horizontal & vertical non clog pumps

horizontal & vertical non clog pumps
FLOWMORE LIMITED
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
FOR
HORIZONTAL &
VERTICAL NON CLOG
PUMPS
www.flowmoregroup.com
Flowmore Limited
PREAMBLE
Dear Customer,
Congratulations for becoming a proud owner of a "FLOWMORE" Pump. We have a
strong belief in satisfaction of our Valued Customers and your repeat purchases from us
will reaffirm your confidence in FLOWMORE.
This is a new set of instructions for the Installation, Operation and Maintenance of
Horizontal and Vertical Non Clog Pumps manufactured by us and these instructions
supersede the previous issue. In this new version, we have tried to cover majority of
the technical details, procedures and work instructions pertaining to satisfactory and
technically sound practice for Installation, Operation & Maintenance of our pumps.
However, if you need any further technical assistance in a specific situation, we will be
happy to provide the requisite feedback and make you comfortable in the event of such
occurrence. Our team of highly experienced and technically competent field staff
constantly endeavors to minimize the equipment down time and to ensure longer
trouble free operation of the equipment supplied by us.
We wish to convey our appreciation for your purchase and hope to receive your
valuable feedback and suggestions for improvement of our products and services.
With Best Wishes,
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
[I]
Flowmore Limited
LIST OF CONTENTS
ARTICLE
NO.
PARTICULARS
PAGE
NO.
ARTICLE
NO.
PARTICULARS
PAGE NO.
1
INTRODUCTION
1
7.3
OPERATION CHECKS
13
2
SAFETY INSTRUCTIONS
1
7.4
STOPPING INSTRUCTIONS
13
2.1
SAFETY SYMBOLS AND EXPLANATIONS
1
8
MAINTENANCE OF NON CLOG PUMPS
14
2.2
SAFETY PRECAUTIONS
1
8.1
PREVENTIVE MAINTENANCE
14
STORAGE
2
8.1.1
DAILY INSPECTIONS
14
3.1
INSPECTION OF PACKAGE/EQUIPMENT
2
8.1.2
QUARTERLY INSPECTIONS
14
3.2
STORAGE REQUIREMENTS
2
8.1.3
ANNUAL INSPECTION
14
3.3
LONG TERM STORAGE
3
8.2
BREAKDOWN MAINTENANCE
14
BRIEF DESCRIPTION OF NON CLOG PUMPS
3
8.3
REPLACEMENT OF PARTS
14
4.1
GENERAL APPLICATIONS
3
8.3.1
VERTICAL PUMPS
15
4.2
TYPES OF NON CLOG PUMPS
3
8.3.2
HORIZONTAL PUMPS
15
VERTICAL PUMPS
4
8.4
ORDERING REPLACEMENT PARTS
15
4.2.1.1
DRY PIT PUMPS
4
8.5
REPLACEMENT OF SHAFT SEALING ELEMENTS
16
4.2.1.2
WET PIT PUMPS
4
8.5.1
REMOVING OLD PACKING
16
HORIZONTAL PUMPS
4
8.5.2
REPACKING THE PUMP
16
INSTALLATION
5
8.6
WEARING SURFACE ADJUSTMENT
16
VERTICAL PUMPS
6
8.7
LUBRICATION
17
5.1.1
DRY PIT PUMPS
6
8.7.1
PROCEDURE FOR GREASE RE- LUBRICATION
17
5.1.2
WET PIT PUMPS
6
8.7.2
PROCEDURE FOR OIL RE- LUBRICATION
17
HORIZONTAL PUMPS
8
9
TROUBLESHOOTING
18
20
3
4
4.2.1
4.2.2
5
5.1
5.2
5.3
DRIVER
9
10
LIST OF TYPICAL CROSS SECTIONAL ASSEMBLY
DRAWINGS
5.4
COUPLING ALIGNMENT
9
11
DRAWINGS
5.5
GROUTING
9
PIPING
10
6.1
GENERAL PRECAUTIONS
10
6.2
SUCTION PIPING
11
6.3
DISCHARGE PIPING
11
OPERATION OF NON CLOG PUMPS
12
PRECOMMISONING CHECKS
12
7.1.1
LUBRICATION CHECKS
12
7.1.2
ROTATION CHECK
12
7.1.2.1
VERTICAL PUMPS
12
7.1.2.2
HORIZONTAL PUMPS
12
SUCTION LINE LEAKAGE CHECK (FOR
VERTICAL DRY PIT AND HORIZONTAL PUMPS)
12
STARTING INSTRUCTIONS
13
6
7
7.1
7.1.3
7.2
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
21 TO 27
[II]
Flowmore Limited
1.
INTRODUCTION:
FLOWMORE Non Clog Pumps are primarily designed for pumping variety of solids in suspension which may be
encountered during pumping of sewage, drain and storm water. The pump internals are so designed that solids in
suspension pass through the pump hydraulic passages without choking or clogging, hence the name, “Non Clog Pumps”.
The principle consideration in pumping sewage and trash water is the capability of a pump to pass solids. Therefore,
hydraulic performance and efficiency, though important, becomes secondary.
FLOWMORE Horizontal and Vertical Non Clog Pumps, when properly installed and operated with reasonable care and
maintenance will operate satisfactorily for a long period of service. Subsequent paragraphs explain the general principles
which should be followed to ensure trouble free operation of the supplied unit.
Additional information for special pump designs/applications and situations which are not covered in this manual, can be
furnished on request for specific requirements. While seeking technical information for such cases, make sure that
correct information about Pump Serial No., Pump Figure and Size is furnished and these inputs can be easily taken from
the name plate of the pump.
2.
SAFETY INSTRUCTIONS:
Centrifugal Pumps manufactured and supplied by Flowmore Limited are designed with Safety for Men and Material in
mind. Where hazards cannot be eliminated, the risks are to be minimized by the use of guards and other design features.
In case any of the hazards cannot be guarded, the Personnel involved must take full responsibility to use safe working
practices as per prevalent Industry norms governed by the law of the land.
2.1.
SAFETY SYMBOLS AND EXPLANATIONS:
SYMBOL
CAUTION
WARNING
DANGER
ELECTRICAL HAZARD
2.2.
EXPLANATION
LEGEND
A hazardous situation that may cause minor or moderate injury, if not
avoided.
A hazardous situation that may cause serious personal injury or even
death, if adequate care is not taken.
A hazardous situation that will cause death or serious injury, if cautions
are ignored.
There may be a possible risk of electricity related hazards, if
precautionary measures are not followed properly.
SAFETY PRECAUTIONS:
CAUTION
WARNING
GENERAL PRECAUTIONS
Read this manual carefully before installing and using the Pump Unit. Improper
installation and unintended use of the pump can cause personal injury and damage to
property, and may void the warranties.
If the agreed conditions of service are proposed to be changed, user must seek
FLOWMORE's written approval before start-up of the pump.
Use fasteners of the designated size and property grade to avoid any catastrophic
failure of items during normal pump operation.
Clear and easy access to all controls, gauges and dials etc. must be maintained at all
times.
Hazardous or flammable materials must be stored in safe areas or racks in pilfer proof
and spill proof containers.
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
DANGER
ELECTRICAL
HAZARD
3.
3.1.
i.
ii.
a.
b.
c.
d.
iii.
iv.
Do not wear loose or frayed clothing or jewellery that could catch on the
controls/knobs/handles or trapped in rotating equipment.
Please do not operate the pump without coupling guard and other safety precautions.
Following personal protective equipment should be used as a minimum requisite, while
working on the pump,
 Hand gloves
 Safety glasses
 Safety shoes
 Helmets
 Ear Plugs
Due care should be taken during hoisting and placement of heavy equipment.
All electrical connections are properly insulated and covered.
Before beginning any alignment procedure, please ensure driver power is disconnected
from the source of power supply.
STORAGE:
INSPECTION OF PACKAGE/EQUIPMENT:
Please inspect the physical condition of the packages/items immediately on receipt. In case the packing cases are
found damaged the same should be opened in presence of the transporter’s representative.
Inspect all the items for any physical damage/short supply as per the packing list. As a visual check, the main
things to be looked for are;
Broken or cracked feet of the pump base
Broken or cracked suction and discharge flanges
Broken or cracked adaptors
For drive motor, check for the broken fan cover/shield, bent eye bolts, broken or cracked feet and damaged
terminal box.
In case of any mismatch in Quantity/Quality of items received, take immediate steps to inform the nearest
FLOWMORE representative, Transport Company responsible for delivery of the equipment and Insurance
Company.
In case the supplied equipment is to be used at a later date, please ensure proper storage of the items as
described in the following paragraphs entitled "STORAGE REQUIREMENTS".
3.2.
STORAGE REQUIREMENTS:
Storage requirements vary depending on the length of storage, the climatic conditions and the equipment. For storage
periods of three months or longer, contact FLOWMORE for specific instructions. Improper storage may lead to invalid
warranties.
Consider a unit in STORAGE when:
i.
It has been delivered to the job site and is awaiting installation.
ii.
It has been installed but operation is delayed due to incomplete plant construction.
iii.
There is long, 30 days or more, period between operation cycles.
iv.
The plant or department is under shut down.
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
Following instructions should be followed to avoid any damage to the pump components under storage.
Condition
Indoor storage
Outdoor storage
Uncovered storage facilities such as uneven
temperatures, higher humidity, and/or dusty
conditions
Pump Rotation
Oil Lubricated Bearings
Requirements
FLOWMORE suggests that the storage area should be clean,
dry and well ventilated with platforms/pallets for stacking
of the pump components.
In this case, apart from the conditions as stated for indoor
storage, components must be covered from all sides with
weather proof black PVC/Plastic sheets or tarpaulins.
Ingress of dust must be prevented to enter the covered
areas to protect the stored items from the effect of
corrosion.
Check and clean the pump/components periodically to
ensure that the pump is free to rotate by hand and that all
components are free from dust, rust and corrosion.
Rotate the pump shaft several rotations by hand every
fortnight (two weeks). This will ensure
a) Adequate coating of bearings with lubricant
b) Retarding of oxidation/corrosion
c) Prevention of possible false brandling
Fill the reservoir completely with suitable grade of
lubricating oil for storage. The excess oil should be drained
to proper level for start up at later date. Ensure periodic
shaft rotation as above.
3.3.
LONG TERM STORAGE:
Ensure that any rust prone surface must be coated either with anti rust oil or a thin layer of grease. Actual condition of
surface finish should be checked from time to time and requisite preventive measures should be taken to ensure due
care of the delivered item/s. In addition, nearest FLOWMORE representative should be consulted for any specific
instructions/guidelines for long term storage.
4.
BRIEF DESCRIPTION OF NON CLOG PUMPS:
4.1.
GENERAL APPLICATIONS
As mentioned earlier, our Non Clog Pumps are basically designed for handling solids or stringy material suspended in a
conveying liquid medium without getting choked or clogged. These pumps are fitted with impellers of our standard twin
blade design which will perform satisfactorily for most applications. However, in applications where excessive stringy
material is to be handled, the pumps can be supplied fitted with a single passage impeller, also termed as “BLADELESS
impeller”. These pumps are recommended for handling raw or treated sewage, light sludge, slurries, industrial material
or wastes and similar liquids where excessive clogging would otherwise be encountered.
4.2.
TYPES OF NON CLOG PUMPS:
All the pumps covered in this manual are basically similar with respect to the hydraulics. However, subject to varying
site conditions, orientation of discharge nozzle and mounting styles, the mechanical design of frame and location of
drivers will change. . Thus, these pumps are available in both vertical and horizontal configurations.
The sketches shown below in Figure- 1 depict various discharge positions which can be adopted for clockwise and
counter clockwise directions of rotation when viewed from drive/ coupling end of a pump. Position no. 9 is considered
standard. These options are available for both horizontal and vertical pumps.
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
(b)-Counter Clockwise Rotation
(a)- Clockwise Rotation
Figure 1- Discharge Nozzle Orientation
4.2.1. VERTICAL PUMPS:
Vertical Non Clog Pumps are supplied in the following two types of construction suitable for specific site conditions;
4.2.1.1. DRY PIT PUMPS:
Pumps of this type are equipped with ball bearings and are designed
to operate in conditions, where submerged condition is not
expected to be encountered. The driver and pump are mounted in a
close coupled configuration and are connected through a flexible
coupling.
(Refer Fig 2 for a typical installation)
Figure-2- Typical installation of a Dry Pit Pump
4.2.1.2. WET PIT PUMPS:
Pumps of this type are equipped with grease or oil lubricated
sleeve bearings and are designed to operate in a suspended
and submerged configuration. The drive motor is mounted on
a motor stand on top of a base plate installed at a floor higher
than the maximum water level. The pump is supported from
below the motor stand through column and shaft assembly
and discharge pipe. The column assembly also encloses and
protects the drive shaft assembly between pump shaft and the
motor shaft. The driver and pump are connected by a flexible
coupling.
(Refer Fig 3 for a typical installation).
Figure-3- Typical installation of a Wet Pit Pump
4.2.2. HORIZONTAL PUMPS:
Pumps of this type are equipped with ball bearings and are designed to operate in a horizontal position. The driver is
generally mounted with the pump on a common base. The pump and driver are usually connected by a flexible coupling.
Typical installations for a horizontal pump with positive and/ or negative suction are depicted in Figures 4(a) & 4(b).
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page4
Flowmore Limited
(b)-Pump under suction lift
(a)- Pump under positive suction
Figure-4 Typical Installations of Horizontal Pumps
5.
INSTALLATION:
It is recommended that the services of a competent and experienced erection/commissioning engineer should be
employed for installation and commissioning of the equipment. However any experienced contractor can install this
equipment if the recommendations and instructions described herein are strictly adhered to.
i.
The pump should be located as near to the liquid being handled, as practical, so that a short and direct suction
pipe may be used. For a stipulated value of required NPSH, the total suction lift should not exceed 4.5 meters,
when pumping the rated capacity at sea level; at temperature not exceeding 30ᵒC. Reduction in suction lift for
change in altitude is approximately 300mm for every 305m above sea level. Also, for ease of maintenance and
inspection during operation, it is advisable to locate the pump so that it is readily accessible.
ii.
The foundation for the pump should be sufficiently substantial to absorb any vibration and to form permanent
rigid support. Foundation bolts of proper size should be located and embedded in the concrete as per the
Approved General Arrangement Drawing or a template to match the drawing dimensions. Foundation pipe
sleeves of diameter about 2.5 times larger than the foundation bolt, should preferably be used to allow final
positioning, wherever required for higher pump sizes. It is recommended that the top of the foundation be
finished reasonably smooth and the height be made 30 mm to 40 mm less than the desired finish level to allow
for grouting.
1.
2.
3.
4.
5.
6.
7.
Base plate
Shims or wedges
Grout
Foundation
Dam
Bolt
Sleeve
(a)-Without Foundation Sleeve
(b)-With Foundation Sleeve
Figure-5 A typical pump foundation
iii.
iv.
Before commencing installation, pump dimensions should be checked and compared with certified factory plans/
pump building dimensions to ensure that the unit will fit into the space provided for it.
If the pump had been in storage, it will be necessary to remove all the grease from the bearings. The bearings
should then be flushed with a suitable compound, and regreased. The proper procedure for performing this
operation is outlined in Instructions for Lubrication under “Maintenance of Non Clog Pumps”.
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Document No- 014-00-21E14-SC-RD
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Flowmore Limited
v.
Thoroughly clean the suction and discharge flange surfaces. Using a solvent, remove the protective coating from
the pump shaft.
CAUTION :
In Vertical Pumps, extreme care should be taken to prevent the solvent used from running down the
shaft into the upper bearing.
The following installation instructions divided into two sections cover the Vertical and the Horizontal pumps one by one:
5.1.
Vertical Pumps:
The installation instructions for Vertical Pumps are further sub-divided into 2 sections, one for Dry Pit Pumps and the
other for Wet Pit Pumps.
5.1.1. Dry Pit Pumps:
Normally these pumps and pumping units are fully assembled upto motor stool at the factory and dispatched to site in
assembled condition complete with flexible coupling fitted on the pump shaft.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Lower the above pumping unit over the foundation bolts already grouted in the dry pit floor.
Using wedges, placed as close to the foundation bolts as possible, raise the pump to the desired elevation.
Using a spirit level, adjust the wedges so that the suction and discharge flanges are vertical.
Dismantle the upper (Motor) half of flexible coupling from the assembled unit.
Mount the motor half of the flexible coupling by sliding it upwards along the motor shaft and inserting the motor
key in the keyway.
Lower the motor over the motor stool, positioning it over the centering seat provided on the motor stool.
Pull down the motor coupling half upto the level of motor shaft and face. Lock the coupling half in this position by
tightening the retaining screw onto the motor key.
Rotate the motor shaft coupling by hand to align and assemble the flexible member between the pump and
motor coupling half.
Securely bolt the motor on the motor stand.
Grouting of pump base should be carried out as per the guidelines provided under “GROUTING”.
Install discharge pipe as per approved layout to complete the installation.
5.1.2. Wet Pit Pumps:
Like Dry Pit Pumps, Wet Pit Pumps and Pumping Units are also fully assembled up to motor stool at the factory, and
dispatched to site in assembled condition. However, large size units and pumping units under maintenance, have to be
assembled at site. Instructions listed below should be meticulously followed;
i.
Lay the pump on the pump house floor and support it to ensure that the pump shaft is horizontal.
ii.
Connect the bottom drive (line) shaft with the pump shaft using the pump shaft coupling.
CAUTION
The coupling should be positioned equally on the both the shaft lengths being assembled together.
iii.
iv.
v.
Slide bottom column pipe over the bottom shaft and tighten it on to the pump adaptor/frame.
Press column bearing bushing into column bearing housing. Put a small amount of grease in the column sleeve
bearing and slide it down over the drive shaft into position in its seat on the column flange. Column bearing
housing will be sandwiched and tightened between flanges of lower column pipe and the next column pipe
using common nut-bolt assemblies.
Assemble next piece of the drive shaft with the bottom shaft through drive shaft coupling.
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page6
Flowmore Limited
vi.
Repeat steps iii to v above, thereby tightening each column bearing housing between flanges of two adjacent
column lengths, till the entire column & shaft assembly is completed.
CAUTION
Extreme care should be taken to clamp the column bearing housings to their proper position.
After each column bearing housing has been clamped in, check that the drive shaft rotates
freely by hand.
2. Make sure that tapped connections for lubrication of pump and column bearings are in one
line. Finally this alignment must be in line with the lubricating line hole provided in the base
plate. If necessary, rotate the volute and column assembly to achieve this alignment.
1.
NOTE:
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xvii.
xviii.
xix.
xx.
xix.
xxi.
On settings requiring three or more sections of columns, the drive shaft will be in two or more
sections. These sections are joined together by a threaded coupling similar to the coupling installed
at the pump.
Place the base plate along its longer edge on the pump house floor, ensuring that the opening for column and
shaft assembly is approximately in line with the pump shaft.
Slide the base plate over the column & shaft assembly so that the top column pipe projects out of the base plate
opening by 300 to 500 mm.
Lay the motor stand horizontally on the shop floor, taking care that the lubricating tank and its outlet are
correctly positioned to match the position of lubricating line.
Push the motor stand towards the projected column pipe, ensuring that the column flange sits in its seat and
butts against the lower face of motor stand.
Tighten column assembly to motor stand and also the motor stand on to the base plate using appropriate
hardware.
Slide top tube bearing bushing/packing box on to the top shaft and tighten it on its seat provided in the motor
stand. Make sure that the lubrication tapped hole/port is in line with the lubrication piping.
Slide the thrust bearing assembly on to the top shaft and tighten it on its seat provided on the motor stand.
Fit top discharge pipe into the space provided on Base Plate and tighten it with the help of lock nuts as shown in
approved cross sectional assembly drawing.
Join the required lengths of lower discharge pipes as per approved assembly drawing and lastly join bottom
discharge pipe/discharge elbow to discharge flange of the volute with the help of requisite hardware to complete
the pumping unit assembly in horizontal direction on the pump house floor.
Lower the assembled pumping unit into the sump, taking care that foundation holes of the base plate match with
the location of foundation bolts grouted into the foundation/ pump house floor.
Using wedges, placed as close to the foundation bolts as possible, raise the pump to the desired elevation and
using a spirit level, adjust the wedges so that the top surface of the motor stand is horizontal.
Push the lower coupling half over the top/head shaft so that it rests at its lowest position, not to forget placing
of ratchet pins in their respective cavities. Rotate the coupling half in position by hand to align respective
keyways for assembling gib key and straight key. Lock the coupling assembly at this location by tightening
retaining screw on to the straight key.
Screw down the Top Adjusting Nut along the top shaft till it snugs down against the top surface of the lower
coupling half. Screw down the Top Adjusting Nut further by turning it through 1/3rd to 1/2 revolution to establish
proper running clearance between the impeller and suction cover. Lock the adjusting nut in position with a split/
cotter pin.
WARNING
The impeller running clearance setting procedure must be followed. Improper setting of the
clearance or not following any of the descriptive procedures can result in unexpected heat
generation, emission of sparks and damage to pump components.
Tighten the flexible link assemblies on the lower half coupling, surrounding the adjusting nut.
Installation, Operational and Maintenance Manual
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Flowmore Limited
WARNING
Utmost care should be taken while fixing the link assemblies to ensure that the links’ connection to
the motor coupling half is ALWAYS LEADING irrespective of CW or CCW direction of pump
rotation.
xxii.
xxiii.
xxiv.
xxv.
xxvi.
The top (motor) half of the flexible coupling is installed on the motor shaft by sliding it upwards above the motor
shaft and inserting the motor key in the key way. Pull the coupling half down upto the level of motor shaft end
face. Lock the motor coupling half in this position by tightening retaining screw on to the motor key.
Lower the motor over the head shaft and position it on the motor stand. Due to provision of centering seats
between the motor and motor stand the pump and motor coupling halves should come in line with each other.
Rotate the motor shaft coupling by hand to align and assemble with the link assemblies already installed over the
pump half coupling.
Tighten the link assembly bolts securely between the pump half and motor half couplings.
Securely bolt the motor in position on the motor stand.
NOTE:
xxvii.
It is recommended that, on the column lengths of six sections or more, every other joint should be
supported by four tie rods securely anchored in the surrounding walls. This will also prevent floating
objects in the pit from causing misalignment of the column assembly.
Grouting of pump base plate should be carried out as per the guidelines provided under “GROUTING” to
complete the installation.
5.2.
Horizontal Pumps:
Horizontal Non clog pumps are driven by a driver mounted on either a common base frame or separate base frame.
Following instructions should be followed to cover installation of horizontal pumps for these two cases:
A.
Horizontal Pump and its driver is mounted on a common Base:
i. Lower the complete Pump, Driver and Base Frame Assembly into place.
ii. Using wedges, placed as close to the foundation bolts as possible, raise the pump to the desired elevation.
Figure-6 Placement of Wedges for Leveling
iii. Using a spirit level, adjust the wedges so that the suction flange is vertical, simultaneously maintaining its
discharge flange in a horizontal plane.
iv. Align the coupling as mentioned in the instructions for COUPLING ALIGNMENT.
v. Grouting of Pump-Motor Base should be carried out as per the guidelines provided under “GROUTING” to
complete the installation.
B. Horizontal Pump and its driver are not mounted on a common base:
i. Install the coupling halves on the pump and driver shaft extensions.
ii. Lower the pump into place.
iii. Using wedges, placed as close to the foundation bolts as possible, raise the pump to the desired elevation.
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page8
Flowmore Limited
iv. Using a spirit level, adjust the wedges so that the delivery flange is horizontal, simultaneously maintaining the
verticality of the suction flange.
v. Lower the motor into place.
vi. Using wedges raise the motor to match height of pump and motor half couplings.
vii. Align the coupling as mentioned in the instructions for COUPLING ALIGNMENT.
viii. Grouting of pump and motor base frames should be carried out as per the guidelines provided under
“GROUTING” to complete the installation.
5.3.
DRIVER:
In most cases, these pumps are driven by an electric motor. Installation and commissioning procedure for these motors
should be carried out as per motor manufacturer’s recommendations and procedures listed in the installation manual
furnished along with the motor.
5.4.
COUPLING ALIGNMENT:
In case of Pump and Driver mounted on common base, the Pump and Driver are factory aligned before dispatch.
However, the coupling alignment should be re-checked on receipt of equipment at site. To carry out these checks, it is
necessary to remove the flexible member(s) such as Pin & Bush, Spider and Tyre from the flexible coupling. Using a
Straight Edge and Taper or Feeler Gauge, check the coupling for angular and parallel alignments. These checks should be
done at four positions around the coupling.
In case the pump and driver are not mounted on a common base, these have to be necessarily assembled and aligned at
site at the time of installation as detailed in 5.2 B above.
To check parallel misalignment of Pump-Motor Coupling, use a straight edge or a dial indicator. The correction is carried
out by suitably shifting the pump or driver on their respective base frames.
Angular misalignment of the coupling may be checked with the help of taper or feeler gauge. The angular misalignment
should be corrected by placing shims of adequate thickness at strategic locations under the driver feet only. Shimming
below the pump feet is not recommended.
When dial indicators are used to check the final alignment, the pump and drive unit are considered to be correctly
aligned when total indicator run out value is within a maximum of 0.05 mm.
WARNING:
Shaft Alignment Procedures must be followed to prevent failure of rotating components like shafts,
couplings and bearings.
5.5.
GROUTING:
i. Clean all the areas of the base frame, pump and motor pedestals that will come into contact with the grout.
ii. Build a dam around the foundation.
iii. Use a good quality Non Shrink Grout Mixture.
iv. Thoroughly wet the foundation that will come into contact with the grout using rich cement slurry.
v. Pour grout through the grout hole into the base plate up to the level of the dam. Adequate care should be
taken, while pouring the grout, to avoid formation of air bubbles. This can be achieved either by stirring of the
grout by a vibrator or directly pumping of the grout into place.
vi. Allow the grout to set for at least 48 hours before full tightening of the foundation bolts.
vii. It is a good practice to fill the remainder of base plate with grout as shown in the schematic diagram to
minimize possibilities of vibrations.
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Flowmore Limited
1.
2.
3.
4.
5.
6.
Base plate
Grout
Foundation
Dam
Bolt
Sleeve
(a)-Grouting of base frame without
sleeve
(b)-Grouting of base frame with sleeve
Figure-7 Grouting of base frame
viii.
Tighten the foundation bolts fully.
6.
PIPING:
6.1.
GENERAL PRECAUTIONS
When installing the pump piping, be sure to observe the following precautions:
CAUTION :
Before connecting station piping to the pump nozzles, take an inventory of tools and materials used
during installation of the pump. The suction and discharge nozzles of the pump make a very
convenient, though totally undesirable, place to lay hand tools and other small items. Invariably,
the erection personnel tend to forget to remove these tools. When the pump is first started, these
items usually are sucked into the pump and cause damage to the impeller and casing. If any doubt
exists, as to the freedom of pump and piping from tools, rags, bolts, nuts, welding slag etc, a lot of
time and expense may be saved by rechecking over this point and flushing the pipelines before
connecting to the pump.
i. Piping should always run up to the pump. Do not move pump to pipe as this may make final alignment
impossible.
ii. Both the suction and discharge piping should be properly aligned and supported independently near the
pump, so that no strain is transmitted to the pump when the flange bolts are tightened.
CAUTION :
Failure to support Suction and Delivery Pipe Work may result in distortion of the pump casing,
with the possibility of early pump failure.
iii. Install piping as straight as possible, avoiding unnecessary bends, Where ever necessary, use long radius
45-degree or 90-degree bends to decrease friction losses.
iv. Remove burrs and sharp edges when making up the pipe joints.
v. Make sure that all piping joints are air-tight.
Installation, Operational and Maintenance Manual
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Flowmore Limited
6.2.
SUCTION PIPING
When installing the suction piping, observe the following precautions:
i. Normally, Non Clog Pumps are recommended to operate under positive suction condition only, necessitating
use of a suction pipe of shortest possible length and as direct as possible with minimum number of fittings. A
suction pipe should NEVER BE SMALLER IN DIAMETER than the pump suction nozzle size.
ii. The sizing and installation of the suction piping should be so determined as to minimize pipe friction losses,
thus ensuring sufficient liquid to flow into the pump. This can be achieved by using suction pipe of one to two
sizes higher than the size of pump suction nozzle in order to limit the suction pipe velocities within 1.5m/s.
CAUTION :
When increasing the pipe size on the suction side, never use a straight taper reducer which
forms an air pocket at the top of reducer. Instead an eccentric reducer should be used to
avoid formation of air pocket just before the suction nozzle.
iii. Horizontal suction lines must have a gradual rise to the pump. Suction lines must always pass under other
interfering pipe lines. Any high point in the suction pipe will act as a chamber for air entrapment and thus
prevent proper operation of the pump.
iv.
To facilitate cleaning of the pump i nl et passag e, a shor t sec ti on of pi pe shoul d be so desi g ned
that i t can be installed adjacent to the pump suction flange and can be readily dropped out of the line.
With this arrangement, any matter causing the clogging of pump impeller is easily accessible and can be
removed immediately.
v.
Where two or more pumps are connected to the same suction line, install gate valves so that any pump can
be isolated from the line. Gate valves should be installed on suction side of all the pumps with a positive
pressure for maintenance purposes. Install gate valves with stems horizontal to avoid air pockets.
vi. The pump must never be throttled by the use of a valve on the suction side. Suction valves should be used
only to isolate the pump for maintenance purposes.
6.3.
DISCHARGE PIPING:
If the discharge piping is short, the pipe diameter can be same as the size of pump discharge nozzle. However, In
case the piping runs longer, pipe diameter should be one or two sizes larger than the pump discharge size. Avoid
high spots, such as loops or bends to form air pockets which result in throttling the discharge system or lead to
erratic pumping.
i. With the exception of vertical wet pit pumps which are invariably submerged, the non clog pumps are
equipped with a pipe tap on the side of the adaptor for attaching a drain pipe to drain off the stuffing
box leakage. This drain pipe must be connected to ensure clean work area around the pump.
ii. A check valve and a gate valve should be installed in discharge line. The check valve, placed between
the pump and gate valve, will protect the pump from excessive back pressure and prevent water
flowing back through the pump resulting in reverse rotation, that may cause damage to the pump. The
gate valve is used for priming before initial starting and when the pump is in shut down. If increasers
(expanders) are used on pump discharge side to increase the size of discharge piping, these should
always be placed between the check valve and the pump.
iii. On pumps handling dirty, gritty or acidic liquids, a sealing/ flushing liquid from a clean external
source of supply should be piped to the tapped connection provided on stuffing box housing. This
will prevent damage to the packings and shaft sleeve.
i v . Pressure gauges should be installed in gauge taps provided on both suction and discharge nozzles.
v . After all the piping is complete, recheck the pump and motor alignment.
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Flowmore Limited
7.
OPERATION OF NON CLOG PUMPS:
WARNING
i.
Please do not operate the pump without priming or in dry condition.
ii.
Please do not operate the pump with closed suction and discharge valves.
In order to ensure satisfactory operation of these pumps, review carefully and perform all the operations outlined as
below:
7.1.
7.1.1.
PRECOMMISONING CHECKS:
LUBRICATION CHECKS:
i. Check that the bearings are filled with sufficient of amount of lubricant. With the exception of vertical wet pit
pump, in case of grease lubricated bearings, this may be done by loosening the hex head cap screws that
secure the bearing covers and sliding/raising them far enough to inspect the bearing. In case of oil lubricated
bearings, the lubricating oil must be filled upto the mark on oil level indicator.
ii. In vertical wet pit pumps, the lubrication lines must be completely full. In order to check this, disconnect the
union joint at the pump frame.
iii. In addition to the above, it is advisable to check the motor bearings for lubrication. This should be done in
accordance with the motor manufacturer's recommendations as listed in the motor installation manual.
7.1.2. ROTATION CHECK:
The electrical motors are usually of poly-phase design and can be operated in either direction of rotation by merely interchanging any two of the phase connections at motor terminal box. It is extremely important that the motor rotates in the
correct direction of rotation to match the pump rotation. Standard direction of rotation of these pumps is CCW(Counter
Clock-wise) when viewed from the coupling end. The direction of rotation is indicated by an arrow cast integral with the
casing. Prior to switching on the electric supply for checking direction of rotation of motor, following instructions should
be followed for the three types of pumps;
7.1.2.1. VERTICAL PUMPS:
a) DRY PIT PUMPS
Disengage the flexible coupling between the pump and motor. Check the rotation. Correct if required, and
complete the final electrical connections. Reconnect the flexible coupling between the pump and its driver.
b) WET PIT PUMPS
Disconnect motor coupling half from the flexible link assemblies. Loosen retaining screw and push up the upper
coupling half along the motor shaft, retighten retaining screw to hold the coupling at this location. Check the
rotation. Correct if required and complete the final electrical connections. Complete the assembly with flexible
links as outlined under INSTALLATION.
7.1.2.2. HORIZONTAL PUMPS
Disengage the flexible coupling between the pump and its motor by removing the pins and rubber cushions from the
flexible coupling. Check the rotation. Correct if required and complete the final electrical connections. Reassemble the
flexible member between the two coupling halves.
7.1.3. SUCTION LINE LEAKAGE CHECK (FOR VERTICAL DRY PIT AND HORIZONTAL PUMPS):
Fill the suction line with liquid and check for leakage of joints. Tighten the leaking joints or replace gaskets where ever
necessary.
Installation, Operational and Maintenance Manual
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Flowmore Limited
7.2.
STARTING INSTRUCTIONS:
i. PRIME THE PUMP AFTER CLOSING THE GATE VALVE IN DISCHARGE LINE.
With the exception of vertical wet pit pump which is submerged, and installations where the water supply has
sufficient head to allow flow of liquid into the pump and to fill the casing, a horizontal pump working under
suction lift must be primed. This may be done by one of the following methods, as best suited to local site
conditions.
a.
Priming by Ejector:
Where steam or compressed air is available, this is a very convenient method of priming. Attach an ejector at
the high point of the casing and make the necessary air or steam connections. Valves should be provided
between the ejector and the pump which may be closed after the pump is primed and started. The time span
required for priming will vary depending upon the conditions in each installation.
b.
Priming by Vacuum Pump
When steam or compressed air is not available a hand or power operated vacuum pump may be used to
evacuate the air filled in the suction line and pump casing. Statements made into preceding paragraph for cut
off valve and priming time will be applicable in this case also.
c.
Priming by Water Supply
When it is feasible to place a foot valve on the suction pipe and a separate external water supply is available,
the pump priming can be very conveniently achieved. The water supply can be connected to the pump casing
at any convenient point and priming is accomplished by allowing the suction pipe and casing to fill. An air vent
must be provided at the highest point of pump casing.
ii.Start the driver-This should be done as per the recommendations of the motor and its control/ switch gear
manufacturers.
iii.Open the discharge valveAfter the pump has attained full speed, open the discharge valve. This should be done slowly in order to bring a
gradual load on the driver, and to prevent development of water hammer in the distribution system. This is
especially important, as water hammer can cause serious damage to the piping and other equipment in the
installation. Water hammer is caused by a sudden build up of pressure, resulting in setting up of pressure waves
moving to and fro in the piping system. This pressure is composed of the pressure built up by the pump and by
the weight and velocity of the liquid being handled. In many cases, this pressure can exceed the bursting
pressure of the pipes, fittings and pipe joints.
7.3.
OPERATION CHECKS:
When the pump is first started, and during normal operation it is advisable to periodically observe the pump behavior for
symptoms of trouble and to follow remedial measures as listed under TROUBLE SHOOTING.
7.4.
STOPPING INSTRUCTIONS:
i. Slowly close the discharge valve, again to prevent water hammer in the distribution system.
ii. Disconnect the power from the drive.
iii. Drain the pump
For shut down periods, stuffing box should be flushed clean and moderately re-lubricated. Re-grease the pump and
motor bearings. Also, it is advisable to provide the pump and motor with a protective covering to prevent moisture
damage to the bearings and motor windings.
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Document No- 014-00-21E14-SC-RD
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Flowmore Limited
8.
MAINTENANCE OF NON CLOG PUMPS:
These pumps, like any other machine, require maintenance under two situations, namely Preventive maintenance and
Breakdown maintenance.
While preventive maintenance involves routine periodic checks to avoid breakdowns and to ensure trouble free
operation, the breakdown maintenance is an emergency situation to locate, identify and rectify the fault in the shortest
possible time.
8.1.
PREVENTIVE MAINTENANCE:
Routine maintenance checks under preventive maintenance are recommended to be carried out at regular intervals as
listed below:
8.1.1. DAILY INSPECTIONS:
Perform following daily checks during routine maintenance activity:
i. Check and record pump operating parameters like discharge pressure gauge readings, bearing temperature,
noise and vibrations. In case of increasing trend in vibration values, analyze cause and take corrective steps.
ii. Check amount of lubricant in respective chambers to ensure adequate lubrication of bearings and sleeves.
iii. Check for dripping of lubricant from pump bearings and take requisite corrective action.
iv. Check the pump and piping for leaks and rectify as necessary.
v. Check for adequate leakage of liquid from the stuffing box. Excessive leakage needs to be arrested.
8.1.2. QUARTERLY INSPECTIONS:
Following checks during tri monthly maintenance activities are recommended:
i. Check that the foundation bolts and the hold-down bolts are tight.
ii. Check the shaft alignment, and realign as required.
iii. Change the lubricant every six months or after 2000 operating hours whichever is less.
iv. Change the lubricant more often if the pumps are operating under adverse atmospheric or other conditions that
might contaminate the lubricant.
v. Under special situations, it may be necessary to partly dismantle the pump for attending to an adverse
observation during any of the above inspection schedules.
Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive.
8.1.3. ANNUAL INSPECTION:
Excessive drop in pump performance and persistent high levels of sound and vibrations are reasons enough to go for
detailed investigations under annual inspection. Such an inspection will normally amount to complete dismantling of
pump to look for internal wear tear and damage to pump components. This also covers an eventuality of rectification of a
defect observed under daily and quarterly inspections but could not be attended due to system requirement. Extent of
dismantling needs to be carefully assessed based on work involved for tackling the identified problem. Before taking a
decision for dismantling the pump, check and record the pump operating parameters as listed under daily inspection.
8.2.
BREAKDOWN MAINTENANCE:
Guidelines listed under ANNUAL INSPECTION AND REPLACEMENT OF PARTS should be meticulously followed to address
problems of equipment breakdown.
8.3.
REPLACEMENT OF PARTS:
Except in cases involving breakage or extreme wear on the casing and suction cover, normally it may not be
necessary to disturb the piping in order to inspect and replace parts in these pumps. Following procedure is given as
a guide to ensure ease of disassembly.
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Flowmore Limited
8.3.1.
VERTICAL PUMPS:
i. Disconnect the drive equipment from the pump. This may be done in the following manner;
a) Tag the pump in off position and lock it out so that it cannot be accidently started.
b) Disconnect supply cables from the driver.
c) Disconnect the flexible coupling between pump and motor and remove the driver from its position on the
motor stool or stand.
ii. In case of dry pit installation, the pump may now be dismantled as per specific requirement.
iii. In case of wet pit installation, the system discharge line needs to be disconnected from the joint above the
pump base plate (Refer typical cross sectional assembly drawing).
a) Lift/remove the pumping unit from the sump and lay it on the pump house floor in horizontal direction.
b) Dismantle the pump as per requirement by following installation instructions, IN REVERSE ORDER, starting
from 5.1.2- xix.
c) It may be necessary to replace the sleeve bearings of either the pump frame or the column assembly. The
old/worn out bearings must first be pressed out of their respective housings and the new ones pressed in their
place. Thereafter ensure that the shaft turns freely in the new bearings.
iv. In the event that it is necessary to replace the pump shaft sleeve, the old sleeve must first be removed by
using a grinding wheel and cold chisel. The new sleeve may be pressed on, if a press is available. Alternatively,
the sleeve may be heated in an electric oven or a hot oil bath to approximately 190˚C to 250˚C. At this
temperature, the sleeve expands well enough to slip onto the shaft by hand.
WARNING
Care should be taken to prevent the hands coming in contact with hot surfaces with asbestos hand
gloves or other suitable protection.
8.3.2.
HORIZONTAL PUMPS
i. Disconnect the drive motor from the pump and remove the driver after removing the hold down bolts
between motor and base frame.
ii. The rest of the pump may now be disassembled as per the requirement.
iii. If it is necessary to remove the ball bearings from the shaft, old bearings must be discarded to be replaced
with the new ones. Extreme care should be taken while replacing the new bearings by pressing them in such a
manner that the force is applied against the inner race of the bearing so that the bearings do not get
damaged.
iv. For replacement of the worn out pump shaft sleeve, follow the procedure outlined above for vertical pumps.
WARNING
Please do not apply unwarranted heat to disassemble any components of pump during the process of
disassembly. It can alter the metallurgy of the component thereby affecting its useful life.
The pump may be reassembled by following the above steps in reverse order.
8.4.
ORDERING REPLACEMENT PARTS :
When ordering the repair parts, please furnish details about type, figure and size of the pump. In addition, ALWAYS GIVE
PUMP SERIAL NUMBER WHICH IS STAMPED ON THE NAME PLATE. When ordering an impeller, please provide impeller
diameter across the blade tips. The order for replacement parts should specify part name, part number, and quantity
required.
In view of continuous improvement of the FLOWMORE products, the company reserves the right to furnish improved
parts for repairs, provided such parts are interchangeable. A part that is received and is not identical in appearance or has
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
a different symbol from the original part, May still be interchangeable with the worn out part. As such, the parts of
improved version should not be returned to the factory without proper confirmation from FLOWMORE.
8.5.
REPLACEMENT OF SHAFT SEALING ELEMENTS:
8.5.1. REMOVING OLD PACKING:
It's time to replace the packing when there is no more adjustment left in the packing gland and there is too much leakage
from the stuffing box. When it occurs, complete set of packing rings must be replaced. Adding an additional ring or just
replacing one or two rings will only lead to premature packing failure and damage to the shaft and sleeve.
i. Tag the pump in the "OFF" position and lock it out so that it can’t be accidentally restarted.
ii. Isolate the pump by closing the suction and discharge valves.
iii. Drain the pump by opening the drain cock or removing the drain plug in the bottom of the volute.
iv. Remove the gland half by unscrewing relevant hardwires.
v. Remove the packing rings with a packing puller with due care so that shaft should not be scored.
vi. Remove the water seal ring & remaining packing rings.
vii. Clean the stuffing box & shaft/sleeve.
viii. Disconnect, inspect and clean the seal water line and seal water port, if provided.
ix. Inspect the shaft or shaft sleeve. If it is scored or grooved, the pump should be dismantled and the shaft/shaft
sleeve should be dressed or replaced.
8.5.2. REPACKING THE PUMP:
The correct packing size can be determined using the following procedure:
i. Measure the inside diameter of the stuffing box and the outside diameter of the shaft/ sleeve.
ii. Subtract the shaft diameter from the stuffing box diameter.
iii. Divide the difference by two to arrive at the correct packing size.
The correct number of rings can be determined using the following procedure:
i. Measure the depth of the stuffing box.
ii. Divide the depth of the stuffing box by the size of the packing as calculated above to get the total number of
rings.
iii. Subtract one from this total if a lantern ring is used in the stuffing box.
Installation procedure of gland packings may be followed as explained in subsequent lines:
i. Always use a good grade of soft packing because inferior grades may allow excessive leakage and early wear
tear of the shaft/sleeve. Great care should be taken to keep the packing material clean and free from dirt. The
two most important aspects of cutting packing rings involve cutting them of right length and cutting them in a
manner that the ends will butt together squarely.
ii. Wrap each ring of packing around the shaft and seat it in the stuffing box completely before adding the next
ring. Open the packing ring by twisting instead of pulling the ends apart. Alight coat of grease on the
outside of the ring will make it much easier to push in to the stuffing box. Stagger the joint so the rings so that
they are 90 degrees apart. Never install a lantern ring at the bottom most position in a stuffing box. Make sure
that the lantern ring, when installed, lines up with the seal water port provided in the stuffing box.
iii. Install the packing gland. Make sure the gland is tightened down evenly. It is usually made out of cast material
and will break easily if it gets in a bind.
8.6.
WEARING SURFACE ADJUSTMENT
Before re-commissioning the pump after repairs, and also during normal operation, it is necessary to check and readjust
the running clearance between impeller and suction cover. Normal recommended running clearance between these two
parts should be set between 0.25 mm to 0.8 mm.
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Flowmore Limited
In case of vertical dry pit pumps, the running clearance adjustment can be achieved by suitably manipulating the
thickness of shims between the upper and lower pump bearing covers and pump frame. For vertical wet pit pumps, the
guide lines specified under the topic INSTALLATION should be followed.
For horizontal frame pumps also the impeller running clearance should be adjusted by suitably manipulating the shims
between the outboard and inboard bearing covers and frame.
8.7.
LUBRICATION:
The pumps are sufficiently lubricated, before dispatch from the factory, for an average service of six months. Although
each pump bearing is furnished with Grease inlet fitting and Grease pressure relief fitting, adding additional lubricant to
the pump bearings will seldom be necessary. Good judgment and care should be exercised while adding grease to a
bearing.
Never try to replace the original factory fitted grease fittings with pressure gun fittings. Such fittings will only tempt the
maintenance personnel to add the lubricant to the bearings, thereby causing more damage to the bearings due to
excessive lubrication.
For vertical wet pit pumps, it is necessary to provide the lubricant to the bearings at all times, as these are sleeve type
bearings and depend upon adequate lubrication to support the load and to reduce friction.
8.7.1.
PROCEDURE FOR GREASE RE- LUBRICATION:
i. Remove the drain plug from the bearing housing located at middle & side face of the bearing housing.
ii. Run the pump for 5-10 minutes prior to adding new grease. S top the pump, lock and tag it for maintenance.
iii. Waste the first shot of grease from the grease gun to remove contaminated grease from the tip. Add new
grease - MP2 OF HINDUSTAN PETROLIUM OR EQUIVALENT- to force the old grease out through the drain.
Continue until new grease comes out of the drain.
iv. Restart the pump and allow it to run for 5-10 minutes while excess grease is expelled from the housing.
v. When no more grease comes out of the drain, stop the pump, re-tag it and tighten the drain plug.
vi. Start the pump and allow it to run for 10-15 minutes. Check the bearing temperature. If it is too hot, remove
the drain plug and allow the excess grease to be expelled till the bearing temperatures reduces to desirable
limits.
8.7.2.
PROCEDURE FOR OIL RE- LUBRICATION:
i. Remove vent plug located at top of the bearing frame.
ii. Remove the drain plug from the oil sump located at its bottom/ side face. C ol l ec t al l wa s te o i l i n a
s ui t abl e p an. R epl ac e dr a i n p l ug af ter dr ai ni n g o f w a ste oi l i s c om p l et e.
iii. Fill HINDUSTAN PETROLIUM MAKE MULTIGRADE MOBIL OIL 20W40 OR EQUIVALENT up to the level
indicated on sight glass. Excess oil will result in over heating of the bearing
iv. Tighten all the plugs & Restart the pump.
Immediately after re-lubrication, bearing temperatures may rise above normal operating temperature. It usually gets
stabilized within 4 to 6 hours of operation. The frequency of re-lubrication will depend upon actual operating conditions.
CAUTION
Please ensure that the bearings are periodically lubricated with designated lubricants only.
Do not re-lubricate a pump while it is running.
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Flowmore Limited
9.
TROUBLESHOOTING:
Symptoms
Causes
Pump is not primed
(For Horizontal Non Clog pump only)
Pump suction/line is clogged
Impeller is clogged
Pump is rotating in wrong direction
No discharge
The suction lift is higher than that
for which the pump is designed
(For Horizontal Non Clog Pumps
only)
Speed is too slow
Discharge head is too high
Air leaks in suction line
(For Horizontal Non Clog Pumps
only)
Air leaks in Stuffing box
Speed is too low
The impeller is partially clogged
Insufficient discharge
Running clearance between the
impeller and pump casing is
excessive
(For Vertical Non Clog Pumps only)
Discharge
head
higher
than
anticipated
The suction lift is higher than that
for which the pump is designed
(For Horizontal Non Clog Pumps
only)
The impeller is worn or broken
Foot valve too small (For Horizontal
Non Clog Pumps only)
Foot valve or suction opening not
submerged fully (For Horizontal Non
Clog Pumps only)
Pump is rotating in wrong direction
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Remedy
Re prime the pump and check that the
pump casing and suction line are full of
liquid.
Remove the obstructions from the
suction/line.
Back-flush the pump in order to clean
the impeller
Correct the direction of rotation by
interchanging any two of the face
connections at motor terminal box.
Check suction pipe friction losses.
Rectify/ modify suction line as
necessary.
Check that motor is properly connected
across the supply line and it receives full
voltage.
Check pipe friction losses. Rectify as
necessary.
Check leaking joints in the suction line.
Rectify as necessary.
Replace gland packing if necessary.
Readjust packing gland.
Check that motor is properly connected
across the supply line and it receives full
voltage.
Back flush the pump in order to clean
the impeller
Adjust the running clearance by top
adjusting nut.
Check pipe friction losses. Rectify as
necessary.
Check suction pipe friction losses.
Rectify/ modify suction line as
necessary.
Inspect and replace the impeller
Replace with adequately sized foot valve
Increase the length of suction pipe to
achieve proper submergence.
Correct the direction of rotation by
interchanging any two of the face
connections at motor terminal box.
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Flowmore Limited
Speed too low
Insufficient Pressure/ head
Dissolved air/gasses in the liquid
being pumped
Impeller is worn or broken
Pump is rotating in wrong direction
The pump is not primed
The suction line has air or vapor
pockets
The suction line has an air leak
Pump looses prime during operation
(For Horizontal Non Clog Pump only)
Defective casing gasket/O’ ring
Dissolved air/gasses in the liquid
being pumped
Suction lift is too high
Water seal ring clogged
Excessive leakage from stuffing box
Insufficient gland pressure
Insufficient packings in the stuffing
box
Worn out shaft/shaft sleeve
Pump operating at low discharge
head, hence delivering excess
quantity of liquid.
Specific gravity and/or viscosity of
the liquid pumped is too high.
Excessive power consumption
Excessive vibrations and noise
Rotating parts are rubbing against
each other
Speed is too high
Mechanical defects:
1. Bent shaft
2. Packing gland too high
3. Insufficient
impeller
running clearance
4. Rotating element binds
Misalignment between pump and
driver
Foreign object stuck in the impeller
eye/ vanes.
Foundation bolts and hold-down
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Check that motor is properly connected
across the supply line and it receives full
voltage.
Follow specific degasification procedure
in consultation with FLOWMORE
Inspect and replace the impeller
Correct the direction of rotation by
interchanging any two of the face
connections at motor terminal box.
Re-prime the pump and check that the
pump and suction lines are full of liquid
Rearrange the piping in order to
eliminate air pockets
Check leaking joints in the suction line.
Rectify as necessary.
Replace the gasket/ O’ ring
Follow specific degasification procedure
in consultation with FLOWMORE
Check suction pipe friction losses.
Rectify/ modify suction line as
necessary.
Clear the obstruction to resume
cooling/flushing water supply into the
stuffing box.
Tighten gland nuts
Check quantity and size of gland
packings and repack the pump
Replace the worn out parts
Throttle the discharge valve to achieve
rated head. If it does not help trim the
impeller diameter in consultation with
FLOWMORE representative.
Replace drive motor with motor of
higher rating. Alternatively trim the
impeller diameter in consultation with
FLOWMORE representative.
Check the parts that are wearing for
proper clearance
Check the motor for its rated speed.
1. Replace the defective parts
2. Loosen the gland nuts
3. Adjust running clearance by top
adjusting nut. Alternatively replace
casing gasket with gasket of higher
thickness.
4. Check the rubbing parts for adequate
running clearance.
Realign the pump and driver
Back flush the pump or physically
dislodge the foreign object.
Tighten foundation bolts and the holdPage19
Flowmore Limited
bolts are loose
Pump operating at low discharge
head, hence delivering excess
quantity of liquid.
Suction and/or discharge pipes
inadequately supported
Excessive strain on suction and
discharge nozzles due to misaligned
suction and discharge pipes
Pump is cavitating
Pump overheats
10.
Mechanical defects :
i.
Bent shaft
ii.
Broken impeller
iii.
Rotating element binds
iv.
Packing gland too tight
v.
Worn out bearings.
A. Bearings :
i.
Misalignment
between
pump and driver.
ii.
Excessive / insufficient
grease/oil lubrication
iii.
Bent shaft
iv.
Rotating element binds
B. Stuffing box :
i.
Excessive packing gland
pressure
ii.
Water seal connection
plugged
iii.
Inferior grade of packings
used.
down bolts of pump and motor
Throttle the discharge valve to achieve
rated head. If it does not help trim the
impeller diameter in consultation with
FLOWMORE representative.
Ensure proper supports below suction
and discharge pipes.
Align the suction and discharge pipes
with respect to pump nozzles.
Locate and correct the system problem
and ensure pump operating at design
point.
i.
Replace the defective part
ii.
Replace the defective part
iii.
Check the rubbing parts for
adequate running clearance.
iv.
Loosen the gland nuts
v.
Replace with new bearings.
i.
Realign the pump and driver
ii.
Check the lubricant for its
suitability and quantity.
iii.
Replace the defective part
iv.
Check the rubbing parts for
adequate running clearances
v.
Loosen the gland nuts
vi.
Unplug and connect cooling
water line
vii.
Use good quality packings with
adequate
lubricating
properties.
LIST OF TYPICAL CROSS SECTIONAL ASSEMBLY DRAWINGS:
SR. NO
DRAWING NO.
1
CSD-NCP-HP-001-00
2
CSD-NCP-HP-002-00
3
CSD-NCP-HP-003-00
4
CSD-NCP-DP-004-00
5
CSD-NCP-DP-005-00
6
7
CSD-NCP-VP-006-00
CSD-NCP-VP-007-00
DESCRIPTION
Cross Sectional Drawing for Horizontal Non Clog Pump for Low to Medium Head
Applications
Cross Sectional Drawing for Horizontal Non Clog Pump for High Head Applications
Cross Sectional Drawing for Horizontal Non Clog Pump for Very High Head
Applications
Cross Sectional Drawing for Dry Pit Vertical Close Coupled Non Clog Pump for Low
Head Applications
Cross Sectional Drawing for Vertical Close Coupled Dry Pit Non Clog Pump for High
Head Applications
Cross Sectional Drawing for Vertical Wet Pit Pump (Oil Lubricated)
Thrust Stand Assembly for Vertical Wet Pit Pump
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
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Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page22
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page23
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page24
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page25
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page26
Flowmore Limited
Installation, Operational and Maintenance Manual
Document No- 014-00-21E14-SC-RD
Page27
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