Product Guide

Product Guide
GRUNDFOS INSTRUCTIONS
Horizontal Split Case
Model AEF
Installation and operating instructions
English (US)
English (US) Installation and operating instructions
1. Symbols used in this document
Original installation and operating instructions.
CONTENTS
Warning
Page
If these safety instructions are not observed,
it may result in personal injury.
1.
Symbols used in this document
2
2.
2.1
2.2
2.3
2.4
General information
Warranty
Personnel qualification
Warnings
Material Safety Data Sheet
2
2
2
3
4
3.
3.1
3.2
3.3
3.4
3.5
Transport and storage
Transport and handling requirements
Receipt and inspection
Rigging and lifting
Storage
Disposal of packaging materials
4
4
4
5
5
6
Warning
4.
4.1
4.2
Identification
Nameplate
Type key for horizontal split case fire pump
6
6
7
Warning
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
Installation
Factory support
Location
Foundation
Rigging and lifting
Installation preparations
Base plate or pump
Piping and connections
Setting the impeller clearance
Alignment
Lubrication, priming and cooling systems
Electrical installation
Control, monitoring and alarm equipment
9
9
9
9
10
11
11
12
12
13
15
15
15
6.
6.1
6.2
6.3
6.4
6.5
6.6
Startup, operation and shutdown
Frost protection
Lubrication
Rotation
Guards
Check list
Startup, operation and shutdown
15
15
15
16
16
16
17
7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
Maintenance
Schedule
Recommended spare parts
Consumables
Tightening torques
Dismantling
Wear Ring
Inspection and Repair
Assembly
Accessories
18
18
18
18
18
19
20
20
21
21
8.
Fault finding (Trouble Shooting)
22
9.
Parts list and sectional drawing
24
10.
Disposal
25
2
Warning
If these instructions are not observed, it may lead
to electric shock with consequent risk of serious
personal injury or death.
When pumping hazardous liquids, special
attention must be paid to the risk of personal
injury.
The surface of the product may be so hot that
it may cause burns or personal injury.
Warning
The sound pressure level is so high that hearing
protection must be used.
Caution
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment.
Note
Notes or instructions that make the job easier
and ensure safe operation.
2. General information
These instructions should be retained for reference regarding
maintenance and operation near the pump.
These are general instructions and may not take into account
local regulations. The user should ensure such regulations are
observed by all parties.
Information in this manual is believed to be reliable. In spite of all
the efforts to provide sound and all necessary information, the
content of this manual may appear insufficient and is not
guaranteed to be compete or accurate in all instances.
2.1 Warranty
This unit is manufactured under a quality management system
standard as certified and audited by external quality assurance
organizations. Genuine parts and accessories have been
designed, tested and incorporated into the products to help
ensure their continued product quality and performance in use.
Damage or failure caused by misuse, abuse or failure to follow
these instructions are not covered by our warranty.
Any modification of our products or removal of original
components may impair the safety of these products in their use.
Warning
2.2 Personnel qualification
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
All operations must be carried out by qualified personnel.
Warning
If the site is left unattended before the
installation is complete, all openings must be
covered to prevent entry of children, animals,
stones or any other foreign objects.
Warning
Do not attempt to lift the entire pump by the
lifting lugs (eyes) of the driver or pump.
Never lift unit using hooks or slings on shafts.
Use unbreakable covers that cannot be removed
without tools.
Use proper lifting techniques when manually
lifting components -keep component close to
body, back straight, lift with legs, DO NOT BEND
AT WAIST.
Warning
Warning
When a pump has experienced temperatures over
400 °F [205 °C], skin contact must be avoided
with components. Additionally, partial
decomposition of fluoro-elastomers (when fitted)
will occur.
Do not work under suspended object unless you
have taken precautions to stop its fall in the
event of sling failure.
Warning
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and
equipment is required when handling these
components.
Warning
Hot or freezing components or auxiliary heating
supplies can present a danger to operators and
persons entering the immediate area. Action
must be taken to avoid accidental contact. If
complete protection is not possible, the machine
access must be limited to maintenance staff only,
with clear visual Warnings and indicators to
those entering the immediate area.
Do not place hands under component in such a
way that the component would fall on the hands if
dropped.
Warning
Pumps are not designed to accept external loads
from belt driven arrangements. A separate jackshaft with a bearing structure suitable for belt
loading is required.
Warning
Do not remove or paint over any safety labels. If
labels are lost or damaged, contact your Peerless
Pump representative for replacement.
Warning
Never do maintenance work when the unit is
connected to power.
Warning
Warning
Rapid changes in the liquid temperature can
cause thermal shock that can result in damage of
pump components and should be avoided.
All guards must be in place on the pump prior to
startup. Read and follow all recommended
guarding and safety instructions for accessories,
if any.
Warning
When the pump is handling hazardous liquids,
care must be taken to avoid exposure to the
liquid by appropriate setting of the pump, limiting
personnel access and by operator training. If the
liquid is flammable and/or explosive, strict safety
procedures must be applied.
Gland packing must not be used when pumping
hazardous liquids.
Do not use pump as a support for piping.
Caution
Caution
Do not mount expansion joints, unless allowed
by Peerless Pump in writing, so that their force,
due to internal pressure, acts on the pump
flange.
Products used in potentially explosive
atmospheres. Special consideration must be
taken when pumps are installed in these
applications. Contact Peerless Pump for more
information.
Warning
Warning
Do NOT place fingers, hands, arms, etc. into any
opening (such as the air relief valve hole).
Do NOT wear loose or frayed clothing or jewelry
that could catch on equipment or become
trapped in the equipment.
Do NOT touch the impeller or other rotating
elements, if rotated, this can cause severe injury.
The area between the stuffing box and bearing
bracket is left open to allow for inspection and
adjustment of packing. Do NOT place hands or
fingers into this area while equipment is in
operation. Do NOT wear loose clothing, long hair,
or jewelry around this area.
Warning
Use only qualified electricians for electrical
installation and maintenance.
Refer to manuals provided with electrical
accessory components and disconnect power
supply as recommended for servicing.
Parts which are provided with lifting lugs, lifting
ears or eyebolts should be lifted by these points
only. They may not be used for lifting the entire
pump.
When lifting the entire pump, use appropriate
slings.
3
English (US)
2.3 Warnings
English (US)
Warning
Warning
Most surfaces on the driver (engine or motor) can
become hot during normal operation.
Do NOT store lubricants or other volatile
substances near the engine. These should be
placed in a designated area having a suitable
storage enclosure.
If packing is too tight, the drain water from the
stuffing box can become hot enough to scald.
Ensure that drain water is not excessively hot
before contact.
The stuffing box and bearing bracket areas on
the pump can become hot in the event of a
malfunction or maladjustment. These surfaces
may remain hot for some time after the unit has
been shut down.
2.4 Material Safety Data Sheet
As a general practice, material safety data sheets (MSDS) are not
supplied with pumps unless required. They may be requested
from Peerless Pump.
2.4.1 Noise level
Warning
Use care when touching these surfaces and wear
protective gloves if necessary to touch these
surfaces when hot.
Whenever pump noise level exceeds 85 dBA,
attention must be given to the prevailing health
and safety legislation to limit the exposure of
plant operating personnel to the noise. The usual
approach is to control exposure time to the noise
or to enclose the machine to reduce emitted
sound.
Warning
Noise levels, especially for diesel engine driven
units, can exceed safe levels. Refer to the noise
level published in the accompanying
documentation, and, if this noise level exceeds
local code or safe levels, place the unit in a
controlled access area and provide ear
protection to personnel authorized to be in this
area.
Fire pump units can start unexpectedly at any
time. Ear protection should be carried by, or
readily available to, all personnel authorized to
be in the pump room with these units.
Warning
Isolate engine before any maintenance work is
done. Switch off the main supply, remove fuses,
secure fuel lines, apply lock-outs where
applicable, and affix suitable isolation warning
signs to prevent inadvertent re-connection.
ISOLATE the fuel supply to the engine BEFORE
working on any part of the fuel supply or control
system
DISCONNECT the batteries by removal of the
NEGATIVE terminal connector. Do NOT place
tools on or near the batteries. This could result in
a short circuit. INSPECT all cables for damage or
signs of failure and replace immediately if
damaged.
Warning
Engine fuel fumes are highly flammable! Do NOT
refuel the engine when it is running or is still hot
from recent running.
When refueling, avoid breathing the fuel fumes,
particularly if the pump; is installed in an
enclosed pump room. Maintain maximum
ventilation to clear the fumes quickly.
Do NOT start the engine while fuel fumes remain
evident or may be present.
Warning
Exhaust gases are hazardous; the exhaust
system MUST be maintained free from leaks and
directed to discharge in a safe area.
Warning
Battery gasses are hazardous and flammable.
The battery area MUST be well ventilated to clear
these gases quickly.
4
3. Transport and storage
3.1 Transport and handling requirements
The pump has been prepared for shipment at the factory in such
a way as to minimize potential damage due to handling and
transport.
Caution
The equipment should not be subjected to
excessive g-forces during the handling or
transport.
3.2 Receipt and inspection
Receiver should report any shortage or damage to the transport
company handling the shipment and to Peerless Pump.
Prior to installation, take inventory of the shipment to ensure that
the parts received match the list of parts on your order.
Note the extent of damage or shortage on the freight bill and bill
of lading. Failure to note damage or missing parts may result in
declined warranty or replacement of parts.
It is important that all the components for a pump unit be
identified and properly stored until installation is to be done.
There may be many small parts (such as line shaft couplings or
hardware) that are best left in their shipping container until
installation.
Do not unpack any more than required to verify that the
equipment is complete and undamaged unless installation is to
be done immediately. Check all packaging material that is to be
discarded to verify that no parts or instructions are being
accidentally discarded. In some shipments, small boxes
containing additional parts are bound to pump skids. Leave small
parts in their shipping container until installation so they don't get
lost. Upon unpacking make certain that accessories with a pump
unit are clearly marked showing which pump unit they are to be
used with.
3.4.2 Uncontrolled storage
When pumps are received unassembled, all the parts should be
located close to the location where the pump will be installed.
For uncontrolled storage periods of three months or less, the
equipment is to be inspected weekly to ensure that all
preservatives are intact and internals are protected.
Caution
Pump parts that are too heavy to be lifted by
hand must be lifted from the transporting vehicle
with a suitable hoist. Lifting chains or cables
must not contact machined surfaces.
English (US)
3.3 Rigging and lifting
Inspect and recoat periodically the equipment with water
displacement rust inhibitors (Rust-Ban 392 or equal), crusting
grease (Rust-Ban 326 or equal), vapor phase inhibitor
Warning
(Shell VPI-260 or equal) and/or rust preventative coating (RustBan 343 or equal).
Parts which are provided with lifting lugs, lifting
ears or eyebolts should be lifted by these points
only. They may not be used for lifting the entire
pump.
All pipe threads and flanged pipe covers are to be sealed with
tape. Furthermore you should place 10 lbs. [4.5 kg] of moistureabsorbing desiccant or 5 lbs. [2.3 kg] of vapor phase inhibitor
crystals near the centre of pump.
When lifting the entire pump, use appropriate
slings.
If the pump is assembled, place an additional one pound in the
discharge of the pump securely fastened.
Warning
Cover the equipment with black polyethylene or equal with a
minimum thickness of 0.006" [0.15 mm]. Provide a small
ventilation hole approximately the size of a small coin.
Install a moisture indicator near the perimeter of the pump.
Do not attempt to lift the entire pump by the
lifting lugs (eyes) of the driver or pump.
Never lift unit using hooks or slings on shafts.
Use proper lifting techniques when manually
lifting components -keep component close to
body, back straight, lift with legs, DO NOT BEND
AT WAIST.
Warning
Do not work under a suspended object unless
you have taken precautions to stop its fall in
event of sling or hoist failure.
3.4 Storage
Standard factory packaging is suitable for protection during
shipment and during covered storage at jobsite for a short period
between installation and startup. The preservatives applied at the
factory have an effective life of two to three months from date of
shipment from factory, depending on the severity of the
environment in which the equipment is exposed. For international
destination this will vary depending on the sea worthiness of
export boxing.
3.4.1 Controlled storage
Storage facilities should be maintained at an even temperature of
at least 10 °F [5.5 °C] above the dew point with relative humidity
lower than 50 % and little or no dust. The equipment is to be
inspected weekly to ensure that all preservatives are intact and
internals are protected.
Inspect and recoat periodically the equipment with water
displacement rust inhibitors (VPCI-368-021, Rust-Ban 392 or
equal), crusting grease (Rust-Ban 326 or equal), vapor phase
inhibitor (Shell VPI-260 or equal) or rust preventative coating
(Rust-Ban 373 or equal).
Protect the equipment from flooding or from
harmful chemical vapors.
Caution
Storage should be free from ambient vibration.
Excessive vibration can cause bearing damage.
Precautions should be taken to prevent rodents,
snakes, birds or insect from nesting inside the
equipment.
Provide a roof or shed shelter to protect from direct exposure to
the elements.
If equipped, connect space heaters on equipment such as
motors, engines or controls.
3.4.3 Standard short-term storage
The pump and equipment, as shipped, have adequate protection
for short-term (two to three months) storage in a covered, dry and
ventilated location at the job site prior to installation.
For short-term (two to three months) storage not in a covered, dry
and ventilated location at the job site prior to installation. For
packed-type pumps, remove stuffing box packing and place it in a
sealed plastic bag. Apply a film of compatible lube oil over the
water displacement rust preventative (Rust-Ban 632 or equal).
Seal the end of the stuffing box with rolled vapor phase inhibitor
paper and seal with weatherproof tape. For packed-type pumps
the packing glands may be left on the pump shaft, but should be
securely fastened in position.
All exposed machined surfaces should be thoroughly coated with
a firm film rust preventative material (Rust-Ban 373 or equal) that
is readily removable with a petroleum distillate product.
All exposed painted surfaces should be dry, clean and free of
grease and other contaminates.
After pump has been thoroughly drained, cover the pump suction
and discharge flanges with a cover (typically cardboard or wood)
to blank off these openings.
Rotate pump shaft per the rotation arrow on pump several
revolutions at least once per week to coat the bearing with
lubricant and to retard oxidation and corrosion, flat spots and
staining. Shaft should end up 90 ° from starting point.
To place the pump in operation, all protective coverings and
coatings should be properly removed. For packed-type pumps,
repack the stuffing box with the proper number of packing rings
from bag. If the packing appears to be damaged or otherwise
unfit, it should be replaced.
See section 3.4.4 Long-term storage when the startup of
equipment is made over three months from the date of shipment
from the factory.
5
Long-term storage protection from the factory does not extend
the warranty in any manner. Warranty policy is twelve months
from startup or eighteen months from time of shipment, whichever
occurs first. This warranty is valid only if equipment has been
properly handled and stored as per the stated requirements.
Should the equipment be stored or handled improperly, then the
warranty is invalid and may be reinstated only after a factory
representative is allowed to inspect the equipment prior to
startup. Expenses for the representative will be billed in
accordance with the latest schedule for field service engineer.
Any repairs or repair parts needed will be billed to the customer at
prices in effect at time of shipment of these repairs/parts.
At the time of pump specification and/or order placement
Peerless Pump should be advised about the extended storage
duration so that special long-term storage protection can be
provided for the equipment prior to shipping to the job site.
Inspection of the equipment by a factory representative prior to
startup is normally required to ensure equipment integrity and
compliance with warranty requirements.
4. Identification
4.1 Nameplate
Each pump has a nameplate which list serial number. See fig. 1
and 2 for pump supplied. The serial number is needed when
contacting Peerless Pump with questions or service request.
When a driver is supplied, there will also be a nameplate on the
driver. When requesting information about the driver, both the
driver serial number and the pump serial number will be required.
Information on the Fire pump nameplate includes the following:
•
pump size/model
•
serial number
•
pump manufacturer and location
•
certification mark (UL/FM fire or other), if any
•
rated flow rate
•
rated speed
•
rated head
•
rated psi
•
impeller diameter.
In addition to complying with the standard short-term and storage
atmosphere conditions, the following considerations are required:
CENTRIFUGAL FIRE PUMP
Dry pump internals and spray the liquid end with a water
displacement rust inhibitor (Rust-Ban 392 or equal).
HORIZONTAL SPLIT-CASE
Enclose vapor inhibitor in pump internals (Shell VPI 260 or
equal).
TM06 0290 5113
Apply a film of compatible lube oil over the water displacement
rust preventative (Rust-Ban 632 or equal).
After pump has been thoroughly drained, cover the pump suction
and discharge flanges with full natural rubber gasket material and
blank off these openings with metal blank flanges and a minimum
of four full sized bolts. Cover the pump stuffing box opening with
a non-hygroscopic tape.
Cover the equipment with black polyethylene or equal with a
minimum thickness of 0.006" [0.15 mm] and seal it with tape.
Fig. 1
Fire pump Nameplate
Provide a small ventilation hole approximately the size of a small
coin.
The pump should be inspected at regular periods.
Model
Rotate the pump shaft per the rotation arrow on the pump several
revolutions at least once per week to coat the bearing with
lubricant and to retard oxidation and corrosion, flat spots and
staining. The shaft should end up 90 ° from starting point.
Serial
Fig. 2
TM06 0217 5113
English (US)
3.4.4 Long-term storage
Flange Nameplate
To place the pump in operation, all protective coverings and
coatings should be properly removed. For packed-type pumps,
repack the stuffing box with the proper number of packing rings
from bag. If the packing appears to be damaged or otherwise
unfit, it should be replaced.
•
pump size/model
•
serial number
•
pump manufacture and location.
3.4.5 Accessories storage
4.1.1 Certifications
Store accessories according to the manufacturer's instructions.
Long-term storage should not be undertaken without written
understanding from manufacturer.
If the product carries an industry certification (UL/FM fire or
other), it will be noted on the pump nameplate. Contact Peerless
Pump for additional information.
3.5 Disposal of packaging materials
4.1.2 Pump
See section 10. Disposal.
The pump size/model is given with a number, letter(s) followed by
a number such as 5AEF12. These would represent the size and
model of pump.
6
Information on the flange name plate includes the following:
English (US)
4.2 Type key for horizontal split case fire pump
Code Example 6AEF16G 1-A-1/7-P-A-B-R-C
6
AEF
16
G
-1
-A
-1
/7
-P
-A
-B
-R
-C
Discharge Flange
Model
Maximum Impeller Diameter [inches]
Hydraulic Variation
<> - None (blank)
G….
….
Flange Rating
1 - 125#x125#
2 - 125#x250#
3 - 250#x250#
4 - 125#x400#
X - Special
Listing or Approval of Pump System
A - UL and FM
B - FM only
C - UL only
D - NFPA compliant
E - ULC
F - CCC
X - Special
Casing Material
1 - Cast Iron
2 - Ductile Iron
4 - 316LSS
5 - CD4MCu
9 - Nickel-Aluminium Bronze
X - Special
Impeller Material
1 - Cast Iron
4 - 316LSS
5 - CD4MCu
7 - Silicon Bronze
9 - Nickel-Aluminium Bronze
X - Special
Type of Sealing
P - Packing
S - Seal Component Style
C - Cartridge Seal
X - Special
System Configuration
A - Bare Shaft Pump
B - Pump + Base
C - Pump + Base + Drive
D - Pump + Base + Driver + Controller
X - Special
7
English (US)
6
Manufacture of Driver
B - USEM / Nidec
C - General Electric
D - Marathon
E - WEG
F - Baldor
N - Clarke
P - Cummins
Q - Caterpillar
R - Deutz
Z - No Driver
X - Special
Pump Rotation
R - Right Hand / Clockwise
L - Left Hand / Counter Clockwise
Controller Type:
A - No Panel
C - Firetrol
D - Tornatech
E - Master
F - Cutler Hammer
X - Special
8
AEF
16
G
-1
-A
-1
/7
-P
-A
-B
-R
-C
5.1 Factory support
For customized products, we recommend that you have a
Peerless Pump service engineer supervise installation and
startup.
5.3 Foundation
The pump must be installed on a foundation rigid enough to
support the entire weight of the pump plus the weight of the fluid
contained in it. Weak foundations or foundations on unstable
ground can cause misalignment, vibration, and even total
foundation failure.
This is to ensure that the machinery is properly installed. You will
then also have the opportunity to review, and see implemented,
factory-recommended instructions.
Note
Warning
This pumping unit is designed to be operated
within certain limits pertaining to fluid pump,
driver conditions, etc. These limits are listed on
the performance curve, or on original contract
documentation.
Do not operate this pump at any pressure, flow
rate, or liquid temperature other than those for
which the pump was originally purchased. Do not
pump any other liquid than the one for which the
pump was originally purchased without the
consent of Peerless Pump or its authorized
representatives. Disregard of this Warning can
result in pump failure and serious personal injury
or death.
Operation outside of these limits may result in
damage to the unit, personal injury, or death.
Consult your Peerless Pump representative for
approval if a need arises to operate outside of
these limits.
The mass of the foundation should be sufficient, preferably five
times that of the rotating element of the pumping equipment, to
form a permanent and rigid support for the base plate.
Foundation and base plate bolt sizing is critical, particularly on
high-pressure pumps, to adequately restrain reaction forces such
as from directional flow change, system transients and sudden
valve closure. Concrete foundations may have anchor bolts
installed in sleeves that are two times the diameter of the bolt to
allow alignment and should be located by a drawing or template.
Caution
Warning
Failure to have each component's surface machined will result in
excessive vibration.
Operation at a reduced capacity for prolonged
periods may shorten the useful life of the seals or
packing, shaft sleeves, bearings, and the shaft.
Fire pumps are applied with full knowledge that
operation at reduced capacity will occur.
Follow the instructions in sections 5.4.1 Leveling and
5.4.2 Grouting. After the grout is cured (a minimum of 48 hours),
the pump unit may be finished for pump installation. Peerless
Pump does not recommend installation of the base plate without
the pump.
Locate pump discharge piping and suction piping
as well as auxiliary equipment, control and
starting panels so that adequate access is
provided for maintenance.
Adequate floor space and working room should
also be provided for maintenance
Note
Note
Steel support structures may not be stiff enough
even if their mass exceeds five times that of the
rotating element. A civil engineer should review
and approve a steel support structure before
pump installation.
Whether the base plate is installed prior to the pump installation
or at the same time, the pump must be attached to the base plate.
Check that the pump feet are clean and free of burrs and nicks.
5.2 Location
Note
Allowable bearing loads of structural steel and
floors can be obtained from engineering
handbooks; building codes of local communities
give the recommended allowable bearing loads
for different types of soil.
To minimize frictional head loss, locate the pump
so that it can be installed with a short and direct
discharge pipe and with the least number of
elbows and fittings. If practical, it should be
placed so that it will be accessible for inspection
during operation. Pumps, drivers and controls
should be protected against flooding, freezing,
etc.
The suction supply system must provide the
pump with Net Positive Suction Head (NPSH)
equal to or greater than that required by the
pump at any capacity on its operating curve. Ask
your Peerless Pump representative for
assistance if; you do not understand how to
calculate or measure suction supply system
NPSH.
Caution
Position the foundation and the foundation bolts
so that pump suction and discharge flanges will
be in accurate alignment with the discharge
piping.
5.3.1 Seismic analysis
When pumps are located in seismically active areas and for
certain critical installations the pumps, supports and accessories
should be earthquake-resistant. The design specifications to
achieve earthquake resistance vary, depending upon
geographical area, class of the equipment (defining how critical
the survival of the equipment is) and the characteristics
(acceleration response) of the structure or foundation supporting
the pump.
Complete specifications for earthquake-resistance requirements
should be supplied by the customer. This includes the following:
•
the seismic criteria, such as acceleration, magnitudes,
frequency spectrum, location and direction relative to pump
•
the qualification procedure required, i.e., analysis, testing or a
combination of these, and requirements for operability during
and/or after test.
9
English (US)
5. Installation
Adequate headroom should be provided to accommodate the
pump to be handled, including rigging.
Caution
Properly sized slings, chains and shackles
should be available for attaching to the lifting
lugs (eyes). Eyebolts are required for handling
pump sections when lifting lugs are not provided.
5.4.1 Leveling
1. Remove the supporting timbers, rope and any other
equipment from the top of the foundation.
2. Disconnect the coupling halves between the pump and driver.
Note
4. Orient the pump so that the discharge outlet and suction inlet
is in the desired direction and the holes in the base align with
the foundation bolts.
5. Continue to lower the pump until the bolts just enter the holes
in the base.
6. If the foundation is concrete, place the wedges under the base
plate, adjacent to the bolt holes, one under each of the four
sides.
7. For structural foundations (made up of I-beams or H-beams),
use shims under the corners.
8. Continue to slowly lower the pump until the base of the base
plate rests on the wedges or anchor bolts with washers and
nuts.
Caution
5.4.2 Grouting
After the base plate is at the correct location and leveled with a
precision level, the base plate needs to be grouted to the
foundation.
Grout compensates for unevenness in the foundation and base
plate and minimizes vibrations levels during operations. It
prevents the unit from shifting after mounting and alignment.
Cross board for holding
foundation bolts
Accurate alignment of the pump shaft in relation
to the motor shaft is absolutely essential for
smooth and trouble-free operation.
9. By using the wedges or washers and nuts on the anchor bolts,
adjust the pump suction flange center line to the correct
elevation.
10. While maintaining the correct elevation, adjust the nuts and
washers or shims to achieve the specified levelness of 0.005"
per ft. [0.4 mm per m] in both directions. The levelness should
be measured by placing a precision level on the machined
face of the discharge flange.
11. Place a machinist's level on the discharge flange, orienting it
parallel with one of the edges of the base.
12. Move the wedges or add more shims until the level reading
reaches 0.005" per ft. [0.4 mm per m].
Foundation bolt
Nut
Template frame
Flat washer
Foundation bolt
assembly
Metal wedge
If the base plate is not already grouted in place,
be certain that the grouting dam around the
foundation opening is in place before lowering
the pump assembly onto the foundation.
3. Lower the pump unit until the base plate is just above the
foundation bolts.
Never attempt to align the pump using a spirit
(carpenter's) level.
Caution
Pump base
Grout
Pipe sleeve
Maleable washer
Fig. 3
Concrete
foundation
TM06 0218 4913
For typical installations, suitable overhead lifting equipment of
adequate capacity to lift the driver, the entire pump (without
driver) or the heaviest subassembly of the pump should be
available at the job site when installing or removing the pump.
readings.
Typical foundation with base plate
Only non-shrinking grouting material should be used for grouting
the base plate to the foundation. Foundation bolts should not be
fully tightened until the grout is hardened, usually about 48 hours
after pouring.
1. Prepare the foundation surface according to the grout
manufacturer's recommendations.
2. Locate the foundation bolts by the use of a template frame
and provide anchorage as shown in fig. 4. See the outline
drawings furnished with each pump for the exact location of
the foundation bolts.
3. Build a dam on the foundation, enclosing an area around the
base plate that includes all alignment wedges. Allow for a
grout thickness of 0.75 to 1.50" thickness [19.05 mm to 38.1
mm]. See fig. 3.
4. Pour the grout through the holes provided in the base plate or
through open ends of steel channel base plates. While
pouring, tamp liberally in order to fill all cavities and prevent
air pockets. If tamping does not eliminate all air pockets, drill
small vent holes through the base surface.
5. Level off the grout flush with the top of the dam.
6. Allow the grout to cure at least 48 hours before tightening the
foundation bolts or starting the pump.
7. Tighten pipe connections to suction and discharge flanges.
8. Check the pump alignment in Section 5.9 Alignment.
9. When the grout has thoroughly dried, paint the exposed
edges to prevent air and moisture from coming in contact with
the grout.
13. Reorient the level on the same surface, 90 ° from the original
position.
14. Again adjust the wedges or shims until a 0.005" [0.12 mm]
level reading is reached, taking care not to upset the
levelness is the first direction.
TM06 0219 0914
English (US)
5.4 Rigging and lifting
15. After each adjustment, check for levelness in both directions.
16. Push in or add to any loose shims to distribute the weight
evenly.
17. Fit nuts on the foundation bolts and tighten them gradually
and uniformly.
18. Check the level readings in both directions.
19. If necessary, loosen the foundation bolts and readjust the
wedges or shims, tighten the bolts again and check the level
10
Fig. 4
Foundation Bolting Location and Anchorage Mount
and leveling
5.6 Base plate or pump
5.5.1 Inspection
Warning
All pump parts were carefully inspected before leaving the
factory, but may have become soiled or damaged in shipping and
handling or storage at site. The installer must therefore check that
all parts are clean and undamaged before installing them.
Never attempt to lift the pump by means of
eyebolts screwed into the driver mounting holes
because the bolts are not strong enough to carry
the weight of the entire pump.
Caution
Do not step or walk on the pump components. Do
not place other parts or equipment on the pump
components.
Use appropriate solvent to wash off any protective coating from
the shaft sections and wipe thoroughly clean and dry.
Dirt, sand, etc. in the system will cause premature wear on the
critical pump internal surfaces, resulting in reduced pump
performance.
Pumps and drivers mounted on a common base plate were
accurately aligned before shipment. All base plates are flexible to
some extent and, therefore, must not be relied upon to maintain
the factory alignment.
Realignment is necessary after the complete unit has been
leveled on the foundation and again after the grout has set and
foundation bolts have been tightened. The alignment must be
checked after the unit is piped and rechecked periodically as
outlined in the following paragraphs. To facilitate accurate field
alignment, we do not dowel the pumps or drivers on the base
plates before shipment.
5.5.2 Engine Preparation
Safe and efficient operation of a pumping unit driven by an diesel
engine, requires the installation to satisfy the following
requirements:
1. It is recommended that the operator become familiar with the
installation and service manual supplied by the engine
manufacturer or Peerless Pump
2. Be well ventilated in order to keep the ambient temperature as
low as possible. Taking 60 °F [15.6 °C] as a datum point,
every 10 °F [-12 °C] rise in temperature reduces the
horsepower of the engine by approximately 1 %.
3. Provide ample air for proper combustion.
4. Provide the engine with an efficient exhaust system so that
the combustion gasses discharge with a minimum of
backpressure.
5. Provide for a fuel system of adequate capacity that meets the
local codes.
5.6.1 Leveling
Flat surfaces that might capture air during grouting should be
vented to prevent voids between the surface and the grout.
The base plate should be leveled by use of wedges (see section
5.4.1 Leveling) or by use of leveling screws supported on
rectangular metal blocks.
The leveling screw threads should be covered with a non-binding
material such as grease, putty or tape before grouting, to facilitate
their removal.
If shims are used, they should be placed to isolate from the initial
application of grout. After the initial grout has cured, the forms
and shims may be removed and the void filled with a second
application of grout.
A gap of about 0.75 to 1.5" [19.05 mm to 38.1 mm] should be
allowed between the base plate and the foundation for grouting.
See section 5.2 Location.
5.6.2 Grouting
The grout material that supports the base plate is a critical
element of the pump support structure and should be carefully
selected. The product warranty is void if this Instruction is not
followed.
If the grout cracks or fails, the structure will be compromised.
When the alignment is correct, the foundation bolts should be
tightened evenly but not too firmly. The unit can then be grouted
to the foundation. It is not recommended to grout leveling pieces,
shims or wedges in place because they introduce discontinuities
and stress concentrations that may cause the grout to crack.
Foundation bolts should not be fully tightened until the grout is
hardened, usually about 48 to 72 hours after pouring. Jacking
screws should be removed after the grout has hardened and the
holes filled with an appropriate sealing material.
Caution
Do not distort the base plate by over tightening
the foundation bolts.
5.6.3 Doweling
Contact Peerless Pump for further information.
6. Provide ample accessibility to service engine.
7. Provide correct rotation of the pump. Engine rotation is
determined at the factory. No change of engine rotation can
be made in the field.
11
English (US)
5.5 Installation preparations
5.7.1 Pipe supports, anchors or joints
Suction and discharge piping should be anchored, supported and
restrained near the pump to avoid application of forces and
moments to the pump in excess of those permitted by Peerless
Pump.
Caution
Do not exceed the forces or moments specified
on the outline drawing when connecting piping to
the suction or discharge flanges.
In order to achieve optimum operation and minimum noise and
vibration, consider vibration dampening of the pump.
Caution
Piping must be independently supported and
arranged so that expansion and contraction, due
to temperature changes, will not cause
misalignment.
Noise and vibration are generated by the revolutions of the motor
and pump and by the flow in pipes and fittings. The effect on the
environment is subjective and depends on correct installation and
the state of the remaining system.
Elimination of noise and vibrations is best achieved by means of
a concrete foundation, vibration dampers and expansion joints.
Note
The selection of vibration damper differs from installation to
installation. In certain cases, a wrong damper may increase the
vibration level. Vibration dampers should therefore be sized by
the supplier of the vibration dampers.
If you install the pump on a foundation with vibration dampers,
always fit expansion joints on the pump flanges. This is important
to prevent the pump from "hanging" in the flanges.
5.7.3 Suction piping
The suction and discharge piping should be of sufficient size and
be internally free of foreign material.
Considerations for suction piping to achieve optimal performance
are:
Piping should be cleaned mechanically and
chemically, and flushed prior to installing the
pump. A large number of pump packing, seal and
seizure troubles are due to improperly cleaned
systems.
The pump should also be inspected internally for foreign matter
that may have entered the pump.
1. When operating under suction lift, line must be kept absolutely
free from air leaks.
2. When operating under suction lift, must be at least one pipe
diameter larger than the pump suction nozzle. In order to
prevent eddies and vortices, the end of the suction pipe must
be at least two pipe diameters below the free liquid surface. If
a foot valve is used to facilitate priming, the foot valve must
have a minimum flow area 1.5 times the area of the suction
pipe. The suction at all points and should not contain loops or
high spots in which air can be trapped.
3. When operating under suction pressure, pipe may be equal
to, but never less than the suction nozzle size.
Failure of the suction piping to deliver the liquid to the pump in
this condition can lead to noisy operation, swirling of liquid
around the suspended pump assembly, premature bearing failure
and cavitation damage to the impeller and inlet portions of the
casing.
Contact Peerless Pump for further information.
5.7.4 Suction valves and manifolds
1
Air pocket
2
Block valves may be installed to isolate the pump for
maintenance.
Foot valves are specially designed non-return valves sometimes
used at the inlet to prevent backspin caused by rapidly draining
water in the discharge pipe.
Incorrect
Path of water
Incorrect
5.7.5 Discharge valves
Air pocket
A non-return valve and an isolation valve should be installed in
the discharge pipe. The non-return valve serves to protect the
pump from backflow and excessive backpressure. The isolation
valve is used when starting and stopping the pump.
Incorrect
We recommend closing the isolation valve before stopping or
starting the pump.
Correct
3
Air pocket
Correct
4
Incorrect
Correct
Correct
Fig. 5
Correct
TM06 0220 0914
English (US)
5.7 Piping and connections
Piping Arrangement
Pump backspin and hydraulic shock can cause severe damage to
pump and motor. Install at least one non-return valve in the
discharge pipe, not more than 25 ft. [7.5 m] after the discharge
flange to help prevent this
Operating some pumps at shutoff may cause a dangerous
increase in pressure or power. If increasers are used on the
discharge side of the pump to increase the size of piping, they
should be placed between the non-return valve and the pump.
5.7.2 Vibration dampers
If expansion joints are used, they should be placed between the
pipe anchor and the non-return valve.
To prevent the transmission of vibrations to buildings, isolate the
pump foundation from building parts by means of vibration
dampers.
5.7.6 Nozzle loads
The selection of the right vibration damper requires the following
data:
The piping should be aligned with the pump nozzles to minimize
pump nozzle loads. Contact Peerless Pump for allowable nozzle
loading for your given design.
•
forces transmitted through the damper
5.8 Setting the impeller clearance
•
motor speed considering speed control, if any
•
required dampening in %.
12
To achieve optimal performance and reduce radial loading, the
impeller should be centered in the volute passageway of the
casing. For new pumps, this is done at the factory, refer to section
7.6 Wear Ring.
Pumps and drivers mounted on a common base plate were
accurately aligned before shipment. All base plates are flexible to
some extent and, therefore, must not be relied upon to maintain
the factory alignment.
After the grout has set and the foundation bolts have been
properly tightened, the unit alignment should be checked.
After the piping of the unit has been connected, the alignment
should be checked again. Alignment may be checked by
mounting a dial indicator to measure shaft movement before and
after tightening flange bolts. If the unit does not stay in alignment
after being properly installed, the following are possible causes:
English (US)
5.9 Alignment
Misalignment may be the cause of:
•
Noisy pump operation
•
Vibration
•
Premature bearing failure
•
Excessive coupling wear
Recheck alignment is required after:
•
Mounting
•
Grout has hardened
•
Foundation bolts are tightened or readjusted
•
Piping is connected or adjusted
setting, seasoning or springing of the foundation
•
Pump, driver or base plate is moved for any reason
•
excessive pipe strain distorting or shifting the machine
•
settling of the building
•
shifting of pump or driver on the base plate or foundation
The procedure for alignment verification for units with the pump
and driver connected by a flexible coupling, mounted on a
common base are:
•
To facilitate accurate field alignment, we do not dowel the pumps
or drivers on the base plates before shipment.
Reliable, trouble-free, and efficient operation of a pumping unit
requires correct alignment of pump and driver shafts.
1. Disconnect the coupling halves.
2. Set the coupling gap to the dimension shown in fig. 6, 7, or on
outline drawings.
Coupling
Max
RPM
Parallel
in. [mm]
Angularity
in. [mm]
Weight
lb. [kg]
Torque
lb-in. [Nm]
1020
4500
0.006 [0.15]
0.003 [0.08]
4.2 [1.9]
460 [52]
1030
4500
0.006 [0.15]
0.003 [0.08]
5.7 [2.6]
1,320 [149]
1040
4500
0.006 [0.15]
0.003 [0.08]
7.4 [3.4]
2,200 [249]
1050
4500
0.008 [0.2]
0.004 [0.1]
12 [5.4]
3,850 [435]
1060
4350
0.008 [0.2]
0.005 [0.13]
16 [7.3]
6,050 [684]
1070
4125
0.008 [0.2]
0.005 [0.13]
23 [10.4]
8,800 [994]
1080
3600
0.008 [0.2]
0.006 [0.15]
39 [17.7]
18,150 [2,051]
1090
3600
0.008 [0.2]
0.007 [0.18]
56 [25.4]
33,000 [3,729]
1100
2440
0.01 [0.25]
0.008 [0.2]
93 [42.2]
55,550 [6,276]
1110
2250
0.01 [0.25]
0.009 [0.23]
120 [54.4]
82,500 [9,321]
1120
2025
0.011 [0.28]
0.01 [0.25]
179 [81.2]
121,000 [13,671]
1130
1800
0.011 [0.28]
0.012 [0.3]
266 [120.7]
176,000 [19,885]
1140
1650
0.011 [0.28]
0.013 [0.33]
392 [177.8]
253,000 [28,585]
Angular misalignment
Parallel misalignment
Fig. 6
P
X
P
Y
TM06 0221 4913 - TM06 0222 4913
Falk/Clarke/Dodge Coupling Misalignment
Coupling misalignment
13
English (US)
ROTEX
Size
E distance
in. [mm]
Max Parallel
in. [mm]
Max Angularity
in. [mm]
Max. axial
in. [mm]
14
0.51 [13]
0.006 [0.15]
1.1 [28]
-0.02 [-0.5] +0.04 [1]
19
0.63 [16]
0.007 [0.18]
1 [25]
-0.02 [-0.5] +0.05 [1.3]
24
0.71 [18]
0.008 [0.2]
0.08 [2]
-0.02 [-0.5] +0.06 [1.5]
28
0.79 [20.1]
0.009 [0.23]
0.09 [2]
-0.03 [-0.8] +0.06 [1.5]
38
0.94 [23.9]
0.01 [0.25]
0.09 [2]
-0.03 [-0.8] +0.07 [1.8]
42
1.02 [25.9]
0.011 [0.28]
1 [25]
-0.04 [-1] +0.08 [2]
48
1.1 [27.9]
0.013 [0.33]
1.1 [28]
-0.04 [-1] +0.08 [2]
55
1.18 [30]
0.014 [0.36]
1.1 [28]
-0.04 [-1] +0.09 [2.3]
65
1.38 [35.1]
0.015 [0.38]
1.1 [28]
-0.04 [-1] +0.1 [2.5]
75
1.57 [39.9]
0.017 [0.43]
1.1 [28]
-0.06 [-1.5] +0.12 [3]
90
1.77 [45]
0.018 [0.46]
1.2 [30]
-0.06 [-1.5] +0.13 [3.3]
100
1.97 [50]
0.019 [0.48]
1.2 [30]
-0.06 [-1.5] +0.15 [3.8]
110
2.17 [55.1]
0.02 [0.51]
1.2 [30]
-0.08 [-2] +0.17 [4.3]
125
2.36 [59.9]
0.021 [0.53]
1.2 [30]
-0.08 [-2] +0.18 [4.6]
140
2.56 [65]
0.022 [0.56]
1.2 [30]
-0.08 [-2] +0.2 [5.1]
160
2.95 [74.9]
0.022 [0.56]
1.2 [30]
-0.1 [-2.5] +0.22 [5.6]
180
3.35 [85.1]
0.024 [0.61]
1.2 [30]
-0.12 [-3] +0.25 [6.4]
KTR Coupling Chart Gap and Maximum Misalignment
Fixture
Fig. 7
Inside micrometer
E distance
3. Test for parallel and angular alignment with a straight edge
and feeler gauge as shown in manufacturer's instructions (at
the end of this section). With coupling halves stationary, make
trials at four places 90 ° apart. Perfect alignment occurs when
a straight edge is level across the coupling halves and the
same gauge just enters between the halves, both conditions
at all points.
4. An alternate test for parallel and angular alignment may be
made with a dial indicator mounted as shown in fig. 8.
•
Scribe the index lines on the coupling halves (as shown) or
mark where the indicator point rests.
•
Set indicator dial to zero.
•
Slowly turn BOTH coupling halves so that index lines match,
or indicator point is always on the mark.
•
Observe dial reading to determine whether pump or driver
needs adjustment.
•
Acceptable parallel and angular alignment occurs when total
indicator reading (complete turn) does not exceed limits
shown on either a tag or decal on the unit or on the unit outline
drawing.
Fig. 8
TM06 0223 4913
E
TM06 1156 1714
Dial indicator
Dial indicator figure
5. When significant operating temperature differential will exist
between the pump and driver (i.e. steam turbine drive with
pump handling cold liquid), thermal growth will cause the
hotter unit to rise. Compensate for this growth by initially
setting the hotter unit 0.003" to 0.005" [0.076 mm to 0.127
mm] low. When both units are at normal operating
temperature, a final check of coupling alignment must be
made. Correct the alignment if necessary.
6. NOTE Check for correct electric motor rotation as described in
the two bullet points under paragraph 6.3 below while
coupling halves are disconnected.
7. Correct for excessive parallel and angular misalignment by
slightly shifting the leveling wedges under the base plate. Tap
lightly (in or out) with a hammer. Retest alignment after each
shifting of a wedge.
8. In some instances, for factory-aligned pumping units, it may
be necessary to change the shims under the pump or driver,
or even relocate these factory-positioned units on the base
plate. Make such changes only after it is certain alignment
cannot be obtained by shifting of the wedges.
9. If wedges are shifted or shims changed a substantial amount
to obtain proper alignment, recheck the piping alignment and
level of the shafts.
14
6. Startup, operation and shutdown
Engine drivers
Warning
Engine driven unit are typically supplied with pump and drive on a
common base plate. For units that are supplied separate, contact
Peerless Pump.
The pump must not be operated beyond the
parameters specified for the application. If there
is any doubt as to the suitability of the product
for the application intended, have the serial
number ready and contact Peerless Pump for
advice.
1. Check the axial misalignment between pump and engine.
2. Check parallel alignment.
3. Check the angle between the pump shaft and driver when
coupled has a Maximum angle of 3 degrees. Consult
Manufacture.
4. At least 3/4 of the key is engaged with the coupler and the
shaft.
If the conditions of service on you purchase order are going to be
changed, (for example liquid pumped, temperature or duty), seek
written agreement from Peerless Pump.
5. Installation of universal drive see manufacturer's Instructions
6.1 Frost protection
5.10 Lubrication, priming and cooling systems
If the pump is to be used in area where there is a potential of
freezing or frost, necessary steps should be taken to protect
pump and cooling systems from freezing and bursting.
If supplied, please see additional documents attached to the
pump or contact Peerless Pump.
6.2 Lubrication
5.11 Electrical installation
Before attempting to start the pump, check the following items:
Electrical conduit and boxes should be located to avoid
obstruction of pump unit.
•
lubrication fitting at packing (if applicable)
•
lubrication for pump bearing
A plot of speed versus torque requirements during the starting
phase of a pump can be checked against the speed versus
torque curve of the driving motor. Contact the drive manufacture
for curve availability. The driver should be capable of supplying
more torque at each speed than required by the pump in order to
accelerate the pump up to rated speed. This condition is
generally easily attainable with standard induction or
synchronous motors, but under certain conditions, such as highspecific-speed pumps over 5000 US units [100 metric units] or
reduced voltage starting, a motor with high pull-in torque may be
required. To achieve a smooth start for the pumping equipment,
autotransformers may be connected to the starting panel or solid
state starters used. These provide a gradual increase in voltage
up to rated voltage, ensuring even acceleration.
•
lubrication of the driver
5.12 Control, monitoring and alarm equipment
All control and alarm systems should be checked for correct
installation and functioning in accordance with the manufacturer's
instructions. All alarm point settings should be checked.
5.12.1 Stopping the unit/reverse runaway speed
A sudden power and/or discharge valve failure during pump
operation against a static head will result in a flow reversal, and
the pump will operate as a hydraulic turbine in a direction
opposite to that of normal pump operation.
If the driver offers little resistance while running backwards, the
rotational speed may approach the pump-specific speed.
This condition is called runaway speed and causes mechanical
problems. Contact Peerless Pump for aid in preventing this
condition.
•
oil-cooling connections for the driver (if applicable)
•
coupling (if required by manufacturer)
Good practice includes the following:
•
Keep lubricant clean. Provide, and use, a dust tight cover on
the storage container.
•
Use the oldest lubricant first.
•
Clean pump lubricant fittings before re-lubricating with grease.
•
Use clean dispensing equipment.
•
Remove 0.25" [6.4 mm] drain pipe plug on bottom outside of
bearing housing cover. Inject clean, new grease, forcing out
the old through the drain opening.
•
Start and run the pump for a short time to eject any excess
grease. Reinstall 0.25" [6.4 mm] pipe plug. Wipe off ejected
grease.
•
Use the proper amount of lubricant -too much result in
churning, unnecessary power consumption, rapid heating to a
high temperature and inadequate lubrication.
Note
Normal bearing temperatures vary with the
seasons and environment and may range from 0
to approximately 250 °F [-18 to 121 °C]. A
continuous rise from the established, normal
operating temperature indicates trouble and
probable failure of the bearing. Shut down the
pump immediately.
15
English (US)
5.9.1 Auxiliary (driver, coupling, etc)
English (US)
6.2.1 Recommended products
6.3 Rotation
The products listed in the following tables are recommended for
the applications mentioned. Other lubricants of equal quality may
also be used.
Motor Driven
Greases for pump bearings
Use a Lithium soap base meeting NLGI Grade 2 specifications
with a minimum dropping point 355 °F [179 °C], operating
temperature range of -10 °F to 250 °F [-23 °C to 121 °C].
Manufacturer
Product
American Oil Co.
AMOCO Lithium Grease AllWeather
Atlantic Richfield Co.
ARCO Multipurpose Grease
Cato Oil and Grease Co
Mystik JT-6
Cities Service Oil Co.
Citgo H-2
Continental Oil Co.
EP Conolith No. 1
-20 ° to +40 °F [-28 ° to +4 °C]
Continental Oil Co.
EP Conolith No. 2
+40 ° to +120 °F [+4 ° to +50 °C]
Chevron
SRI#2
Gulf Oil Co
Gulf Crown No. 2 or Ep 2
E.F. Houghton and Co.
Cosmolube No. 2
Exxon
POLYREX EM
Hydrotex
Deluxe No. M-33 Super Shield
Imperial Oil and Grease
Co.
Molub-Alloy No. 1
Keystone Div., Pennwalt
Corp.
80 X LT
Mobil Oil Corp
Mobilux Ep No. 2
The Pennzoil Co.
Pennzoil 705 HDW
Philube IB and RB
Shell Oil Co.
Sunaplex No. 2 EP
Prestige 42
Novatex Grease No. 2
Union Oil Co
Unoba Ep-2
When packing or regreasing see the below table for amount of
grease for bearing type.
Bearing Size
Volume of Grease
oz [cm3]
Amount of Grease
[gram]
206/305
1 (29.5)
28
207/306
2 (59.1)
56
208/307
2.25 (65.5)
63
210/308
2.5 (73.9)
70
212/310
3.5 (103.5)
100
213/311
4.5 (133)
128
16
Prior to checking rotation ensure the power is disconnected and
locked out to prevent accidental energizing of the driver.
Disconnect the coupling so that the motor shaft can spin without
driving or contacting the pump shaft.
Rotate the motor by hand in both directions to check freedom
without binding. Momentarily energize the motor to check that
rotation is in the same direction as the arrow on the pump. If
motor is three-phase type, reverse rotation (if required) by interchanging any two of the three power leads. The rotation of most
single-phase motors is fixed by internal wiring and cannot be
easily changed.
After proper rotation has been confirmed, reconnect coupling and
shaft guarding.
Engine Driven
Rotation of engine is a constant set by manufacture and
confirmed at ordering. No checks are required.
Warning
All guards must be in place on the pump prior to
startup. Read and follow all recommended
guarding and safety instructions for accessories,
if any.
Guards must not be removed while the pump is
operational
Alvania EP Grease
Alvania EP Grease 1 (for prolonged
ambient temperature
below 0 °F [-18 °C]
Texaco, Inc.
Never do maintenance work when the unit is
connected to power.
6.4 Guards
Phillips Petroleum Co.
Sun Oil Co.
Warning
6.5 Check list
6.5.1 System flushing
When the pump is installed in the completed piping system, we
recommend to backflush the system to remove debris such as
stubs of welding rod, welding slag and loose scale. The pump and
other sensitive part should be protected with startup strainers,
which should in turn be removed upon completion of the flushing
cycle.
6.5.2 System decontamination
After the system has been flushed to remove debris, determine if
your system needs to be decontaminated. If so, do that before
priming and filling.
6.5.3 Priming
The pump should not be run unless it is completely filled with
liquid, as there is danger of damaging some of the pump
components.
If the system has suction pressure, bleed all air from the pump
casing and suction pipe by the opening of the automatic relief
valve at the top of the pump. Rotate the shaft a few times if
possible to evacuate any air trapped inside the impeller
passages.
The function of a stuffing box is to limit or eliminate leakage of the
pumped fluid and to prevent air from entering along the shaft.
Pumps are equipped with packing seals. These instructions are
intended for pumping units handling water.
Packed Type Seal
A packed type stuffing box must correspond to the suction
conditions of the installation. The pump is shipped with the
packing installed unless otherwise specified by the customer.
Check the packing carefully, allowing a slight leakage for
lubrication. Never force the packing into a leak-proof position
since this will create excessive friction and cause damage to the
packing or shaft sleeve. Maximum packing life can be expected
when the leakage approximates a minimum of 40-60 drops per
minute. A reduction of leakage considerably reduces the life of
both the packing and shaft sleeve. If leakage is excessive, tighten
the gland bolts evenly, about 1/6 of a turn at a time. Do not be
confused if the leakage seems to increase after and adjustment
of the packing has been made. The leakage will normally reduce
after a period of time as the packing adjusts itself to its new
position. It should be kept in mind that it takes time for newly
installed packing to "run-in" and that during this initial period,
frequent attention and adjustments are necessary. It sometimes
takes several days to achieve the desired results. Peerless Pump
recommends the use of lantern rings and water seal lines.
Once the stuffing box housing and stuffing box gland have
reached approximately the same temperature as that of the pump
parts, the running-in of the stuffing box gland has been
completed. If the stuffing box leaks too much, retighten slightly
and evenly while the pump is running. To ensure continuous
lubrication, a few drops should always drop from the stuffing box
to protect the packing or shaft sleeve against damage, see chart
for recommendations for drop rate.
When the leakage can no longer be controlled by adjusting the
gland, all rings of packing should be replaced. The addition of a
single ring to restore gland adjustment is not recommended.
If the pump is to be left idle for a long period of time, we
recommend to replace the packing prior to restarting the pump 1.
6.6 Startup, operation and shutdown
Starting
Prior to making an initial start, after installation or major
maintenance check the following:
•
Correct installation and rotation of driver.
•
Coupling alignment.
•
Bearing lubrication on pump and driver.
•
Proper lubrication for stuffing boxes. For pumps having
mechanical shaft seals, make certain that the liquid
temperature, pressure, cooling and lubrication of seal faces all
meet the manufacturer's requirements
•
Gauges (if used) of correct range and in good condition.
•
All foundation, pump, and driver bolts properly tightened. All
external fasteners (nuts, bolts, screws) on pump checked
against recommended torque values.
•
When possible, turn the pump shaft by hand to make sure that
parts do not bind.
•
Ensure the suction valve is fully open.
Recommended stuffing box packing arrangements for use with
water
Suction pressure
range
Packing shaft / sleeve
PTFE graphited synthetic
latticed braided
6.0 psiA - 100 psiG
Crane C1065 or C1070
[.41 bar - 6.9 bar]
SAE 40 Bronze or Stainless
Steel
100 - 175 psiG
[6.9 bar - 12 bar]
175 - 250 psiG
[12 bar - 17 bar]
Leakage
rate
20 to 50
Drops/Minute
Continuous carbon filament
yarn, latticed
braided packing containing
colloidal graphite
Crane C1627
SAE 40 Bronze or Stainless
Steel
1/3 pint/
minute
[.16 Liters/
Minute]
Continuous carbon filament
yarn, latticed
braided packing containing
colloidal graphite
Crane C1627
Hardened Stainless Steel
1 pint/minute
[.47 Liters/
Minute]
Refer to local fire code.
•
After the pump has run a reasonable time, measure the
temperature of bearing and stuffing box housings. The
temperature of the stuffing box should approximate that of the
pumped liquid. If it is to hot (overheats), the packing is too tight
and should be checked.
6.6.1 Air in system
Entrained air reduces pump total head and flow rate. To avoid air
in the system, take these precautions:
•
All UL/ULC listed fire pumps will have water seal piping only
when suction pressure is less than 30 psiG [2.1 bar].
All FM approved fire pumps will have water seal piping regardless
of the suction pressure.
See supplemental instruction 4850332 for high-pressure fire
pump applications.
Return lines into tanks should terminate a minimum of two
pipe diameters below the low liquid level.
6.6.2 Lubrication system
Before running the drivers, either separately or connected to the
pump, check lubrication requirements in the instructions of the
driver. Check that the following points have been fulfilled:
•
Grease-lubricated bearings have been properly greased with
the driver manufacturer's recommended grade.
6.6.3 Driver settings
Follow the instructions of the manufacturer.
6.6.4 Performance testing
Caution
The stuffing box gland must not be too tight
during startup in order to let sufficient liquid
lubricate the shaft and the packing.
Once the unit is energized, check operating speed, flow rate,
suction and discharge pressure, and power input. While it may
not be possible to exactly repeat the factory performance, initial
field test data becomes a valuable baseline for future checking to
determine possible wear and need to perform maintenance.
Auxiliary piping and gasket joints should be checked for leaks and
proper makeup.
17
English (US)
6.5.4 Shaft sealing
English (US)
7. Maintenance
7.2 Recommended spare parts
Warning
The list of recommended spare parts will depend on factors such
as the following:
Never do maintenance work when the unit is
connected to power.
•
Normal supplier lead time when ordering parts.
•
If pumping equipment is for use as normal duty or severe duty,
and if there is backup pumping while a unit is down for
maintenance and parts replacement.
Warning
Do not attempt to lift the entire pump by the
lifting lugs (eyes) of the driver or pump.
Below is a suggested list of spare parts.
For intermittent or non-critical service
Warning
•
Stuffing box packing (Item 13
Do not work under suspended object unless you
have taken precautions to stop its fall in the
event of sling failure
•
Ball Bearing Set (Item 16 and 18)
7.1 Schedule
To ensure satisfactory operation of the pumping equipment,
frequent inspection and periodic maintenance are required.
An inspection and maintenance log should be kept and the
inspector is to immediately report any problems. A suggested
guide for preventative maintenance for normal applications is
given below. Unusual applications with abnormal heat, moisture,
dust, etc., may require more frequent inspection and service.
Item
•
Bearing Seal Set (Item 47 and 169)
•
Bearing Cover Gaskets (Item 73B)
•
Set of Shaft Sleeves (Item 14 and 14A)
•
Set of Sleeve O-Rings (Item 14B)
•
Set of Casing Rings (Item 7)
•
Set of Impeller Rings, if supplied (Item 8)
•
Gasket, Casing (Item 73A)
•
Packing gland and studs or gland bolts.
For continuous or critical service (in addition to above)
•
Complete Rotating Element preassembled.
Action
Frequency
7.3 Consumables
Packing,
packing box
Inspect for excessive
leakage
First 150 hours of
operation, then every
2000 hours of
operation or quarterly
Items normally used in the maintenance of pumping equipment
may include the following, but depending on the type of unit some
items may vary:
Packing,
packing box
Adjust gland and replace
packing
As necessary
Pump-motor Check for change in
alignment
alignment
Annually
Vibration
Check for change in
vibration
Annually
Bearings
Lubricate (grease)
• Light Duty,
approximately 10 hour/
week
• Normal Duty,
approximately 8 hour/
day
• Sever Duty,
approximately 24 hour/
day
Fasteners
• Every 2000 hours
or at least once a
year
• Every 2000 hours
or at least every six
months
• Monthly
Check for loose fasteners Annually
•
Lubricant (grease or oil)
•
Cleaning materials
•
Touch-up coating.
•
Hand tools
•
Measuring equipment (feeler gauges, dial indicator, etc.)
7.4 Tightening torques
Proper tightening of fasteners is very important. The torque
values depend on the size and grade of the fasteners used.
The values in the table below apply to non-lubricated parts.
Fastener size
Torque
lb-ft [Nm]
Torque
lb-ft [Nm]
MEDIUMCARBON
STEEL
Fastener Size in. [mm] SAEJ429GRADE5
105-120,000PSI
TENSILE
MEDIUMCARBON
ALLOYSTEEL
SAEJ429GRADE8
150,000PSI
TENSILE
0.25 - 20 [6.4 - 508]
8 [10.8]
9 [12.2]
0.38 - 16 [9.7 - 406]
25 [33.9]
34 [46.1]
0.50 - 13 [2.7 - 330]
62 [84]
83 [112.5]
0.625 - 11 [15.9]
125 [169.5]
166 [25]
0.75 - 10 [9.1 - 254]
225 [305]
295 [400]
0.88 - 9 [2.4 - 229]
325 [441]
477 [647]
1-8 [5.4 - 203]
465 [630]
715 [969]
shaft sleeve set
screws to
130 inch-pounds
torque.
176 newton meter
[Nm]
When assembling a pump, cross-tighten the screws in order to
avoid misalignment, binding and leakage.
Torque value shown are for clean lubricated threads and gasket
joints.
18
Warning
Drain the pump and isolate pipework before
dismantling the pump.
8. Place slings around the shaft near the bearing housings and
lift rotating element from lower casing (1A). Tap lightly on the
underside of the bearing housings to separate the housings
from the brackets as required.
9. Place rotating element in a convenient work surface.
10. Loosen set screws and remove the coupling half.
Warning
11. Tap from the back of the hub or use a puller.
There may be occasions when a part such as the
impeller has either been shrunk-fit onto the pump
shaft or has become difficult to remove due to
products that are corrosive in nature.
12. Remove coupling key (46), and outboard deflector (40B).
If you elect to use heat to remove the part, it must
be applied with great care. Before applying heat,
ensure any residual hazardous liquid trapped
between the two parts is thoroughly drained out
to prevent an explosion or emission of toxic
vapor. Impeller design varies and so does the
amount heat and the duration of heat application
required to loosen the impeller.
Contact Peerless Pump for help in removal of
impellers.
Warning
Before opening the terminal box of an electric
motor, make sure that the power supply has been
switched off.
Before starting disassembly of the pump, it is recommended that
a set of spare parts as shown in section 7.2 Recommended spare
parts be obtained. Peerless Pump does not recommend reuse of
gaskets, O-rings, packing rings, or ball bearings.
1. Shut down pump.
Warning
Disconnect power to the pump driver before
starting any repairs.
2. Clear a large area adjacent to the pump as a storage space
for pump parts as they are dismantled.
3. Disengage the coupling halves. Refer to the coupling
manufacturers' instructions.
4. Remove the nuts from the gland bolts (17B) and remove
packing glands (17) from the shaft (6). The packing gland
halves are separable.
5. Remove all fasteners securing the upper casing (1B) and from
the bearing caps (41 and 43) from lower casing (1A). Match
mark bearing caps to lower casing (1A).
6. Use the jack screws on the bottom side of the lower casing
split flange to separate the upper and lower casings. Turn the
jack screws back below the split flange surface to avoid
reassembly interference.
7. Remove the upper casing by use of lifting lugs or customer
supplied eye bolt 0.5 - 13" [13-330 mm] UNC threaded into
top.
Warning
Parts which are provided with lifting lugs, lifting
ears or eyebolts should be lifted by these points
only. They may not be used for lifting the entire
pump.
13. Take out cap screws to remove bearing covers (35 and 37)
and the gaskets (73B). Remove inboard bearing cover seal
(47) from cover (35) only if replacement of seal is required.
14. Remove retaining ring (18A) from outboard end of shaft.
15. Remove housings (31 and 33), bearings (16 and 18), and
bearing housing seals (169) as units with a bearing puller.
16. Remove deflectors (40A).
17. Remove casing rings (7).
18. Remove packing rings (13), lantern rings (29) if pro-vided, and
stuffing box bushings (63).
19. Loosen shaft sleeve set screws then loosen shaft sleeves (14
and 14A) with a spanner wrench.
Note
Sleeve (14) has right-hand thread, sleeve (14A)
has left-hand thread. Remove sleeves from shaft.
20. A seal between the shaft and sleeve is made with an O-ring
(14B) in a groove in the sleeve. Use care not to damage the
O-ring.
21. Remove the impeller from shaft with an arbor press.
Note
The interference between impeller hub ID and
shaft OD meets ANSI B4.1 standards for
"Preferred Limits and Fits for Cylindrical Parts"
and corresponds to standard fit LC-.
22. Remove impeller key (32).
23. Clean all parts.
24. Clean all metal parts (except bearings) with a solvent. Use a
bristle brush (NOT metal or wire) to remove tightly adhering
deposits.
25. A fiber scraper may be used to remove the gasket and shellac
from casing flanges.
26. Recondition or replace worn parts Perform detail inspection
as follows:
27. Check O-rings and bearing cover gaskets for cracks, nicks or
tears; packing rings for excessive compression, fraying or
shredding, embedded particles (dirt or metal). Replace if
defective in any way.
28. Mount the shaft between centers or on vee blocks. Check for
eccentricity throughout entire length with a dial indicator;
eccentricity must not exceed 0.003" [0.08] total indicator
reading. Check that threads are clean and sharp. Surfaces on
which bearings mount must be smooth, have a finish of 32 µin
[0.81 µm] or better, and the shoulders square and free from
nicks.
29. Examine passages for cracks, dents, gouges or embedded
material.
When lifting the entire pump, use appropriate
slings.
19
English (US)
7.5 Dismantling
English (US)
7.6 Wear Ring
7.7 Inspection and Repair
Wear rings provide a close-running, renewable clearance to
reduce the quantity of liquid leaking from the high-pressure side
to the suction side. These rings depend on the liquid in the pump
for lubrication. They will eventually wear so that the clearance
becomes greater and more liquid passes into the suction. This
rate of wear depends on the characteristics of the liquid pumped.
Badly worn wear rings will result in severe degradation of pump
head and flow rate, particularly on small pumps. Examination of
wear patterns can provide valuable information in diagnosing
pump problems and determining their origin.
Inspection. Visually inspect parts for damage affecting
serviceability or sealing. Emphasize inspection of mating parts
having relative motion- wear rings, for example. Perform detail
inspection as follows:
Worn wear rings or surfaces can be replaced to restore hydraulic
performance.
Note
Standard pumps are furnished without impeller
rings; the wear surface is an integral part of the
impeller. Impeller wear rings maybe field installed
by machining. Refer to note following paragraph
2-2b for standard fits to be produced when
making such repair. Replace impellers which
cannot be salvaged by such repair.
Measure the OD of the impeller wear surface or impeller ring (8)
and the ID of the casing ring (7). Compute the diametrical
clearance (ID minus OD) and compare with the limits below. If
measured diametrical clearance exceeds two times values, repair
or replace to restore design clearance. ID surface of casing ring
must be smooth and concentric with ring OD.
Diametrical Clearance
in. [mm]
Pump Size
3AEF9, 4AEF10, 4AEF11, 4AEF12,
5AEF8, 5AEF11, 5AEF12, 5AEF14,
5AEF15, 6AEF10, 6AEF12, 6AEF14,
6AEF16, 6AEF18, 8AEF13, 8AEF14,
8AEF15, 8AEF17, 8AEF20
0.015 to 0.019
[0.381 to 0.48]
10AEF16, 10AEF20
0.018 to 0.022
[0.457 to 0.559]
6AEF17
0.025 to 0.029
[0.635 to 0.737]
Note
Clearances in are for standard bronze or cast
iron fitted pumps. For materials with a tendency
to gall, such as stainless steel, increase
clearances by 0.010" [0.25 mm].
Note
For bronze impellers and rings, the rings are
shrunk on the hub according to standard fit FN-4
of ANSIB4.1. Hardened impeller rings are
installed according to ANSI B4.1 standard fit
FN-1.
If impeller clearance is found to be out of tolerance, replace
casing wear ring. It may be necessary to consider machining
impeller wear surface for wear ring installation (if not originally
supplied) to return to approved clearance. If the impeller must be
machined to install new impeller rings, be sure machining is
concentric with impeller bore.
Note
20
Use care not to reduce impeller hub OD when
machining off old impeller rings.
1. Check O-rings and bearing cover gaskets for cracks, nicks, or
tears; packing rings for excessive compression, fraying or
shredding, embedded particles (dirt or metal). Replace if
defective in any way.
2. Mount the shaft between centers or on vee blocks. Check for
eccentricity throughout entire length with a dial indicator;
eccentricity must not exceed 0.003" [0.08 mm] total indicator
reading. Check that threads are clean and sharp. Surfaces, on
which bearings mount must be smooth, have a finish of 32 µin
[0.81 µm] or better, and the shoulders square and free from
nicks.
3. Examine impeller passages for cracks, dents, gouges or
embedded material.
Repair. Make needed repairs in the following manner:
1. If ID of casing rings (7) is grooved, scored or eccentric,
replace the casing rings.
2. If impeller wear surfaces or impeller rings (8) are defective,
the impeller must be machined to install new impeller rings.
Be sure machining is concentric with impeller bore. Use care
NOT to reduce hub OD when machining off old impeller rings.
3. Install new impeller rings (8) on the impeller (shrink or press
depending on material).
4. Replace worn shaft sleeves.
5. Replace shafts having excessive run-out (eccentricity).
Caution
Take care not to damage any components and
avoid contamination (dirt, debris, moisture, etc.)
of the unit.
See section 7.4 Tightening torques for torque values.
1. Support pump shaft in blocks and rails to protect it from
bending or being damaged during the re-assembly process.
2. Check that the shaft is straight and free of nicks and
scratches. Remove with a fine file all burrs and scratches.
3. Coat the shaft (6) lightly with oil.
4. Place impeller key (32) in shaft key way.
5. Align impeller (2) on shaft and install with an arbor press or
brass tubular sleeve and hammer. When assembled, the
impeller vanes must rotate in the proper direction.
6.
Impeller hub must be centered on shaft journal.
7. Install shaft sleeve set screws in shaft sleeves. Assemble
shaft sleeves to the shaft and hand tighten against the
impeller. Do not tighten shaft sleeve set screws.
8. Install the stuffing box bushings (63).
9. Locate casing rings (7) on impeller.
10. If casing and or impeller wear rings are required, fit wear rings
into the casing or onto the impeller skirt. Contact Peerless
Pump if rings should be pressed or secured to part as needed.
Rings final clearance should provide the clearance shown in
the table in section 7.6 Wear Ring. If clearance is not
achieved, machine rings prior to proceeding.
11. Place in board deflectors (40A) on shaft.
12. If previously removed, install bearing housing seals (169) into
housings (31 and 33).
13. Press housing-bearing-seal assemblies on shaft to seat
bearings against shaft shoulders.
14. Install bearing retaining ring (18A) in groove against the out
board bearing.
15. Install gaskets (73B) on bearing covers. Use factory supplied
parts or cut replacement gaskets from 0.06" [1.52 mm] No.
444 Vellumoid. (SAEP3415A).
EXCEPTION: For all models using 3306 size outboard bearing,
gasket 73B is 0.03" [0.8 mm].
16. Attach in board and outboard bearing covers (35 and 37). In
the assembled position, the greased rain tap must be located
at bottom in a horizontal plane.
22. Adjust the shaft sleeves (14 and 14A) to center the impeller in
the lower casing volute, and tighten both shaft sleeves with a
spanner wrench, then add Locktite to the shaft sleeve set
screws. Then tighten shaft sleeve set screws according to
section 7.4 Tightening torques.
23. Cover the top side of the casing gasket with a mixture of
graphite and oil.
24. Install the gland bolts (17B). Carefully locate the upper casing
on the lower, making certain the dowel pins engage.
25. Install cap screws and tighten working from the center of the
casing to each end, to the torque values in section
7.4 Tightening torques. If any cap screws require
replacement, use only parts with equal or greater tensile
strength. See 7.4 Tightening torques.
26. Rotate shaft by hand to check that it turns freely.
27. Push the stuffing box bushings (63) to the rear of the stuffing
boxes.
28. I If the stuffing box is not packed from factory, it should be
packed prior to startup following the below guide.
29. Clean the stuffing box.
30. Check that the packing rings are of proper cross-section and
length.
31. Stagger the joints 90° apart.
32. The rings should butt tightly but not overlap at the joints.
33. Tamp down the individual packing rings, but not too tightly, as
this may result in burning the packing and scoring the shaft or
shaft sleeve.
34. Where compatible, lightly lubricate the inner and outer
packing diameter with a suitable lubricant. When a lantern ring
is required, make sure that sufficient packing is placed in
below the lantern ring so that the bypass line intersects the
packing container bore adjacent to the lantern ring and is not
blocked by the packing.
35. The pipe supplying sealing liquid should be fitted tightly so
that no air enters. If the liquid to be pumped is dirty or gritty,
clean sealing liquid should be piped to the stuffing box in
order to prevent damage to the packing and shaft sleeves.
36. Clear sealing liquid is also required if the stuffing box
materials are not completely compatible with the pump liquid.
The sealing liquid should be at a pressure sufficient to ensure
a flow of clean liquid into the pump but not so high as to
require excessive tightening of the packing.
17. Install outboard deflector (40B), and coupling key (46);
assemble coupling half on the shaft and tighten the setscrews.
37. Insert two packing rings, lantern ring (29) if provided, and
three packing rings. Insert each ring separately and stagger
the joints of successive rings 90degrees.
18. Affix the new casing gasket (73A) to the lower casing (1A)
with shellac.
38. Insert the packing glands (17) and set the gland bolt nuts
finger tight.
Caution
It is very important that specified material and
thickness be used for casing gasket. Machined
surfaces of both casings must be perfectly clean
and free from burrs or nicks.
Caution
The stuffing box gland must not be too tight
during startup in order to let sufficient liquid
lubricate the shaft and the packing.
39. Rotate shaft by hand to check that it turns freely.
19. Use slings around the shaft near bearings to set rotating
element into lower casing.
40. Replace all drain plugs if removed during disassembly.
20. Position the casing rings (7) and both bearing housings so
that all dowel pins engage in slots in the lower case split
surface.
42. Make sure that the pump shaft spins freely.
21. Assemble both bearing caps per match marks and tighten the
cap screws.
See the manuals supplied with the accessories.
41. Re-lubricate the bearings. See section 6.2 Lubrication.
7.9 Accessories
21
English (US)
7.8 Assembly
English (US)
8. Fault finding (Trouble Shooting)
Note
When direct-connected to electric motors, determine whether or not the motor is direct-on-line and receives full
voltage.
Fault
1. Discharge pressure too low.
Cause
Remedy
a) Speed too low.
Check speed/rotation.
b) System pressure lower than anticipated.
Check the system curve.
c) Air or gas in liquid.
Check liquid to remove air.
d) Worn wear rings.
Check clearance between wear surfaces.
e) Impeller damaged.
Check that parts are not damaged.
f)
2. Insufficient suction head.
3. Noise level increased.
4. Insufficient flow.
Impeller diameter too small.
Check rotation.
h) Pump lost prime.
Re-prime pump.
i)
Insufficient available NPSH.
Confirm NPSH available.
j)
Restricted passages.
Clean impeller and casing passages.
k) Leaking joints.
•
•
•
•
a) Suction line drawing air.
Tighten joints.
Tighten packing.
Check o-ring between sleeve and shaft.
Check gaskets.
Tighten line connections.
b) Suction lift too high or insufficient NPSH.
Check NPSHA.
c) Air or gas in liquid.
Remove air/gas from liquid.
d) Clogged strainer.
Clean the strainer.
a) Poor alignment of pump.
Suction and discharge pipe clamps loose.
• Ensure proper alignment of the pump and
the driver.
• Support the suction and discharge piping.
• Check vibration dampers, flexible piping and
conduit connectors.
b) Cracked foundation.
Check foundation.
c) Worn ball bearings.
• Check bearings.
• Check lubrication.
d) Driver unbalanced.
Disconnect driver and operate it alone. Check
pump for large pieces of debris, such as wood,
rags, etc.
e) Hydraulic resonance.
• Alter the resonant piping.
• Change the pump speed.
• Insert a pulsation damper on the pump/
piping system.
• Insert flow straighteners.
a) Pump not primed.
Check suction conditions.
b) System head exceeds shut off head.
Check system head curve vs. performance
curve.
c) Speed too low.
Check rotation speed.
d) Suction lift too high or insufficient NPSH.
Check NPSHA.
e) Clogged strainer or impeller.
Clean the strainer and impeller passages.
f)
Wrong direction of rotation.
g) Leaking joints.
Check rotation.
Tighten joints.
h) Broken shafting or coupling
Rotate shaft and inspect.
i)
Closed suction valve.
Check suction valve.
j)
Not enough suction head for hot or volatile
liquids.
Check NPSHA.
k) Foot valve too small;
l)
Worn or damaged hydraulic parts.
m) Excessive clearance between wear
surfaces.
22
Check specified diameter.
g) Wrong direction of rotation.
Check foot valve.
Inspect part.
See section 7.6 Wear Ring for ring clearance.
Cause
Remedy
a) Leaking joints.
•
•
•
•
b) Suction lift too high or insufficient NPSH.
Check NPSHA.
6. Excessive power required.
English (US)
Fault
5. Pump loses prime after starting.
Tighten joints.
Tighten packing.
Check o-ring between sleeve and shaft.
Check gaskets.
a) Speed too high.
Check rotation speed.
b) Pump operating outside of the allowable
operating region (AOR).
• Check system curve.
• Check valve settings.
c) Specific gravity or viscosity of liquid
pumped is too high.
Check predicted performance based on liquid
conditions.
d) Bent shaft or rotating element.
Check parts and straighten as needed.
e) Stuffing-boxes too tight.
Check drip rate of liquid from packing.
f)
Check clearance between wear surfaces.
Impeller clearance too small causing
rubbing or worn wear surfaces.
g) Electrical or mechanical defect in motor
Contact local service center for diagnostics.
h) Restriction in rotation.
Check for binding of rotating elements.
i)
Check lubrication type and amount.
Incorrect lubrication of driver.
23
TM06 0979 1314
English (US)
9. Parts list and sectional drawing
Fig. 9
Packed Type Cross Sectional Drawing
Item No.
1A, 1B, 41, 43
2
Item No.
Description
Upper and Lower Casings
31
Inboard Bearing Housing
Impeller
32
Impeller Key
6
Shaft
33
Outboard Bearing Housing
7
Casing Ring
35
Inb. Brg. Housing Cover
8
Impeller Ring (Optional)
37
13
Packing Ring
14, 14A
Shaft Sleeve
14B
RH
LH
Out. Brg. Housing Cover
40A
Inboard Deflector
40B
Outboard Deflector
Shaft Sleeve "O" Ring
46
16
Inboard Ball Bearing
47
Inb. Brg. Cover Seal
17
Packing Gland
63
Stuffing Box Bushing
Coupling Key
17A
Gland Clip (when used)
73A
Casing Gasket (Not Shown)
17B
Gland Bolt
73B
Bearing Cover Gasket
18
Outboard Ball Bearing
123
Bearing End Cover
18A
Bearing Lock Washer
127
Water Seal Piping
Lantern Ring (Op tional)
169
Bearing Housing Seal
29
-
24
Description
Casing Hardware
English (US)
TM06 0980 1314
Fig. 10 Packed Type with Double Row Thrust Bearing Cross Sectional Drawing
Item No.
1A, 1B, 41, 43
Description
Item No.
Description
Upper and Lower Casings
31
2
Impeller
32
Impeller Key
6
Shaft
33
Outboard Bearing Housing
7
Casing Ring
35
Inb. Brg. Housing Cover
8
Impeller Ring (Optional)
37
13
Packing Ring
14, 14A
14B
Shaft
Sleeve
RH
LH
Inboard Bearing Housing
Out. Brg. Housing Cover
40A
Inboard Deflector
40B
Outboard Deflector
Shaft Sleeve "O" Ring
46
Coupling Key
16
Inboard Ball Bearing
47
Inb. Brg. Cover Seal
17
Packing Gland
63
Stuffing Box Bushing
17A
Gland Clip (when used)
73A
Casing Gasket (Not Shown)
17B
Gland Bolt
73B
Bearing Cover Gasket
18
Outboard Ball Bearing
123
Bearing End Cover
18A
Bearing Lock Washer
127
Water Seal Piping
22
Bearing Lock Nut
169
Bearing Housing Seal
29
Lantern Ring (Optional)
-
Casing Hardware
10. Disposal
This product or parts of it must be disposed of in an
environmentally sound way. Contact the nearest Peerless Pump
company or service workshop.
Subject to alterations.
25
26
2005 Dr. Martin Luther King Jr
US-46202 Indianapolis, Indiana U.S.A.
Phone: (+1) 317.925.9661
www.peerlesspump.com
Peerless Pump companies
Peerless Pump Indianapolis
98692495 0514
ECM: 1137721
Reliability
m
When It Matters
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