. Remove the drain plug located
on the bottom of the pump housing. Do not
reinstall the plug or close the drain valve until
reassembly is completed.
Figure 24: Removing the Inboard Bearing Bracket
Using Pry Bars
Failure to follow these instructions could result in
moderate personal injury or property damage.
6. Bend back the lockwasher tab and remove the
locknut and lockwasher.
DISASSEMBLY PROCEDURE TO REMOVE
BEARING FRAMES – ALL PUMPS
1. Remove the coupling guard. See the Guards
section.
7. Remove the bearing with pullers. (See Figure
25.) A universal fixture kit (part number
AC2394) may also be used. (See Figure 26.)
The universal fixture kit should not be used on
pumps with 2” frames as the bearing backup
ring may damage the bearing cap’s lip seal.
(See Figure 27 for a listing of pump sizes with
2” frames.)
2. Remove the capscrews that secure the
coupling element to the hubs. Remove the
coupling element. Depending on the type of
coupling, proceed to step a or step b.
a. For
non-spacer
coupling
assemblies: move the driver to
allow
sufficient
access
for
26
11. Remove lip seals from both caps and the
inboard bearing bracket.
DISASSEMBLY PROCEDURE TO REMOVE
STANDARD MECHANICAL SEALS
1. Loosen the set screws in the sleeve.
2. Remove the four gland assembly capscrews.
3. Remove the gland assembly and the sleeve
from the shaft. (See Figure 28.) The use of a
bearing puller attached to the step in the
sleeve may be required.
Figure 25: Removing the Bearing Using
Pullers
Figure 28: Removing the Gland Assembly and
Sleeve
4. Remove the gland gasket.
Figure 26: Removing the Bearing Using a
Universal Kit
5. While pushing down on the mechanical seal
head, remove the retaining ring from the shaft
sleeve groove. (See Figure 29.)
8. For 2” frames only: remove the bearing
backup ring. (See Figure 27.) (See Figure 22
for a listing of pump sizes with 2” frames.)
Figure 29: Mechanical Seal Head and Gland
with Retaining Ring Removed
Figure 27: Removing the Bearing Backup Ring
(2” Frames Only)
6. Remove the mechanical seal head from the
sleeve assembly.
9. Remove the bearing cap from the shaft.
Remove the slinger.
7. Remove the gland assembly from the shaft
sleeve.
10. Repeat steps 1 through 9 to remove the
bearing frame on the other side. When
finished,
proceed
to
the
appropriate
disassembly procedure depending on the type
of seal in your pump.
8. Remove the stationary mechanical seal seat
from the gland bore.
9. Remove the quad ring from the shaft.
27
Procedure to Remove Coverplates and
Shaft Assembly – All Pumps.
10. Repeat steps 1 through 9 for the other side.
11. If only the mechanical seals are to be
replaced, proceed to the section entitled
Assembly Procedure to Install Standard
Mechanical Seals.
DISASSEMBLY PROCEDURE TO REMOVE
CARTRIDGE SEALS
If disassembly of the pump is required,
proceed to the section entitled Disassembly
Procedure to Remove Coverplates and
Shaft Assembly – All Pumps.
DISASSEMBLY PROCEDURE TO REMOVE
STUFFING BOX AND PACKING.
Figure 31: Cartridge Seal Cross Section
1. Loosen the set screws in the sleeve.
2. Remove the four cartridge seal capscrews.
3. Remove the cartridge seal from the shaft.
(See Figure 32.)
Figure 30: Flushed Stuffing Box Cross Section
1. Remove nuts, washers, studs, and glands.
2. Remove the packing rings and lantern ring.
3. Loosen the set screws in the sleeve and
remove the sleeve from the shaft. The use of
a bearing puller attached to the step in the
sleeve may be required.
4. Remove the four stuffing box capscrews.
Figure 32: Removing the Cartridge Seal
5. Remove the stuffing box.
4. Remove the cartridge seal gasket.
6. Remove the stuffing box gasket.
5. If only the cartridge seal’s cassette is to be
replaced, loosen the screws from the
cassette/sleeve assembly and fit them to the
threaded holes in the same part. Tighten
evenly allowing the cassette to be pulled out
from the gland and remove it from the shaft.
(See Figure 33.)
7. Remove the quad ring from the shaft.
8. Repeat steps 1 through 7 for the other side.
9. If only the packing rings and sleeve are to be
replaced, proceed to the section entitled
Assembly Procedure to Install Stuffing Box
and Packing.
If disassembly of the pump is required,
proceed to the section entitled Disassembly
28
Jacking
Screw
Holes
Cassette and
Sleeve
Gland
Figure 33: Cartridge Seal Gland and Service
Kit (Cassett and Sleeve)
Figure 34: Removing the Coverplate Using
Jacking Screws
6. If only the cartridge seal or cartridge seal
cassette is to be replaced, proceed to the
section entitled Assembly Procedure to
Install Cartridge Seals.
3. Remove the volute gasket.
4. Pull the impeller and shaft assembly from the
volute. (See Figure 35.)
7. If disassembly of the pump is required,
proceed to the section entitled Disassembly
Procedure to Remove Coverplates and
Shaft Assembly – All Pumps.
CAUTION: Equipment Damage
To prevent premature seal failure or possible
injury, the unitized seals should not be used as an
alternate or substitute for the balanced seals
installed in a high suction pressure rated VSX
pump.
Failure to follow these instructions could result in
serious property damage and/or moderate
personal injury.
Figure 35: Removing the Shaft Assembly
5. Repeat steps 2 through 4 to remove the other
coverplate.
6. Remove the impeller retaining rings.
DISASSEMBLY PROCEDURE TO REMOVE
COVERPLATES AND SHAFT ASSEMBLY – ALL
PUMPS
1. Ensure shaft threads are protected using tape
or nuts. (See Figure 34.)
7. The impeller is press fitted on the shaft. The
use of a press is required for removing and
mounting the impeller to the shaft.
8. Remove the impeller key from the shaft.
2. Remove the volute capscrews. Using jacking
screws, pull the coverplate from the volute.
(See Figure 34.)
ASSEMBLY PROCEDURE TO INSTALL
COVERPLATES AND SHAFT ASSEMBLY – ALL
PUMPS
NOTE: Inspect all parts for wear and damage.
Replace where needed.
1. Insert the impeller key into the shaft key slot.
2. Install the first impeller retaining ring. (See
Figure 36.)
29
Figure 36: Installing the Impeller Retaining
Ring
Figure 38: Installing the Gasket on the
Coverplate
Refer to Figure 52 to check that the impeller,
shaft, and volute are orientated correctly for
the required rotation before proceeding.
7. Using guide pins (threaded rod or a headless
bolt) threaded into the volute, install
coverplate. One coverplate has one notch
(See Figure 39.), and the other coverplate has
two nothces (See Figure 40.). Ensure the
coverplate notches are aligned to the notches
in the volute.
3. Press the impeller with a suitable press onto
the shaft.
4. Install the second impeller retaining ring.
5. Lubricate the quad rings with P-80®3 Rubber
Lubricant Emulsion, soapy water, or
equivalent and slide them over the shaft ends
for installation in the quad ring grooves. (See
Figure 37.)
One
Notch
Figure 39: Installing the Coverplate Using the
Guide Rods
Figure 37: Installing the Quad Rings
6. Slide the volute gasket onto the coverplate.
(See Figure 38.) Grease may be used to hold
the gasket in place.
Two
Notches
3
P-80 is a registered trademark of International Products Corp.
30
NOTE: Handle the seals with care. Clean the
glands and seals before assembly. Take care not
to damage the seals during assembly.
Figure 40: View of the pump interior after one
coverplate has been installed
8. Install the volute capscrews.
NOTE: Refer to Table 6 for all capscrew torque
requirements.
9. Insert the shaft assembly into the volute. (See
Figure 41.) Ensure that the shaft threads are
protected using tape or nuts. (See Figure 34.)
Figure 43: The Seal Seat Installed in the Gland
2. Slide the gland assembly over the shaft
sleeve.
3. Lightly lubricate the shaft sleeve with P-80
Rubber Lubricant Emulsion, soapy water, or
equivalent and slide the mechanical seal head
onto the sleeve.
Figure 41: Installing the Shaft Assembly
10. Repeat steps 6 through 8 to install the second
coverplate.
4. While pushing down on the mechanical seal
head, install the retaining ring into the shaft
sleeve groove.
ASSEMBLY PROCEDURE TO INSTALL
STANDARD MECHANICAL SEALS
5. Apply anti-seize compound only to the area of
the shaft that will be under the sleeve. (See
Figure 44.)
Figure 44: Applying Anti-seize Compound to
the Shaft
Figure 42: Standard Mechanical Seal Cross
Section
6. Place the gland gasket onto the gland. Grease
may be used to hold the gasket in place. Slide
the complete assembly over the shaft until the
sleeve bottoms out onto the shaft locating
shoulder. (See Figure 45.)
1. Press the stationary mechanical seal seat into
the gland bore. (See Figure 43.) To ease
assembly, lightly lubricate the bore with P-80
Rubber Lubricant Emulsion, soapy water, or
equivalent.
31
6. Install the four stuffing box capscrews.
7. Install set screws in the sleeve and tighten to
50 inch-lbs.
NOTE: The last ring in each box may not be
required until after the pump has operated for a
period of time.
8. Assemble the glands, studs, washers, and
nuts square with the stuffing box and pull up
tight. (See Figure 46 of an exploded
assembly.)
Figure 45: Installing the Gland Assembly
7. Install the four gland assembly capscrews.
8. Install the set screws in the sleeve and tighten
to 50 inch-lbs.
9. Install the slinger.
10. Repeat steps 1 through 9 to install the seal on
the other side. When finished, see the section
entitled Assembly Procedure to Install
Bearing Frames – All Pumps.
ASSEMBLY PROCEDURE TO INSTALL
STUFFING BOX AND PACKING
1. Place stuffing box, wetted end down, onto the
bench and slide the sleeve through stuffing
box bore letting it set onto bench
Figure 46: Exploded View of Stuffing Box with
Lantern Ring
9. Repeat steps 1 through 8 for the other side.
When finished, see the section entitled
Assembly Procedure to Install Bearing
Frames – All Pumps.
2. Install packing rings over the sleeve and down
into the bore so that the ends butt, leaving no
gap between the packing and stuffing box.
Press the packing to the bottom of the stuffing
box. Stagger the joints of each packing ring at
least 90°.
NOTE: After the bearing frame has been installed,
loosen the nuts to permit the packing to expand.
Retighten until finger tight. Final adjustment of the
gland nuts must be done while the pump is
running. Allow approximately 30 minutes between
adjustments. A good adjustment should allow
approximately one drip per second.
NOTE: On a flushed stuffing box, the lantern
ring will replace the third packing ring from
the bottom, requiring only five rings of
packing per side. (See Figure 30.) The
lantern ring must be aligned with the seal
water inlet when the packing is compressed.
On non-flushed (plugged) stuffing boxes, a
sixth ring of packing is supplied for each side
and takes the place of the lantern ring.
ASSEMBLY PROCEDURE TO INSTALL
CARTRIDGE SEALS
1. Apply anti-seize compound only to the area of
the shaft that will be under the sleeve.
3. Apply anti-seize compound only to the area of
the shaft that will be under the sleeve.
2. If installing an entire cartridge seal, place the
gasket onto the gland of the cartridge seal.
(See Figure 47.) Grease may be used to hold
the gasket in place. Slide the complete
assembly over the shaft until the gland fully
seats into the coverplate bore. Install and
tighten the four cartridge seal capscrews.
Push the sleeve fully home to axial stop and
tighten set screws to 130 inch-lbs.
4. Place the stuffing box gasket on the stuffing
box. Grease may be used to hold the gasket
in place.
5. Slide the sleeve/stuffing box subassembly
over the shaft until the sleeve bottoms out
onto the shaft locating shoulder.
32
If installing a cartridge seal cassette, use P80 Rubber Lubricant Emulsion, soapy water,
or equivalent to lubricate the static face oring. Slide the cassette onto the shaft
ensuring the seal faces properly enter the
cavity. Lightly tighten the cassette to the
gland with capscrews. Finish torque to 170
inch-lbs. Push the sleeve fully home to axial
stop and tighten set screws to 130 inch-lbs.
Figure 49: Installing the Bearing Backup Ring
(2” Frame Pumps Only)
3. Heat the bearing using an induction heater.
CAUTION Bearing Damage
Do not exceed a temperature of 275°F when
heating the bearing. Damage to the bearing
components may result if 275°F is exceeded.
Figure 47: Cartridge Seal and Gasket
Failure to follow these instructions could result in
property damage and/or moderate personal injury.
3. Repeat steps 1 and 2 for the other side. When
finished, see the section entitled Assembly
Procedure to Install Bearing Frames – All
Pumps.
CAUTION Extreme Temperature Hazard
ASSEMBLY PROCEDURE TO INSTALL
BEARING FRAMES – ALL PUMPS
1. Install the lip seal into the bearing cap bore.
The lip seal should sit against the bottom of
the machined bore. The lip should face away
from the bearing cavity. Install the bearing cap
onto the shaft. (See Figure 46.)
Bearing surfaces are hot.
protection to prevent burns.
Use
appropriate
Failure to follow these instructions could result in
property damage and/or moderate personal injury.
4. Using gloves, slide the heated bearing onto
the shaft against the shaft shoulder. For 2”
frame pumps, slide the heated bearing onto
the shaft against the backup ring.
NOTE: The bearings are single shielded and the
shield should face inward toward the impeller.
5. Install a lockwasher and locknut onto the
shaft. Tighten using a spanner wrench or
hammer and punch. Make sure the locknut is
secured and then bend over the tabs on the
lockwasher. (See Figure 50.)
Figure 48: Bearing Cap and Lip Seal
2. For 2”-frame pumps only, install a bearing
backup ring onto the shaft. (See Figure 49.)
(See Figure 22 for a listing of pump sizes with
2” frames.)
33
8. Fasten the bearing cap to the bearing bracket
with four capscrews.
9. Using grease fitting at the bottom of the
bracket, fill the bearing cavity until grease is
seen coming out from the lip seal(s).
NOTE: Use only Exxon Polyrex EM grease.
10. Repeat steps 1 through 9 to assemble the
other bearing frame.
NOTE: Only the inboard bearing bracket has a lip
seal.
GENERAL ASSEMBLY INSTRUCTIONS
1. Install the flush kit, and if required, reinstall the
drain plugs, and close the drain valve.
Figure 50: Installing the Lockwasher and
Locknut
2. Install and align the coupling, following the
instructions in the Coupling Alignment
section.
6. For inboard bearing bracket only:
Install the lip seal into the bearing bracket
bore. The lip seal should sit against the
bottom of the machined bore. The lip should
face away from the bearing cavity. (See
Figure 51.)
3. Install the coupling guard and bracket guards.
(See the Guards section.)
4. Open the isolation valves and check the
pumps for leaks. If no leaks are present,
return the pump to service. (See the
Operation section.)
Figure 51: Bearing Bracket and Lip Seal
7. Coat the inside of the bearing bracket
bore with grease and slide it into place
over the bearing. Install four capscrews to
secure the bracket to the coverplate.
34
TO CHANGE ROTATION
Figure 52: Impeller to Volute Orientation
WARNING: Unexpected Startup Hazard
1. Remove the pump from the base.
Disconnect and lockout power before servicing.
2. Follow
the
Disassembly
applicable to the pump.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
Procedures
NOTE: Only one of the coverplates must be
removed to change rotation.
3. Press the (press-fitted) impeller off the shaft.
Observe the direction in which the vane tips
are pointing. Turn the impeller end for end
(180°) and press it back onto the shaft. Refer
to the section entitled Assembly Procedure
to Install Coverplates and Shaft Assembly.
The vane tips should be pointing in the
opposite direction. (See Figure 52.)
WARNING: Electrical Shock Hazard
Electrical connections to be made by a qualified
electrician in accordance with all applicable codes,
ordinances, and good practices.
Failure to follow these instructions could result in
serious personal injury or death, or property
damage.
4. Reinstall the rotating assembly per the section
entitled Assembly Procedure to Install
Coverplates and Shaft Assembly. Check the
impeller to volute relationship per Figure 52.
WARNING: Rotating Components
Hazard
Do not operate pump without all guards in place.
5. Complete the reassembly by following the
procedures applicable to the pump.
NOTE: Unless the motor rotation is reversed the
impeller will run backward. Check the motor for
proper rotation before putting the pump back in
service.
Failure to follow these instructions could result in
serious personal injury or death and property
damage.
35
TO CHANGE STANDARD MECHANICAL
SEALS
See the following sections:
ƒ
1 set of bearings
ƒ
1 set of wearing rings (if required)
ƒ
1 set of casing gaskets, quad rings and lip
seals
ƒ
2 mechanical seals (complete)
A.
GENERAL DISASSEMBLY INSTRUCTIONS
B.
DISASSEMBLY PROCEDURE TO REMOVE
BEARING FRAMES – ALL PUMPS
C.
DISASSEMBLY PROCEDURE TO REMOVE
STANDARD MECHANICAL SEALS
D.
ASSEMBLY PROCEDURE TO INSTALL
STANDARD MECHANICAL SEALS
Parts should be ordered as far in advance of their
use as possible since circumstances beyond the
control of the company may reduce existing stock.
Not all parts are stocked and must be
manufactured for each order.
E.
ASSEMBLY PROCEDURE TO INSTALL BEARING
FRAMES – ALL PUMPS
To facilitate rapid handling of your order for spare
parts, be sure to include the following information:
F.
GENERAL ASSEMBLY INSTRUCTIONS
1. Serial number of the pump. (See the pump
nameplate.)
TO CHANGE CARTRIDGE SEALS
See the following sections:
2. Name of the part.
A.
GENERAL DISASSEMBLY INSTRUCTIONS
3. Quantity of each part.
B.
DISASSEMBLY PROCEDURE TO REMOVE
BEARING FRAMES – ALL PUMPS
C.
DISASSEMBLY PROCEDURE TO REMOVE
CARTRIDGE SEALS
4. Material desired. (Parts will be furnished in
original materials unless specified as a
material change. All material substitutions
should be discussed with the factory.)
D.
ASSEMBLY PROCEDURE TO INSTALL
CARTRIDGE SEALS
E.
ASSEMBLY PROCEDURE TO INSTALL BEARING
FRAMES – ALL PUMPS
F.
GENERAL ASSEMBLY INSTRUCTIONS
DEALER SERVICING
If trouble occurs that cannot be rectified, contact
your local Bell & Gossett representative. The
representative will need the following information
in order to provide assistance:
1. Complete nameplate data of the pump and
motor.
TO CHANGE THE PACKING OR SLEEVE
See the following sections:
A.
GENERAL DISASSEMBLY INSTRUCTIONS
2. Suction and discharge pipe pressure gauge
readings.
B.
DISASSEMBLY PROCEDURE TO REMOVE
STUFFING BOX AND PACKING
3. Ampere draw of the motor.
C.
ASSEMBLY PROCEDURE TO INSTALL STUFFING
BOX AND PACKING
D.
ASSEMBLY PROCEDURE TO INSTALL BEARING
FRAMES – ALL PUMPS
E.
GENERAL ASSEMBLY INSTRUCTIONS
4. A sketch of the pumping hook-up and piping.
ORDERING PARTS
The pumps covered by this manual have been
designed and built with certain replaceable
wearing parts. The recommended inventory of
spare parts depends upon the installation and the
importance of continued operation.
For normal service, with repairs to be made in the
field, the following parts are recommended for
stock.
36
Table 6:
Capscrew Type
Head Marking
1/4
6
SAE Grade 2
Brass
Stainless Steel
SAE Grade 5
SAE Grade 8
Capscrew Torque
Capscrew Torque (Foot-Pound)
Capscrew Diameter
5/16 3/8 7/16 1 / 2 5/8 3 / 4 7/8
13
25
38
60 120 190 210
1
300
4
10
17
27
42
83
130
200
300
10
20
35
60
90
180
325
525
800
13
28
46
75
115
225
370
590
895
or
37
© COPYRIGHT 2006 BY ITT
INDUSTRIES, INC.
PRINTED IN U.S.A. 1-06
Bell & Gossett
8200 N. Austin Avenue
Morton Grove, IL 60053
Phone: (847) 966-3700
http://www.bellgossett.com
38
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement