80274-01 r0 manual installation operation aquabold

ERI AquaBold Pump INSTALLATION, OPERATION, AND MAINTENANCE MANUAL

2 x 3 x 5 3 x 4 x 7 4 x 6 x 9

Energy Recovery Inc 17608 Commerce Drive, New Boston, MI 48164

Tel: 1-734-639-5000 / Fax: 1-734-639-5001 www.energyrecovery.com

ERI AquaBold Pump Manual

Energy Recovery Inc Page i 80274-01 r0

TABLE OF CONTENTS

1 INTRODUCTION .....................................................................................................................1

1.1 About This Manual .......................................................................................................1

1.2 Available Support Resources .......................................................................................1

1.3 Icons Used in This Manual ..........................................................................................1

2 Safety Precautions ......................................................................................................................3

3 Critical Startup Checklist ...........................................................................................................4

3.1 Know Your Machine ....................................................................................................4

3.1.1 Driver Instruction: ........................................................................................4

3.1.2 Piping: ..........................................................................................................5

3.1.3 Instrumentation: ...........................................................................................5

3.1.4 Mechanical Seal: ..........................................................................................5

3.2 Before any operation of the pump - CRITICAL ..........................................................6

3.2.1 Check Driver Rotation: ................................................................................6

3.2.2 Starting Pump...............................................................................................6

3.2.3 Once running, check ....................................................................................6

4 RECEIVING YOUR UNIT .......................................................................................................7

4.1 Inspection .....................................................................................................................7

4.2 Short-Term Storage: 1 day - 6 months .........................................................................7 4.3 Long-Term Storage: 6 months or more .......................................................................7

5 INSTALLATION ......................................................................................................................8

5.1 Mounting ......................................................................................................................8

5.2 Coupling Installation ..................................................................................................10

5.3 Filtration .....................................................................................................................10

5.4 Guidelines for Installing the Suction and Discharge Piping ......................................10

5.5 Flushing ......................................................................................................................11

5.6 Motor Rotation ...........................................................................................................12

6 STARTUP ................................................................................................................................13

7 PUMP OPERATION ...............................................................................................................14

7.1 Suction Conditions .....................................................................................................14

7.2 Discharge Conditions .................................................................................................14


Energy Recovery Inc Page ii 80274-01 r0

7.3 Minimum Flow Conditions ........................................................................................15

7.4 Maximum Flow Conditions ........................................................................................15

7.5 Drivers ........................................................................................................................15

7.6 Entrained Gases ..........................................................................................................15

8 SERVICING/MAINTENANCE ..............................................................................................16

8.1 Guidelines ...................................................................................................................16

8.2 Mechanical Seal Replacement ....................................................................................16

8.2.1 Seal Removal .............................................................................................16

8.2.2 Seal Re-installation ....................................................................................18

8.3 Pump Disassembly .....................................................................................................20

8.4 Pump Reassembly ......................................................................................................26

8.5 Thrust Bearing Inspection/Replacement ....................................................................27

9 TROUBLESHOOTING ...........................................................................................................32

9.1 Pump Troubleshooting ...............................................................................................32

9.2 Mechanical Seal Troubleshooting ..............................................................................35

10 ERI CUSTOMER/FIELD SUPPORT .....................................................................................37

11 REVISION LOG ......................................................................................................................38

12 DRAWINGS AND DATA .....................................................................................................38

Figures

1 Pump Lifting Diagram

2 Mounting Diagram

3 Shim Diagram

4 Temporary Filter Setup During the Flushing Process

5 Pump Lifting Diagram

Tables

1 Seal Gland Nut Torque Values

2 Impeller Tolerances

3 Torque Values

4 Pump Troubleshooting


Energy Recovery Inc Page iii 80274-01 r0

5 Mechanical Seal Troubleshooting

ERIAquaBold Pump Manual

Energy Recovery Inc Page 1 80274-01 r0

1 INTRODUCTION

1.1 About This Manual

This manual contains instructions for the installation, operation, and maintenance of Energy Recovery, Inc.s (ERIs) AquaBold high-pressure, multistage centrifugal pump. This information is provided to ensure the long life and safe operation of your AquaBold pump. This manual is intended for use by personnel with training and experience in the installation and operation of fluid handling systems.

ERIs AquaBold pump is intended for clean water or liquid applications where high efficiency and low maintenance are important considerations. This pump offers optimal performance, durability, and reliability, with minimal maintenance. Our superior materials of construction, enhanced corrosion resistance, and improved bearing and debris management will provide you with years of service life.

The ERI AquaBold pump features our proprietary Hiperax hydrodynamic water lubricated thrust bearing, which eliminates the balance drum/disc, balance chamber, and return line. The Hiperax bearing reduces complexity with its efficient and compact design. All radial bearings, interstage bushings, and wear rings are constructed to allow closer running clearances and greater efficiency. A single, unitized mechanical seal is employed on the suction side of the pump and is designed for easy inspection and maintenance.

Typical uses of the ERI AquaBold pump include reverse osmosis high pressure feed service, boiler feed, nitrogen oxide (NOx) suppression, pollution control, and hydrocarbon processing. The ERI AquaBold pump can be used as the high pressure pump for systems utilizing any type of energy recovery device, including the ERI Turbocharger and PX Pressure Exchanger devices.

1.2 Available Support Resources

ERI technicians are based worldwide and are available to assist you. ERI provides many technical services with the goal of making your project a success. ERI technicians are available for commissioning, process, and instrumentation drawing reviews (P&ID) and technical consultation. We are always available by phone to answer any system design or operational questions at 1-510-483-7303 and ask for Technical Support. Please go to our website at www.energyrecovery.com to find local contact information in your area or e-mail our service team at [email protected] for additional information.

1.3 Icons Used in This Manual

The following icons (symbols) are used to indicate specific types of information

Good ideas to use: A reminder to do something.



Equipment use alert: Failure to follow these procedures may result in damage to the equipment.

Safety alert: Failure to follow these procedures can endanger you or others

Electrical hazard: Failure to follow these procedures can endanger you or others.



2 SAFETY PRECAUTIONS

Suggested Safety Instructions:

During installation, maintenance or repair of ERIs AquaBold pump, safety systems should be installed prior to initial operation or before attempting any repairs. Failure to take responsibility for safety may lead to injury of operator or others.

The ERI AquaBold pump has been designed to provide safe and reliable service. However, it is industrial rotating machinery that creates high pressure. Therefore, operators and personnel must exercise good judgment and proper safety practices to prevent injury and avoid damage to the equipment and surrounding areas. It must be understood that the information contained in this manual does not relieve operation and maintenance personnel of the responsibility of exercising normal good judgment in the operation and care of this product and its components. The safety officer at the location where this equipment is installed must establish a safety program based on a thorough analysis of local industrial hazards. Proper installation and care of shutdown devices and over-pressure and over-flow protection equipment must be an essential part of any such program. In general, all personnel must be guided by all basic rules of safety associated with high-pressure equipment and processes. Operation under conditions outside of those stated in the pump datasheet can result in damage to the pump.

Lock-Out/ Tag-Out Guidelines:

Follow your companys Lock-Out/Tag-Out procedure when servicing ERIs AquaBold pumps.



3 CRITICAL STARTUP CHECKLIST

3.1 Know Your Machine

Before servicing and starting up the ERI AquaBold pump, read the entire manual and carefully review the specification sheet, the outline drawings, and performance curves. It is important to become familiar with this pump before start-up and operation.

1. Report any external damage to the pump before proceeding.

2. Verify that the pump has been properly installed as specified in this manual.

3. Verify that the feed water quality meets the ERI specifications. Debris in the feed water can DAMAGE pump bearings and seals.

4. Verify that the feed water supply pressure meets ERI specifications.

5. Verify that all the piping that feeds the pump has been thoroughly flushed.

6. Verify that you have the following information on site and available during start-up.

A. ERI AquaBold Pump Installation and Operations Manual

B. Pump Specification Sheet

C. Pump Curves

D. Driver Manual

E. Coupling Manual

F. Mechanical Seal Manual

3.1.1 Driver Instruction:

Carefully follow the installation and starting instructions provided by the manufacturer of the driver.

1. Verify that the driver is correctly aligned with the pump.

2. Verify that the correct driver bearing grease is on site.

3. Verify that the electrical connections are correct.

4. Verify all overload protections are in place and functioning properly.

5. Verify that the available electrical power supply meets the system requirements.



3.1.2 Piping:

1. Verify that there is no strain on the piping connections to the pump. The pump should NOT carry any loads induced by piping. Piping should be independently supported.

2. Make sure pump flange bolts, seal environment piping, and port connections are properly secured.

3. Verify that temporary start-up screens, if used, are properly installed, including differential pressure indicators (recommended).

4. Verify that the auxiliary piping conforms to ERIs drawings.

5. After the pump-motor assembly has been installed at its final location, verify again that all piping connections are lined up.

6. Verify that the tools required for normal start-up and maintenance activities are on site. See the ERI Recommended Tool List for your pump.

3.1.3 Instrumentation:

1. Verify the connection points of the instruments and open all root valves.

2. Calibrate and verify the set points of all measurement equipment (flow meters, current or ampere meters, pressure meters, pressure switches, etc.).

3. Verify that the variable-frequency drive (VFD) configuration, if used, is correct.

4. ERI recommends thatat a minimumthe following instruments are installed before operation.

Suction pressure indicator LOW suction pressure switch Feed water flow meter Discharge pressure indicator HIGH discharge pressure switch Voltage and current indication

3.1.4 Mechanical Seal:

Understand the installed mechanical seal type and how it operates. Some applications require special systems to control the environment of the seal and some applications require special seal flush systems. Always ensure that the seal is flooded before operation and that the seal is properly vented.



3.2 Before any operation of the pump - CRITICAL

Ensure that the pump has been flooded and that all air has been purged from the system. Air entering the pump during operation can damage seals and bearings. NEVER operate the pump dry for ANY length of time. Be sure to thoroughly flush the suction piping to the pump BEFORE connecting to the pump itself to ensure all construction debris is removed.

3.2.1 Check Driver Rotation:

Driver rotation must be in the same direction as the arrow on the pump casing. If the pump cannot be flooded during the check, uncouple the pump before checking driver rotation.

3.2.2 Starting Pump

Start pump with suction valve completely open while throttling discharge valve to bring pump to design operating point. If a VFD is used to control the driver, start the pump at the specified minimum flow rate and ramp up the pump to normal operating speed.

3.2.3 Once running, check

Check total head, flow rate, and power consumption against pump specification sheet. Check that specific gravity, viscosity and net positive suction head (NPSH) are in accordance with specification sheet. These conditions will significantly alter performance of pump. There should be no abnormal noise or vibration during running.

Please read the entire pump manual for more detailed information. Please contact [email protected] with any questions or to discuss problems.



4 RECEIVING YOUR UNIT

4.1 Inspection

When you receive the ERI AquaBold pump, check for any damage. If you find any, inform the carrier and ERI immediately.

Check the outline drawings and bill of material to ensure that all auxiliary items are properly included.

Check the pump shaft. Seal drag may cause it not to turn freely at first; this is normal.

4.2 Short-Term Storage: 1 day - 6 months

If the pump is to be stored near strong chemicals or salt water, protect it immediately. To do this, follow the steps from the long-term storage procedures below.

Protect the unit from moisture and dust.

Make sure that the factorys shipping covers the housing flanges and the seal ports are securely in place.

Carefully follow the storage instructions provided by the manufacturer of the motor or turbine.

4.3 Long-Term Storage: 6 months or more

If you store the ERI AquaBold pump for a long period of time, the following procedures are very important. If you require further instructions, please contact ERI.

Be sure the storage area is indoors.

Do not allow contact of airborne chemicals with the internal components of the unit.

If the unit is being stored near strong chemicals or salt water, protect it immediately.

Protect the unit from moisture and dust.

Turn pump shaft by hand approximately 1-2 turns every 1 to 2 months to prevent brinelling of motor bearings particularly if pump is stored in high vibration environment.

Make sure that the factorys shipping covers for housing flanges and seal ports are securely in place.

Prevent corrosion of the non-stainless steel components of the motor, and coupling.

After long-term storage, have an authorized ERI service engineer inspect all components and supervise any necessary repair to be sure that they work properly. Any components not made by ERI (except mechanical seals) must be inspected or replaced as determined by the



manufacturers authorized personnel, at the purchasers expense. Any Field Service work must be clearly stated at the time of purchase.

5 INSTALLATION

5.1 Mounting

A. Be sure to lift the pump hydraulic end in the proper fashion. NEVER lift the pump by its shaft as this will cause internal damage.

Figure 1: Pump Lifting Diagram

B. During pump installation, ensure that adequate surrounding space is available for inspection, operation and maintenance requirements.

C. The pump and driver for the frame mounted units should be bolted to a concrete foundation or an adequately supported structure substantial enough to absorb any vibration and to provide a rigid support.

D. Failure to provide adequate mounting per this manual can result in damage to the pump and therefore void the product warranty.

1. ERI recommends to choose a solid ground location and build the foundation form 3 inches larger overall than the bedplate.

2. Use bedplate anchor bolts of the same size specified in the outline drawing. Provide pipe sleeve with an internal dimension (I.D.) 2.5 to 3.0 times the bolt diameter. Provide flat washers between the bolt head and pipe sleeve to keep the bolt from slipping through the pipe sleeve. See Figure 2.



Figure 2: Mounting Diagram

3. Bolts should be of sufficient length so that they will project at least -inch or 6.35 mm above the nuts after allowing for bedplate, shim and nut thickness. Locate the bolts accurately according to the outline drawing.

4. Pour concrete and tamp or vibrate during the pouring process to ensure no hollow spot forms. This is especially important around the anchor bolts. Do not allow any concrete to fall inside the pipe sleeves.

5. Level off the concrete surface. Leave a rough finish to provide a good base for grout. Allow the foundation to cure for one week before installing.

6. Hoist the bedplate above the foundation and lower into position over the anchor bolts. Anchor bolts can be moved laterally in the hollow of pipe sleeve for ease of alignment with the holes in the base plate.

7. Using a precision level across the bedplate (front-to-rear and side-to-side), insert steel shims as required next to each bolt until the bedplate is level in all directions. See Figure 3. Secure the anchor bolt nuts finger tight only.



Figure 3: Shim Diagram

8. Provide a wood dam around the base perimeter of the bedplate and thoroughly wet the top surface of the foundation. The use of non-shrink grout is recommended. Grout should be of a consistency to flow out under the bedplate against the wood dam. Grout should be puddled continuously as it is poured to expel air and to completely fill the space under the bedplate. Fill to the level of the grout hole.

9. Allow the grout to harden for at least 48 hours. Tighten the anchor bolts.

5.2 Coupling Installation

Please refer to coupling manufacturers instructions included with your shipment.

5.3 Filtration

The thrust bearing of the ERI AquaBold pump is a hydrodynamic bearing. This bearing works on a fluid film layer. Debris infiltration into the pump can break this fluid film layer and cause damage to the bearing. Nominal filtration of 10 microns is required in order to protect the bearing from debris damage.

5.4 Guidelines for Installing the Suction and Discharge Piping

A. Good installation practice dictates that there should be a minimum straight length of pipe on the suction of the pump equal to three (3) times the suction pipe diameter. This is to allow the liquid to flow into the pump casing/impeller without turbulence. Furthermore, good installation practice dictates the use of suction piping at least one size larger than the pump flange and reduction of the pipe diameter at the pump flange. Never use suction piping of a smaller diameter than the pump suction inlet.



B. Both the suction and discharge piping should have no unnecessary elbows, bends and fittings as they increase friction losses in the piping. The size of pipe and fittings should be selected carefully to keep the friction losses as low as practical.

C. Suction and discharge block-and-bleed valve designs are recommended to isolate the pump during shutdown and to drain the process piping when removal of the pump is necessary.

D. Under no circumstances should the suction pipe be forced in order to align it to the pump suction inlet. The flange bolts should slip into the aligned flange holes without straining the piping.

E. If the ERI AquaBold pump is provided with flanges, gasket surfaces should be parallel and flange bolts should slip into the aligned flange holes without straining the pipe to fit the pump.

F. Piping layouts should be designed to provide sufficient support and flexibility to minimize forces and moments induced by the piping onto the pump.

G. The suction line should be cleaned thoroughly and a temporary strainer made of a corrosion resistant material of approximately 40 mesh must be installed during initial startup to protect the pump internals from damage by mill scale, welding slag, or other foreign particles. Failure to adequately clean the piping system prior to startup can void the pump warranty and cause severe internal damage to the pump.

H. All piping must be supported independently of the pump. Proper support for the suction and discharge piping is essential in order to avoid pipe strain on the pump casing.

I. Always provide a suction pressure gauge on all installations to monitor suction conditions. Install the gauge as close as possible to the suction flange. When temporary suction strainers are used, ensure that the gauges are installed on both sides of the strainer.

J. Always provide a discharge pressure gauge on all installations to monitor discharge conditions. Install the gauge as close as possible to the discharge flange.

K. Check valves should be placed on all the installations where back flow through the pump is possible. If a check valve is installed in the discharge line, provisions should be made to vent the space between the pump and the check valve or the pump may not prime.

5.5 Flushing

Suction piping must be flushed while disconnected from the pump. Flushing through the pump can introduce debris that can damage the pump internals.

The suction line should be clean and a temporary suction strainer of approximately 40 mesh made of a corrosion resistant material must be installed during initial startup to protect the pump from damage by mill scale, welding slag or other foreign particles during initial startup (Figure 4).



Figure 4: Temporary Filter Setup During the Flushing Process

1. Differential pressure gauge 2. Filter

Use a filter with a length 3 times the diameter of the piping. Conical filters have proved suitable.

5.6 Motor Rotation

Reverse rotation of your ERI AquaBold pump may damage the unit. Ensure that the motor shaft rotation is in the same direction as the arrow on the pump marked rotation.

A. Decouple the pump and motor shafts.

B. Be sure that the motor shaft turns freely by hand.

C. Determine that the motor is wired for the correct rotation by jogging the motor for one second. The motor direction can be verified by observing the motor shaft or fan.

D. If the motor rotation is in the incorrect direction, reverse the rotation by changing any two of the motor leads.



6 STARTUP

A. Review the pump specification sheet noting design parameters and possible seal system requirements.

B. Check to ensure that the driver has been serviced per the instructions supplied by the driver manufacturer.

C. Check to ensure that the screen has been installed in the temporary suction strainer with proper orientation

D. If a buffer fluid or external seal flush is required, ensure that this system is pressurized prior to flooding the suction. Failure to pressurize the buffer system will allow the process fluid to contaminate the buffer fluid and may also allow contaminants in the process stream to damage the seal face.

Starting your ERI AquaBold pump against a completely closed discharge valve will dead-head the pump and may damage the process seal and bearings.

E. Fully open the suction and discharge valves to flood the suction. If there is a check valve in the discharge piping, ensure that the space between the pump and check valve is vented.

F. Purge or vent all high points in the suction and discharge lines.

G. After the suction is flooded, adjust the control valve to approximately 50% of normal flow. This is necessary to prevent overloading of the driver and to prevent the pump from operating off the end of the curve at startup.

During startup, pay close attention to the discharge pressure gauge. The pressure should rise quickly and remain steady. If the pressure rise is sluggish and drops back to a lower level, stop the pump. The erratic pressure behavior is a sign that air and/or vapors are in the pump and suction line. The pipe system and pump should be purged of all air and gases prior to startup.

J. Start the driver. Adjust the control valve or VFD to the desired flow and check the head, flow, and motor horsepower against the anticipated conditions.

L. Continually check the pressure drop across the suction strainer. Never allow the suction pressure to drop below the minimum design pressure that would ensure adequate NPSH). This minimum suction pressure should be established before commissioning.

M. When the pressure drop across the strainer increases, the temporary screen is becoming clogged with particles and must be cleaned out. The pump should be shutdown and the



discharge and suction valves blocked in to isolate the pump and screen. After the strainer has been cleaned and reinstalled, the pump must be primed just as during the initial start up.

N. Examine the debris and/or particles removed from the strainer each time it is cleaned. Typically, the strainer contents will be matter foreign to the process and it will take longer and longer for the strainer to clog up. If no new debris shows up for a reasonable period of time, the temporary strainer and pressure gauge can be removed.

O. If the temporary strainer keeps clogging up at a relatively steady pace and the clogging material is process oriented particles, such as undissolved crystals, high boiler compounds or other entrained particles which are expected to continue forming in the pumpage at about the same constant rate, some permanent modification in the pumping system may be required.

7 PUMP OPERATION

While the application of the ERI AquaBold pump in any particular system is not within the scope of this instruction manual, the importance of proper application to successful pump operation cannot be ignored. Several factors must always be considered.

7.1 Suction Conditions

A. The most common reasons for improper centrifugal operation are those relating to proper flow of liquid into the impeller. To avoid turbulence at the eye of the impeller, the suction pipe should be straight for at least 3 pipe diameters beyond the suction inlet of the casing. Suction piping size should be equal to or larger than the pump suction inlet.

ERI recommends that the margin between the required and available NPSH be at least 3 feet (1 meter).

B. The pressure of the liquid reaching the impeller eye must or should have sufficiently high pressure to prevent flashing in the impeller. The result of this liquid flashing is a phenomenon called cavitation. Cavitation can cause damage to the impeller and inducer and is caused by insufficient NPSH. Cavitation is sometimes noticeable as a pumping gravel noise in centrifugal pumps. The easiest way to prevent cavitation is to maintain suction pressure at a high enough level to overcome the effects of high vapor pressure and excessive friction losses in the suction piping. Careful design of the pump suction conditions will ensure that the available NPSH exceeds the NPSH required by the ERI pump.

7.2 Discharge Conditions

A. Ensure that the pipe system is not over pressurized and that the discharge pressure of the pump does not exceed the design rating of the equipment.

B. Care must be exercised in the fitting of non-return valves to discharge pipe work as this may prevent correct venting of the pump prior to start up.



C. When operating your ERI AquaBold pump, always vary the flow with a valve installed in the discharge line. Never throttle flow from the suction side. Attempting to throttle flow from the suction side may result in Failure of the pump due to inadvertent dry run of the seals or cavitation.

7.3 Minimum Flow Conditions

A. Centrifugal pumps can also experience vibrations from internal flow separation and recirculation at low flow conditions. The minimum flow of your ERI AquaBold pump is shown on the pump data sheet. The pump data sheet is provided during the proposal process. While a pump can operate without harm with some noise due to recirculation, excessive noise and vibration are signs that the pump may be subject to damage if operation is continuous.

B. Protection against operation below minimum flow is possible by use of either a continuous bypass or by a flow controlled bypass. Any bypass designs must return the liquid to the suction tank or to a location with a similar heat sink capability. If a bypass design is used, part of the total flow through the pump is never pumped to the process. Therefore, the operator must consider the combined process flow and bypass flow requirements when specifying the pump for an application.

C. Noise and vibration may be accentuated by resonance in the discharge line, especially when a control valve is located well down-stream from the pump. Optimum performance will be achieved when the control valve is located within 5 feet (1.5 meters) from the pump discharge.

7.4 Maximum Flow Conditions

Maximum flow of the ERI AquaBold pump should be limited to the value on the pump data sheet. This maximum flow limitation assumes that the driver horsepower and NPSH requirements of the unit are not exceeded.

7.5 Drivers

A. The equipment should only be used with the driver specified at the time of order. The driver horsepower rating has been specifically designed for the design conditions. An engineering review is recommended before making any changes. The driver size should not be changed without consulting ERI.

B. The driver bearings should be greased in accordance with the bearing lubrication recommendations provided by the driver manufacturer.

7.6 Entrained Gases

A. Entrained gases in the fluid will reduce the head and capacity of a centrifugal pump. Entrained gases in the process stream may also damage the process seals.



B. During the design of the suction vessel and piping, ensure that sufficient submersion of the pipe work is maintained and that air entrainment and vortices do not occur. Failure to do so will allow vapors and undissolved gases into the pump and may cause a seal failure. Tanks should be designed to allow sufficient residence time for the gases and vapors to disengage from the liquid.

8 SERVICING/MAINTENANCE

8.1 Guidelines

The normal operating routine, including both minor and major overhaul intervals, depends to a great extent upon the pump service and duty cycle. The operating life of a piece of equipment is, under normal circumstances, determined by the action of the operator. All operating parameters should be frequently observed and recorded. Any deviation from normal range of operating values should be immediately investigated to determine the cause and to take corrective actions. The following items should be serviced at the intervals indicated.

Driver: Service the driver according to the manufacturers recommendations.

Seal Leakage: Seal leakage out of the seal drain port should be periodically checked. Seals should be replaced if leakage increases to an unacceptable level. With a double seal system, the buffer pressure and usage should be monitored to ensure that the seals are functioning properly.

Coupling: If a flexible coupling is used, refer to the manufacturers recommendations for service intervals.

8.2 Mechanical Seal Replacement

One of the benefits of the ERI AquaBold pump is that the mechanical seal can be replaced without disturbing the pump-motor alignment. Follow these steps to replace the mechanical seal.

8.2.1 Seal Removal

1. Remove the motor adapter protection screen.

2. Drop out the coupling spacer (if applicable) and the pump side coupling hub.

3. Remove the four (4) seal gland nuts.



Seal Before Removal

Remove the seal gland.

Remove rotating seal and spring.



8.2.2 Seal Re-installation

Press non-rotating seal component into the seal gland. The shiny side of the seal should face up.

Separate the two parts of the rotating seal.

Slide the seals spring onto the shaft.



Slide the portion of the rotating seal with the metal ring onto the shaft. It will take some force to push it on.

Press the other portion of the rotating seal onto the shaft.

Install the seal gland onto the shaft.



Be sure to press the gland all the way in until it meets the suction housing. Re-install the gland nuts to the following torque values listed in Table 1.

Table 1: Seal Gland Nut Torque Values

ERI AquaBold Pump Model Torque, ft-lbs (N-m) 2 x 3 x 5 40 (54) 3 x 4 x 7 40 (54) 4 x 6 x 9 90 (122)

8.3 Pump Disassembly

Before disassembling the pump, remove the mechanical seal according to the instructions in Section 8.2. The pump must be disassembled in the vertical position. Place the pump vertically on a clean and level table with a hole in the table large enough to allow the pump shaft to pass through. If a table is not available, the pump should be stood up on the bell housing motor adapter.

Important note: Do not use the shaft as a lifting point for the pump. This can damage the internal parts.

Figure 5: Pump Lifting Diagram

Follow the steps below to completely disassemble the pump hydraulic end. Please see Section 8.4 for steps to inspect the thrust bearing in the horizontal position.

When it is desired to inspect or repair the internal parts of the AquaBold pump, please follow the following instructions. A complete inspection will require precision measurements of outer and inner diameters. Suitable measuring equipment such as OD micrometers and ID micrometers or telescoping bore gauges should be available.

The pump to be worked on needs to be shut down and secured for maintenance following the plants approved safety procedures. Motor controllers need to be tagged out of service and/or locks placed on circuit breakers or motor starters to ensure there will be no inadvertent startup of the pump while undergoing service. The pump and piping system should be depressurized and



isolated from the pump by valves that are secured and tagged or by isolation flange blanks. Failure to properly secure the pump may result in damage to the equipment and possibly severe injury to personnel.

Once the pump is in the vertical position, the bare shaft end must be supported.

Remove end cap nuts and end cap

Before After



Remove impeller retaining sleeve nut and sleeve. You must prevent opposite end bare shaft from turning while removing the nut.

Remove final diffuser stage

Remove final impeller



Remove final impeller key and interstage sleeve

Remove thrust bearing

Remove radial positioning stage retaining screws. There are two (2) screws per hole.



Remove the motor end containment shell nuts

Remove the containment shell



Remove the radial positioning stage (RPS)

Before After

Remove the next impeller

Remove the impeller key and interstage sleeve



Continue this process until all diffuser stages, impellers, keys, and sleeves have been removed. You may then lift the shaft out of the suction housing. Once all of the components are removed, measurements can be taken to check clearances. Refer to Table 2 below for tolerances.

Table 2: Impeller Tolerences

Maximum Allowable Diametrical Clearance AquaBold Pump Model Impeller Wear Ring Interstage Bearing

2x3x5 .014 .007 3x4x7 .016 .007 4x6x9 .019 .009

Drive End Radial Bearing End Radial Thrust Bearing 2x3x5 .006 .007 3x4x7 .007 .007 4x6x9 .008 .009

8.4 Pump Reassembly

To re-assemble the pump, follow the disassembly instructions in the reverse order. Be sure to re-install impellers in the same order that they were removed. Make sure that all o-rings and seals are properly installed during re-assembly. ERI recommends replacing all o-rings and seals when the hydraulic pump end is serviced.

Additional Measuring

There are two additional steps during re-assembly. After installing the RPS, check that the RPS is perpendicular to the shaft. The measurement must be within 0.003 around the entire RPS stage.

When re-installing the shaft retaining nut, refer to Table 3 below for torque values.



Table 3: Torque Values

Model Retaining Nut Size Torque, ft-lbs (N-m) 2 x 3 x 5 3/4 - 10 130 (176) 3 x 4 x 7 7/8 - 9 202 (274) 4 x 6 x 9 1 - 8 271 (367)

Check end thrust tolerence

After assembly is complete but before the seal is re-installed, check the end thrust of the pump. The end thrust must be within the following tolerance before proceeding.

Total thrust should be in the range indicated in 0.0150.030 inches or 0.3810.762 mm.

If the end thrust is out of tolerance, there was an error during re-assembly and the procedure must be repeated. All parts should be checked to ensure they were installed properly.

The seal may now be installed per the instruction in Section 8.2. After seal installation, re-install the coupling and follow the normal startup procedures.

8.5 Thrust Bearing Inspection/Replacement

The pump can remain in the horizontal position.



Remove suction and discharge piping.

Remove end cap retaining nuts



Remove final diffuser stage

Remove shaft retaining nut. Be sure to secure the opposite end of the shaft to prevent the shaft from rotating.



Remove final impeller retaining sleeve

Remove final impeller



Remove thrust bearing

Thrust bearing removal is now complete. To re-install, follow these instructions in reverse order. No precision measurements are required during removal or installation of the thrust bearing.



9 TROUBLESHOOTING

9.1 Pump Troubleshooting

Table 4: Pump Troubleshooting Problem Possible Cause Investigative/Corrective Action No flow, no pressure

at startup. Pump not completely

primed. Bleed all vapors and gases from system. Also

bleed vapor or air from the seal flush port. Allow more cool-down time if pumping a low

temperature fluid. Verify that pump and suction line are full of

liquid. NPSH available is lower

than requirement shown on pump specification

sheet.

Suction line blocked. Check suction strainer and valves.

Excessive pressure drop through suction piping.

Flow restricted by vapor pockets in high points of suction and discharge piping.

Inability to vent past a check valve in the discharge piping.

Suction tank pressure too low. Entrained gases in pumped liquid.

NPSH reduced by a more volatile process liquid.

Failure of drive component, impeller key, high-speed shaft bearing,

or coupling.

Replace as necessary.

Wrong direction of rotation on motor.

Direction of driver shaft rotation is shown by arrow on gearbox housing.

Note: Impeller and driver rotate in different directions. Rotation can be check by viewing driver fan (or input shaft on frame-mounted units). Reverse any two leads on motor to

change direction of rotation. Pump starts and then

stops pumping. Improperly primed pump. Attempt to prime pump. If priming is not

possible, inspect suction piping for obstructions.

Determine if there is a check valve on the discharge. If so, determine if the vapors

between the pump and the check valve are properly vented.

Suction screen plugged. Suction line blocked. Check suction strainer and valves.

Air or vapor pockets in suction line.

Vent suction piping at the highest point. Determine if the piping must be redesigned to



Table 4: Pump Troubleshooting Problem Possible Cause Investigative/Corrective Action

eliminate the formation of air or vapor pockets.

Note: An eccentric reducer with Belly side on top will create a vapor pocket.

Insufficient flow or pressure.

Flow rate is higher than pump design allows.

Check head rise and flow rate against performance curve.

Wrong direction or driver shaft rotation.

Direction of driver shaft rotation is as shown by arrow on gearbox housing.

Note: Impeller and driver rotate in different directions. Rotation can be checked by

viewing driver fan or input shaft on frame-mounted units. Reverse any two leads on

motor to change direction of rotation. Air trapped in pump or

pumping entrained vapors or gases.

Check shutoff pressure. If deficient, vent pump.

Determine if there is a check valve on the discharge. If so, determine if the vapors

between the pump and the check valve are properly vented.

Impeller damage by passage of solid particles.

Inspect impeller for nicked, bent, or worn blades. Replace impeller if damaged.

Available NPSH is lower than required as shown on pump specification sheet.

Refer to solutions provided under No Flow, No Pressure at Startup.

Flow too low, causing overheating of fluid and loss of NPSH after a short

period of satisfactory operation.

Increase pump flow rate. Increase bypass flow rate or use seal cavity bypass to continuously increase inlet flow

rate. Vent to the highest point of the pump. Install bypass to recirculate portion of pump

discharge back to the supply tank. Pressure gauges or flow

meters in error. Remove and replace with calibrated

instrument. Corrosion pitting on pump

casing. Minor pitting may be polished with emery

cloth. Major pitting indicates a failed part and should be replaced.

Inspect remainder of pump to determine if other areas of pump are damaged from

corrosion. Replace damaged parts. Identify source of corrosion mechanism. Determine if process conditions can be

changed. Consult your authorized ERI sales representative for assistance on alternative

pump materials of construction. Corrosion and/or erosion of diffuser throat (may also be

If edge of throat has opened in size, head rise may be reduced. Opening the throat will



Table 4: Pump Troubleshooting Problem Possible Cause Investigative/Corrective Action

accompanied by corrosion and/or erosion of diffuser surface adjacent to the

impeller).

increase flow rate and horsepower consumption. Corrosion and/or erosion of the

diffuser and cover surfaces will significantly increase horsepower consumption.

Pump discharge throat partially plugged.

Disassemble pump and inspect pump casing for an obstructions. Replace damaged

hardware with genuine ERI parts. Driver speed too low. Check driver speed against value provided

on the pump specification sheet. Driver overloaded. Fluid specific gravity or

viscosity is exceeds original pump design.

Decrease specific gravity and/or viscosity. Reduce pump flow to the level that will reduce driver power consumption to an

acceptable level. Electrical failure in motor. Check circuit breaker heater size and setting.

Check motor voltage. Check motor current in each phase. The

current should be balanced within 3%. Mechanical failure of

pump Rotate shaft assembly and check for ease of

rotation. Inspect thrust and journal hearings. Replace

failed parts. Pump operating beyond

capacity. Check actual pump flow and head against

the values provided on the pump specification sheet.

Excessive discharge pressure pulsations

(may sound like hammering or gravel being

pumped).

Flow rate too low. Increase flow through pump. Add bypass if required.

Insufficient NPSH Refer to solution for insufficient NPSH under No Flow, No Pressure at Startup.

Defective flow control valve.

Repair or replace valve.

Excessive noise and vibration.

Rotation incorrect. Direction of driver shaft rotation is shown by arrow on pump housing. Note: Reverse any two leads on motor to change direction of

rotation. Worn or damaged

bearings. Disassemble pump and replace damaged

components with genuine ERI parts. Insufficient NPSH. Refer to solution for insufficient NPSH under

No Flow, No Pressure at Startup.



9.2 Mechanical Seal Troubleshooting

Table 5. Mechanical Seal Troubleshooting Problem Possible Cause Investigative/Corrective Action Sudden increase in seal

leakage. Severe cavitation or loss of suction pressure causing

vibration and bouncing of seal face.

Correct pump suction condition causing cavitation. Bleed vapor from seal cavity and restart pump. Install double seal system if loss

of suction cannot be prevented. Replace seal and rotating face with genuine ERI parts if either part shows wear or damage.

Seal icing on low temperature pumps or icing when handling fluids which have high vapor pressures at a temperature of less

than 32F (0C).

Purge dry nitrogen gas into seal drain area. Install double seal system and use a

compatible, non-aqueous, nonvolatile external seal drain area.

Solid particles in seal cavity or seal spring area.

Replace seal and rotating face. Supply clean, external seal flush or install double seal system if particles cannot be

removed by a separator or filter. Seal stationary spring action

is rough and sticky. If parts are corroded, check for material

compatibility. Check for the accumulation of solids in the

seal retainer area. If solids are found, consider the installation of a double seal system.

Worn or damaged seal. Disassemble high speed shaft assembly and replace worn or damaged components with

genuine ERI parts. Wear pattern on seal

rotating faces not uniform in the circular direction.

Inspect shaft sleeve and impeller hub for high spots. Replace if necessary. Install new seal

and rotating face. Shaft sleeve not parallel causing rotating face to be cocked. Check for dirt or debris caught between sleeve, rotating face, or adjacent

parts. Wear pattern on stationary face of seal is smooth but

not uniform.

Replace seal and rotating face.

Edges of stationary face chipped and seal face is worn (usually caused by

vapor formation in the seal cavity).

Prevent loss of pump suction. Install double seal system if loss of suction cannot be

prevented. Supply cool seal flush. Consult with your

authorized ERI sales representative to determine if a heat exchanger is required.

Seal rotating face is cracked or broken. ( May

be caused by damage

Prevent loss of pump suction. Install double seal system if loss of suction cannot be

prevented.



Table 5. Mechanical Seal Troubleshooting Problem Possible Cause Investigative/Corrective Action

during assembly or by thermal shock from running

the seal dry.)

Supply cool seal flush. Consult with your authorized ERI sales representative to

determine if a heat exchanger is required. Seal rotating face is worn in area of contact stationary

face (usually caused by icing from air in drain).

Install nitrogen purge in drain area. Install a double seal system.

Chemical degradation of seal faces, seal parts, or o-

rings.

Investigate process fluid properties and change seal and o-ring materials if needed.



10 ERI CUSTOMER/FIELD SUPPORT

The Technical Services staff of ERI offers complete and commissioning support for all products, including field installations and at the location of the RO system manufacturer. Although commissioning service is not a requirement, some customers might feel more comfortable with the offered service. Please contact your ERI representative to request a rate quote.

Should a problem develop with any ERI product, our Technical Services Group is prepared to handle customers concerns whether the location is domestic or overseas. An ERI representative can provide service rates upon request.

Energy Recovery, Inc. 1717 Doolittle Drive San Leandro, California 94577 USA

Tel: +1 510 483 7370 Fax: +1 510 483 7371 Email: [email protected] Web: www.energyrecovery.com



11 REVISION LOG

Revision Description Date Approval 0 Initial Release 4/14/11 ERK

12 DRAWINGS AND DATA

1. ERI AquaBold Pump Assembly Drawings

80274-01 r0 manual installation operation aquabold

Documents

pump critical

eri aquabold pump installation

starting pump

maintenance manual

coupling installation

check driver rotation

driver instruction

critical startup checklist