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VI Rev07 PDF
VI Rev07 PDF
GUARANTEE ............................................................................................................ 3
HOW TO USE THIS MANUAL .................................................................................. 4
1. SAFETY PRECAUTIONS..................................................................................... 7
1.1 General.........................................................................................................................................7
1.2 Major warnings .............................................................................................................................8
1.3 Components and auxiliaries .........................................................................................................9
1.4 Pump to be scrapped ...................................................................................................................9
4. INSTALLATION.................................................................................................. 15
4.1 General....................................................................................................................................... 15
4.2 Pump installation and foundation ............................................................................................... 15
4.3 Pump - motor alignment ............................................................................................................. 17
GUARANTEE
Seller, Weir Gabbioneta srl, guarantees to Buyer that the equipment at the time of
shipment is free from defects in material and workmanship and conforms in all
respects to the agreed technical specifications. This guarantee shall be ineffective
and shall not extend to:
This guarantee shall not cover normal wear parts (as per API 610 - IX edition - par.:
3.33), such as wearing rings, bushings, shaft seals and bearings, nor gaskets / O
rings, after pump disassembling.
This guarantee shall be ineffective if the guarantee period indicated in the Purchase
Order, with reference to the time of shipment, has elapsed.
Sellers sole obligation under the foregoing guarantee is limited, at Sellers option, to
replacing or repairing defective equipment.
The guarantee contained herein is made only to and for the exclusive benefit of
Buyer and does not extend to any subsequent purchaser or user of the equipment,
unless specifically mentioned in the Purchase Order.
For those pumps supplied with optional lubrication systems, control systems
accessories/instrumentation and/or driver, refer to the combined description,
operation and maintenance procedures in the Documentation supplied with
this manual.
The instructions contained in this manual do not attempt to cover all details, nor
provide for every possible contingency to be met in connection with installation,
operation and maintenance.
The supplying of instructions does not imply in any manner that Weir Gabbioneta srl
accepts liability for work carried out by a customer or contractor personnel. Liability
is limited to and as stated in our Terms and Conditions of Sale.
Should further information be desired, or should particular problems arise which are
not covered sufficiently for the purchasers purposes, the matter should be referred
to Weir Gabbioneta srl. All inquiries regarding installation, operation and
maintenance, spare parts or service should be directed to:
2 G c T1/T51
2
RICEVUTA ORG. NOTIFICATO2
ATEX/ITA/40.2003.4876/ 0081
receipt notified body
ANNO DI COSTRUZIONE
year of construction
POSIZIONE
item
TIPO POMPA
pump type
MATRICOLA
serial number
PORTATA
m3/h
capacity
PREVALENZA
m
total head
VELOCITA
rpm
speed
TIPO CUSCINETTI
bearing type
MASSA TOTALE
kg
total mass
TEMPERATURA AMB.
C
ambient temperature
MAWP barg at C
CORPO POMPA
pump casing
HYDROTEST barg
MAWP barg at C
CAMICIA VAPORE
steam jacket
HYDROTEST barg
1
The marking herein reported is to be intended as an example. See the note reported on the
following page about the temperature class.
2
This information is indicated only for category 2 equipment.
STATEMENT
If CE marking is included in the nameplate, the pump complies with the following
European Directives:
Machinery Directive 98/37/CE
PED1 97/23/CE
Electro Magnetic Compatibility Directive 89/336
and amendments.
If x marking is included in the nameplate, the pump complies with the following
European Directives:
ATEX 94/9/CE
Note: the plant responsible must assure that the pumped fluid temperature
allows to respect the temperature class required in the installation area.
1
PED applies only to pump components (reservoirs, etc.)
1. SAFETY PRECAUTIONS
1.1 General
This pump has been designed to provide safe and reliable service within the
designated specifications. It is a pressure containing, rotating machine; therefore,
good judgment and proper safety practices must be exercised by responsible and
qualified personnel to avoid damage to the equipment and surroundings or possible
serious injuries.
It is important that due consideration is given to all hazards resulting from the
presence of:
electrical power
hot liquids
hot surfaces
rotating parts
toxic gases
flammable liquids and gases
explosive atmospheres
environmental noise
Noise levels of the pump unit are given in the Data Sheet supplied in the
Documentation that goes along with this manual.
This manual contains four types of hazard seriousness messages. They are as
follows:
Hazards that could result in serious injury to the pump and others,
or extensive damage to the pump unit or surroundings
Hazards that could result in damage or malfunction to the pump or its parts,
leading to subsequent downtime and expense.
DO NOT START OR OPERATE this pump unless the installation has been verified
to be correct and all pre-startup safety and control functions have been checked.
DO NOT START OR OPERATE this pump unless you have a complete
understanding of the location and function of all upstream and downstream
equipment that may affect the flow of liquid to or from the pump.
NEVER WEAR NECKTIES or other loose clothing while in the proximity
of the pump or auxiliary equipment.
NEVER DISCONNECT THE SUCTION OR THE DISCHARGE FLANGES
of the pump, without first isolating the pump from the inlet and outlet
systems by closing and tagging block valves. Open connections
not protected with block valves should be covered with blind
flanges, rated for the pressure conditions that may prevail.
Both ALL PUMP DRAINS and ALL HEATING JAKED DRAINS
must be opened to depressurize the pump.
DO NOT REMOVE any covers, guards, gland housings,
drain covers, plugs etc, while the unit is operating.
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS
that are not described in this manual.
The user must to be sure that product will be disposed in accordance with the
regulations in force, so as to prevent any potential negative consequences to the
environment and human health.
Weir Gabbioneta srl VI pumps are vertical single stage pumps, with a side discharge
column, typically used as sump pumps.
Discharge column, line shaft and support column may consist of multiple sections,
depending upon the pump setting, specified on the Data Sheet.
The discharge column is mounted with a sliding fit through the sole plate, to account
for thermal expansions, if any.
As a standard, VI pumps do not require mechanical shaft seals, since the sump and
the support column are at atmospheric pressure.
A soft packing is normally fitted in the stuffing box to prevent inlet of dirt into the
sump or outlet of vapours or odours.
When the sump is under vacuum or under pressure, or in hazardous areas, the
Purchase Order and the pump Data Sheet specify the use of mechanical seals
(special VI applications).
These special applications are not covered by the present instruction manual.
VI pumps are also applied at high temperatures for molten salts. In these
applications, support column and pump discharge column are jacketed and heated
to prevent crystallization.
On semi-open impeller pumps the suction casing can be fitted with wear plates, if so
required by the Data Sheet.
Bearing housings can be air-cooled or water cooled, depending upon the conditions
of service, specified on Data Sheet and Purchase Order.
As a standard, bearing housings are equipped with replaceable labyrinth end seals
and deflectors.
If specified by the Purchase Order, the end seals (or bearing isolators) can be of the
Inproseal type (non contacting oil seals of the labyrinth type) or magnetic type.
This VI pump has been specifically built for the application mentioned in the data
sheet. Information about the main characteristics of this pump is recorded :
Pump nameplate and certified drawing specify the pump serial number. This
number is a unique identifier of the pump; it must be specified when ordering
replacement parts and in all correspondence with the factory.
The serial number is also stamped on the discharge flange O.D., for identification
and reference purposes. It is an alphanumeric code of 5 digits and 1 letter (item).
After testing, the pump is prepared for shipment according to procedures G.08.01.01
or G.08.01.02 depending on which type of storage is chosen: the standard or long
term one.
Prior to crating, the pump unit is given a final inspection from a quality inspector,
who checks for completeness and appearance.
3.2 Lifting
Skid mounted units should remain on their respective skids until placement on their
permanent foundations. When a pump unit is on its skid, the skid should be used for
lifting. Pump units shipped on baseplates can be lifted using lifting provisions on the
baseplate.
For correct sling selection, refer to the unit gross weight specified outside the
crating.
Lift slowly and carefully to ensure stability and safety.
NEVER attempt to lift the unit USING pump or driver eyebolts. These
eyebolts are intended for lifting the individual components only. Using any
of the eyebolts to lift the entire unit presents a SERIOUS SAFETY HAZARD.
1
Refer to API Practice 686 - 1996
Weir Gabbioneta srl pumps are normally prepared for short term storage up to 6
months.
The pump should remain in its container, with all covering left intact. Indoor storage
is preferred. The unit should be stored in a clean non-corrosive atmosphere and
protected against damage, loss, bad weather and foreign material, such as dust or
sand, where temperature and humidity values should be maintained at levels
preventing condensation (T = -1050C, R.H. < 90%).
Crates shall be placed on solid flooring but shall not be placed straight on floor.
Temperature control is not necessary.
The pump should remain in its container, with all covering left intact. Indoor storage
is preferred. The unit should be stored in a clean non-corrosive atmosphere and
protected against damage, loss, bad weather and foreign material, such as dust or
sand, where temperature and humidity values should be maintained at levels
preventing condensation (T = -1050C, R.H. < 90%).
Crates shall be placed on solid flooring but shall not be placed straight on floor.
Temperature control is not necessary.
3.5 Preservation
Remove the packing material and check all items are in accord with the packing list.
Ensure that parts are not missing or damaged. Handle all parts with care.
If any parts are missing from the shipment, contact Weir Gabbioneta srl.
Ensure that loose parts are not discarded with the packing material.
Before to put it into service, the pump must be checked in order to assure its
functionality. A Weir Gabbioneta specialist should carry out this check.
If the equipment has been stored for more than 6 months (if standard storage is
applicable) or more than 18 months from last long term storage preparation, the
equipment shall be put into service by a Weir Gabbioneta technician,
otherwise the warranty expires.
When the equipment is installed on the plant but not yet put into service it is
recommended to fill in the bearing bracket and, if applicable, the seal reservoir.
At least once a month, it is advisable to turn by hand all the rotating systems to keep
free the internal parts with reduced clearance and the mechanical seal. Verify that
the external metallic parts made of non-inox material are correctly protected against
corrosion (with product equivalent to Valvoline Tectiyl) and restore the protection if
necessary.
Two different situations may occur, they request different means of conservation:
a) the equipment is installed on the plant, it is completely empty and never started:
. internal and external surfaces protections are still operating and it is enough that
the equipment is installed in a clean non-corrosive atmosphere and protected
against damage, loss, bad weather and foreign material, such as dust or sand.
Temperature and humidity values shall be maintained at levels preventing
condensation (T = -1050C, R.H. < 90%).
. If equipment is not put into service within the foreseen storage period, a Weir
Gabbioneta technician shall check it before to start it, otherwise the warranty
expires.
b) the equipment was installed on the plant and started for a period to check it in
rated conditions, than it was stopped waiting for the real starting of the plant:
surfaces protections are not operating. Once stopped, the pump shall remain filled
with pumped fluid. Otherwise protections must be restored according to paragraph 5
of procedure G.08.01.04 possibly by a Weir Gabbioneta technician.
4. INSTALLATION (1)
4.1 General
Proper installation of pump and driver is vital for successful operation of the system.
It is for this reason that competent and experienced personnel should be employed
during installation.
Refer to the Certified Drawing in the Document enclosed with this manual, prior to
installation.
Refer to the certified outline drawing and carefully read all installation notes,
piping connection details, dimensions and any other special data.
Remove all protective coatings and foreign matter from the unit.
Provide a proper and adequate foundation for the pump sole plate or suction
barrel (if any).
Insert shims around each anchor bolt and level suction barrel flange.
Grout the suction barrel to the foundation as required.
A foundation or frame must maintain alignment under all normal and abnormal
conditions. This includes the way a foundation or frame is supported on the soil
and/or superstructure, soil settling, soil resonance, thermal distortion and piping
forces.
Sufficient space should be provided around and above the foundation to allow for
proper installation and maintenance.
On vertically suspended can pumps, the foundation shall be designed so that the
pump can is directly attached to the mounting plate and is removable without
damaging the grout. The foundation must be water tight.
A minimum clearance of 50 mm (2") should be maintained between the outside of
the can and the inner liner surface.
1
Refer to API Practice 686-1996
The foundation (or the support structure) must minimize vibration by being non-
resonant within the operating range of the pump unit.
Normal excitation frequencies (i.e.: 1- and 2-times running frequencies or blade-
passing frequencies) can cause abnormal vibrations.
Upon request, Weir Gabbioneta srl engineers can provide assistance in the design
and dynamic analysis of tuned foundations.
A certified outline drawing is furnished with each pump unit and is included in the
Documentation enclosed with this manual. This drawing includes dimensions for
locating anchor bolts, unit overall weight and single component weights, as well as
general information required to determine foundation dimensions and design.
Templates must be rigid enough to prevent bolts from shifting while concrete is
being poured. After concrete has been poured and before it has hardened,
recheck positions of anchor bolts.
The mounting plate or the frame shall be installed in accordance with the
construction drawing and leveled with a master level or a precision machinist's level.
Mounting plate level is to be set to within 40 m per meter (0.0005 in/ft) by adjusting
the jacking screws and inserting shims.
After the installation of the motor, motor to pump alignment must be checked, prior
to inserting the bolts on the coupling halves.
Generally no operation is required, because alignment between motor and pump
shaft is ensured by the rabbet joint provided on motor to pump mounting surface.
It is however advisable to check concentricity of the motor fit and perpendicularity of
its mounting surface, by turning the motor shaft by hand, after installing on this one
a bracket carrying a dial gauge. Both readings shall not exceed respectively 0.05
and 0.025 mm per each 100 mm of DBSE.
5.1 Warnings
The operator should read Section 2 and the Documentation enclosed with this
manual to become familiar with the pump, before attempting to start and operate it.
DO NOT START OR OPERATE this pump unless the INSTALLATION has been
verified to be CORRECT and all SAFETY FUNCTIONS have been checked.
Maximum temperature of pump open surfaces is similar to the pumped fluid one.
If the pumped fluid temperature is too high, pump surface could burn if touched.
5.2 General
The following recommended start-up and operation procedures apply to the basic
pump configuration. For information on any optional equipment refer to the
Documentation enclosed with this manual.
The following is a recommended list of items that should be checked before start-up:
examine suction and discharge piping for manually operated check valves
and recirculation line. All check valves must be fully open, before start-up;
identify the pipe section fitted with the temporary suction strainer (if any). The
installation of this strainer (refer to fig. 1) is a recommended practice to
prevent dirt or welding slags from entering the pump, which may damage the
impeller and other internal components. The strainer must be made in
stainless steel, with an open area from 3 to 5 times the cross section of the
suction piping (60 mesh is a recommended practice);
check that strainer is not clogged;
identify the differential pressure gauge, installed on the strainer. This gauge
must be monitored to detect clogging and need for cleaning or replacement.
visually inspect the unit, the grouting and the anchor bolts for any missing or
improperly fitted component;
Several lubrication options are available; the selected option, installed on this pump,
has been specified in the Purchase Order.
Unless otherwise specified, bearing housings are arranged for oil lubrication. The
bearing adapter sleeve, running on the pump shaft picks up oil from the reservoir in
the bearing housing and conveys it to the bearing.
The oil level within the bearing housing must be sufficiently high to allow the sleeve
to run in the oil. However, an oil level that is too high may result in oil leakage past
the shaft seals or in excessive friction.
Check oil level in the glass level gauge installed on the bearing housing.
For details on the recommended type of oil refer to the Lubricant List, in the
Documentation enclosed with this manual.
Use only clean, fresh (non corrosive) water. Maximum allowable cooling water
pressure is indicated on the pump data sheet.
Cooling water flow should be adjusted to maintain oil temperatures in the sump
between a minimum of 40 C ( 100 F) and a maximum specified by applicable
standards (e.g.: max 82 C / 180 F for a maximum ambient temperature of 43 C or
110 F).
Before starting the pump for the first time, open all bearing housing drains and allow
any residual oil to drain. Then close the drains and fill the bearing housings with a
light, warm oil. Rotate the shaft and then drain this oil.
The oil recommended for permanent operation (see below) should now be added to
the bearing housing through the vent plug hole, after removing the vent plug and the
constant level oiler, until oil comes out from the oiler hole.
Re-install the oiler and add oil as necessary through the constant level oiler, until the
oil level in the level gauge is correct.
The constant level oiler maintains a constant level of oil in the bearing housing as
long as there is oil in the bottle and the oiler operates properly.
The presence of oil in the constant level oiler does not necessarily
mean that oil in the bearing housing is at the proper level.
During pump operation, regularly check oil levels, bearing temperatures and
vibration levels.
Bearing temperatures may vary depending on type and size. Continuously rising
bearing temperatures or abrupt temperature rises are indicative of premature wear
of bearings and short-term failure.
antifriction bearing
87 95
bearings outer race
thrust bearing
93 115
shoe
hydrodynamic
bearings
line bearing 93 115
shoe
proximity probe
65 100
(m peak to peak)
velocimeter
5.4 8.5
(mm/s RMS)
These limits apply to the broad band r.m.s. values of vibration velocity and
displacement, in the frequency range from 10 Hz to 1000 Hz, and are valid for
operation at the rated flow rate of the pump.
The vibration levels indicated on the table are applicable only for the vibration
produced by the machine itself and not for the vibration that is transmitted to the
machine from external sources.
For all cryogenic services venting connection in discharge head must be always
opened during both operation and stand-by conditions.
Pumps that are not running continuously are in standby operation, where they
must be ready to operate at any time with little or no advance notice.
Materials used in pump construction vary with the characteristics of the pumped
liquid. These materials were selected according to the original rating of the pump.
NEVER attempt to RE-RATE a pump without the assistance of the
manufacturers representative misapplication of materials COULD
result in serious equipment damage and/or personal injury.
In some applications, both the seal flushing and the heating pump system must be
maintained open during pump shutdown, to prevent the formation of crystals.
6.1 Introduction
This pump is a high quality machine that has been carefully assembled and
thoroughly tested at the factory. It requires periodic maintenance and service. This
section describes periodic maintenance requirements.
Refer to Section 8 for major service and overhaul instructions.
Maintenance requirements may vary with the application and the service conditions.
The following guidelines are recommended for pumps operated under normal
conditions. It is also recommended to establish a Maintenance Program.
Every 6 months
Check cooling jacket on bearing housings for sludge or
sediments.
Weir Gabbioneta srl recommends that the pump be periodically shutdown and
subjected to a major inspection. The frequency of this inspection will depend on the
service conditions, the convenience of scheduling the shutdown and the users
experience with similar machines.
Wear Rings Wear, signs of foreign matters Treat with fine emery cloth
Sleeve Wear, signs of foreign matters Treat with fine emery cloth
Weir Gabbioneta srl recommends that only original parts be used in their pumps.
The use of Weir Gabbioneta srl parts ensures that the replacement components are
manufactured from the highest quality materials, exacting tolerances and
specifications, thereby ensuring efficient and long-lasting operation, under service
conditions that the pump was built for.
When required, Weir Gabbioneta srl can supply the most frequently requested spare
parts on an emergency basis, for shipment worldwide.
The following is a list of recommended spare parts that should be kept in inventory
at the users plant to handle all repairs, excepted the most extensive ones:
The serial number, identifying the pump, should be used in all inquiries and parts
orders. The serial number is an alphanumeric code, consisting of 5 digits and 1
letter (item).
This number appears on the nameplate and is stamped on the discharge flange
O.D. of the pump casing.
This Section should be consulted when the pump is not operating satisfactorily.
The following table lists the most common symptoms, probable causes and
corrective actions that should be taken.
If the problem cannot be completely remedied using the table, refer your questions
to:
When contacting the factory, it is of the greatest importance to provide suction and
discharge pressures, power input, rotational speed as well as electric motor data or
steam pressures, in the case of turbine driven equipment.
Pump does not Pump and suction pipe have Thoroughly vent suction pipe and pump
deliver liquid not been filled completely with casing.
liquid
Pump does not 1. Air leaks into suction pipe Check and tighten bolts on suction flange.
deliver enough Replace gasket on suction flange.
liquid 2. Suction lift too high Check installation against drawings
3. Speed too low Check driver electrical or steam
connections
4. Wrong direction of Change power input cables to motor.
rotation Check rotation arrows on turbine and
pump. If incompatible, review terms of
Purchase order.
5. Impeller(s) damaged Replace impeller(s)
6. Worn wear rings Replace wear rings
Pump loses 7. Air or gas in liquid - see Tighten bolts on suction piping or replace
prime after start- n 2 & 3 gaskets on suction line.
up
Insufficient 8. Viscosity too high or see Check actual liquid against pump data
discharge n 4 & 7 sheet
pressure
Pump overloads 9. Specific gravity or Check pump and motor data sheet.
driver viscosity of the pumped
liquid different from the
rated ones
10. Head and capacity Adjust discharge valve
different from the rated
ones
11. Wrong alignment Re-align the unit - see Section 4
12. Mechanical defects : bent Disconnect coupling and check shaft
shaft ; internal rubbing runout. Replace shaft if runout exceeds
0.025 mm at shaft end - Refer to Section
8.
13. Packing or mech. seal Loosen packing gland bolts.
spring too tight, causing Check setting of mechanical seal.
excessive friction
Pump vibrations 14. Pump operates at too low Open valve on discharge piping
capacity
15. Misalignment Disconnect coupling and check alignment
as per Section 4.
16. Worn bearings Replace bearings Refer to Section 8.
17. Unbalanced coupling Remove coupling halves and check for
unbalance.
18. Piping strain Check piping supports. Refer to Section 4.
Bearing failure 19. Improper lubrication Verify that the proper lubricant is being
used. Check oil for sediments and
condensate.
20. Improper water cooling Adjust water-cooling to maintain oil
temperature as recommended by Section
5.
21. Misalignment See Vibrations n 16
22. Excessive thrust See Mechanical defects n 13
23. Rust Rust may develop during improper
storage of the unit. Refer to Section 3.
Seal failure 24. Improper flushing of seal Check flushing line(s) for circulation of the
cavity flushing liquid
25. Wear of the shaft sleeve See Mechanical Defects n 13
When RESTARTING a pump after repair or maintenance, always treat the pump
as if it were A NEW PUMP being started for the first time. Refer to section 5.
8.2 General
Any pump part can be replaced in the field using instructions presented in this
section, if qualified personnel and facilities are available. If not, it is recommended
that a service representative from Weir Gabbioneta srl be employed to make the
field repairs.
VI pumps are fitted with antifriction bearings mounted inside a bearing housing that
can be air- or water-cooled, as specified by Purchase Order and Data Sheet.
Lip-seals may be provided on request. In this case the oil deflector is press-fitted
onto a shaft sleeve that runs under the lip seal. Unscrew set screws and remove oil
deflector and shaft sleeve.
Inproseals are optional, non-contacting oil seals that replace standard labyrinth type
bearing housing seals. Refer to the Documentation enclosed with this manual for
removal and installation of Inproseals.
Install shims (65/5) and the new bearing (25/8) on the adapter sleeve (43).
Tighten oil ring (75) according to torque values given on Table 1 (page 43).
Install adapter sleeve (43) with bearing and oil ring on the shaft (5/3).
Tighten locknut according to torque values given in Table 1 (page 43) and
check pump for free rotation.
Bend one tab of the lockwasher and complete the installation of the upper
(38/5) and lower (38/2) bearing housing covers.
Re-install oil nipple (59/2) with plug, shaft key (14/1) and upper coupling half.
Lock the setting tabs into the slot on the mechanical seal sleeve.
Unscrew the set screws on the mechanical seal cartridge, according to the
instruction given in the Documentation enclosed with this manual so as to
loosen the seal cartridge from the shaft.
Unscrew screws (28/27) on upper coupling half and allow the rotor to
gradually reach its lowest setting.
Unscrew screws (28/41) of the split ring (20/19) and remove this one.
Slide the upper coupling half (410/5) sufficiently upwards to allow removal of
the coupling spacer (410/3).
Unscrew screws (28/27) on lower coupling half and remove the coupling
spacer (410/3).
Unscrew screw (28/16) of the lower coupling half (410/4).
Using a suitable puller, remove the half coupling (410/4) and the key (14/7)
from the pump shaft
The mechanical seal cartridge can now be removed according to the
instructions contained in the Mechanical seal Instruction manual - Refer to
the Documentation enclosed with this manual.
All SHARP edges must be REMOVED before mounting the mechanical seal.
To replace the mechanical seal, follow the instructions given in the Documentation
enclosed with this manual and reassemble the pump in reverse sequence, i.e.:
check the concentricity and perpendicularity of seal chamber with pump shaft
axis (se points 2.7.3.11 2.7.3.13 of API 610 8 Ed.). The eventual required
corrections can be done acting on bearing housing centering.
tighten the screws on the seal gland;
Install coupling halves and spacer. By tightening screws (28/27) on upper
coupling half the complete rotor is lifted to reach its original setting.
tighten the set screws on the seal sleeve;
disengage setting tabs.
reinstall the split ring (20/19) against the hub of the coupling half and tighten
the screws (28/41)
Weir Gabbioneta srl VI pumps are vertical single stage pumps, with a side discharge
column, typically used as sump pumps.
Discharge column, line shaft and support column may consist of multiple sections,
depending upon the pump setting, specified on the Data Sheet.
The discharge column is mounted with a sliding fit through the sole plate, to account
for thermal expansions, if any.
The impeller is secured to the shaft with a sliding fit and a key.
Separation of the impeller from the shaft may require a puller,
due to the presence of crusts or scales.
DO NOT apply HEAT to ease removal of impeller or sleeve.
Unscrew nuts on stud bolts (36/7), (36/10) and screws (28/22) and remove
casing (1) from discharge and support column.
Remove bearing bushing (147) from pump casing (1) after unscrewing nuts
on stud bolts (36/48) with a suitable puller.
Unscrew nuts on screws (54/34) and remove column (151/1).
As a standard, intermediate bearing bushings (147/1) can be removed from
their seats with a puller. In special VI versions bearing bushings are mounted
with screws on the intermediate bearing, to facilitate replacement. Remove
screws (28/12) to remove the bushing.
Remove all columns in sequence. During pump disassembly, the shaft must
be accurately supported to prevent bending.
Before removing the upper column (151/3), unscrew nuts on gland (88), remove the
gland and the packing (89) from the stuffing box.
Remove column (151/3) from soleplate after unscrewing nuts on studs (36/8).
Remove discharge elbow (180) by unscrewing nuts on stud bolts (36/9).
Remove O-ring (89/1) or packing (89/5) and remove discharge column from
soleplate.
Remove sleeve (87/2) from the shaft, using a suitable puller. Remove key
(14/2).
Unscrew set screw (185/6) on shaft coupling (410/6) and slide the coupling
along the shaft until split rings (20/4) can be removed.
Remove keys (14/21).
Remove shaft sleeves (87/3), keys (14/5) and circlips (20).
Remove circlip (20/5) and upper shaft sleeve (87) with "O" ring (19).
Inspect impeller wear rings for wear or scoring (closed impeller version).
Inspect the casing wear rings for wear or scoring (closed impeller version).
Inspect the suction casing or the wear plate for wear or scoring (open
impeller version).
Replace wear rings when the clearance between stationary and rotating parts
has doubled with respect to the value indicated on the data sheet.
Replace the suction casing when the wear is in excess of 2 mm.
Replace the wear plate when the hardened surface has been worn out.
Inspect the pump shaft for scoring or corrosion. Shaft and shaft sleeves
should not be corroded nor oxidized. In case of corrosion, replace the part.
Impeller and casing wear rings can be removed using a suitable puller, after removal
of the set screws.
Replacement of wear rings requires drilling and tapping of new holes for the set
screws.
9.3 Balancing
Before proceeding to the balancing, calculate the residual admissible weight with the
formula:
where:
p = residual admissible weight grams
Pe P = impeller weight
p kg
r r = impeller radius where material is removed mm
e = residual admissible eccentricity of the
center of gravity (C.G.) m
The value of e is given by a diagram and can be found in the following table for the
most commonly used rotational speeds.
Balance each impeller by removing some material from the discs, at radius r, by
milling or grinding.
From the upper end of the pump, reinstall discharge column, shaft sections with
sleeves and columns as previously described, in reverse sequence.
Install pump casing (1) after coating sleeve (87/2) with light oil.
Tighten nuts on stud bolts (36/7), (36/10) and screws (28/22). Torque as
per Table 1 (page 43).
Install key (14), impeller (6), lockwasher (64/2) and impeller nut (94).
Tighten the impeller nut and bend the lockwasher tab.
Install the suction casing (3) and tighten nuts on stud bolts (36). Torque as
per Table 1 (page 43).
Install the suction strainer (11).
Install packings and gland (88) in the stuffing box. Do not tighten nuts on
stud bolts (90), until the pump is in operation.
Lift the pump and install it into the sump.