LL PPuummppss  

USER INSTRUCTIONS: INSTALLATION, OPERATION

AND MAINTENANCE.

 

INSTALLATIONRECEIVING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11LIFTING THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Temporary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Long Term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14SETTING THE BASEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grouting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ALIGNMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Method One. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Method Two. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DOWELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . 17

Suction Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

STUFFING BOX LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . 20Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Cartridge Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Cyclone Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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RECEIVING THE PUMPCheck pump for shortages and damage immediatelyupon arrival. (An absolute must!) Prompt reporting tothe carrier’s agent, with notations made on the freightbill, will expedite satisfactory adjustment by thecarrier.

Pumps and drivers are normally shipped from thefactory mounted on a baseplate. Couplings may either

be completely assembled or have the coupling hubsmounted on the shafts and the connecting membersremoved. When the connecting members areremoved, they will be packaged in a separatecontainer and shipped with the pump or attached tothe baseplate.

LIFTING THE PUMPThe following instructions are for the safe lifting ofyour pump.

The unit should be unloaded and handled by liftingequally at four or more points on the baseplate. Thelugs on the upper half casing are designed for liftingthe upper half casing only.

HORIZONTALBare Pump1. Using a nylon sling, chain, or wire rope, hitch

around both bearing housings. (See Fig. 3)

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2

Pump, Base, and Driver2. Care must be taken to size equipment for

unbalanced loads which may exist if the driver isnot mounted on the base at the time of lifting.Driver may or may not be mounted at the factory.

3. Pump, base, and driver assemblies where thebase length exceeds 100 inches may not be safeto lift as a complete assembly. Damage to thebaseplate may occur. If the driver has beenmounted on the baseplate at the factory, it is safeto lift the entire assembly. If driver has not beenmounted at the factory and the overall baseplatelength exceeds 100 inches, do not lift entireassembly consisting of pump, base, and driver.Instead lift the pump and baseplate to its finallocation without the driver. Then mount the driver.

Bases supplied with lifting holesLarge bases are supplied with lifting holes in thesides or the ends of the base. (See Fig. 4)

Using ANSI/OSHA Standard “S” hooks, place the “S”hooks in the holes provided in the four corners of the base.Be sure the points of the hooks do not touch the bottom ofthe pump base. Attach nylon slings, chains, or wire rope tothe “S” hooks. Size the equipment for the load, and so thelift angle will be less than 45° from the vertical.

Bases supplied without lifting holesPlace one sling around the outboard bearing housing.

�! WARNINGDo not use lugs on top half of casing.

Place the remaining sling around the back end of the driveras close to the mounting feet as possible. Make certainsling will not damage housing cover or conduit boxes.

Join the free ends of the slings together and place overthe lifting hook. Use extreme care when positioning slingunder the driver so it cannot slip off. (See Fig. 5)

VERTICALHalf Pedestal1. Place nylon sling chain or wire rope around both

flanges. Use a latch hook or standard shackle andend loops.

Be sure the lifting equipment is of sufficient lengthto keep the lift angle less than 30° from thevertical. (See Fig. 6)

Fig. 3

Fig. 5

Fig. 4

DO NOT LIFTENTIRE PUMPWITH THESELUGS.

Fig. 6

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3STORAGE

The following storage procedures apply to the pumponly. Other accessories such as motors, steamturbines, gears, etc., must be handled per therespective manufacturer’s recommendations.

TEMPORARYTemporary storage is considered one month or less.If the pump is not to be installed and operated soonafter arrival, store it in a clean, dry place having slow,moderate changes in ambient temperature. Rotate theshaft periodically to coat the bearings with lubricantand to retard oxidation, corrosion, and to reduce thepossibility of false brinelling of the bearings. Shaftextensions and other exposed machine surfacesshould be coated with an easily removable rustpreventative such as Ashland Oil Tectyl No. 502C.

For oil lubricated bearings, fill the frame completelywith oil. Before putting equipment into operation, drainthe oil and refill to proper level.

LONG TERMStorage longer than one month is considered longterm storage. Follow the same procedure fortemporary storage with the following addition. Addone half ounce of a corrosion inhibiting concentratedoil such as Cortec Corp. VCI-329 (for both grease andoil lubricated bearings). Seal all vents and apply awater proof tape around the oil seals in the bearingframe. Remember for oil lubricated bearings to drainthe oil from the frame and refill to the proper levelbefore running pump.

Fig. 7

Full Pedestal2. Install eyebolts in the three holes provided at the top of

the support, being sure to tighten securely. Attachchain or wire rope using latch hook or standard shackleand end loop.

Be sure to use shoulder eyebolts that aremanufactured per ANSI B18.15 and sized to fit theholes provided.

Be sure lifting equipment is of sufficient length tokeep the lift angle less than 30° from the vertical.(See Fig. 7)

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LOCATIONThe pump should be installed as near the suctionsupply as possible, with the shortest and most directsuction pipe practical. The total dynamic suction lift(static lift plus friction losses in suction line) should notexceed the limits for which the pump was sold.

The pump must be primed before starting. Wheneverpossible, the pump should be located below the fluidlevel to facilitate priming and assure a steady flow ofliquid. This condition provides a positive suction headon the pump. It is also possible to prime the pump bypressurizing the suction vessel.

When installing the pump, consider its location inrelation to the system to assure that sufficient NetPositive Suction Head (NPSHA) is available at thepump inlet connection. Available NPSH must alwaysequal or exceed the required NPSH (NPSHR) of thepump.

The pump should be installed with sufficient accessibilityfor inspection and maintenance. A clear space with amplehead room should be allowed for the use of an overheadcrane or hoist sufficiently strong to lift the unit.

NOTE: Allow sufficient space to be able todismantle pump without disturbing the pump inletand discharge piping.

Select a dry place above the floor level whereverpossible. Take care to prevent pump from freezing duringcold weather when not in operation. Should the possibilityof freezing exist during a shut-down period, the pumpshould be completely drained, and all passages andpockets where liquid might collect should be blown outwith compressed air.

Make sure there is a suitable power source available forthe pump driver. If motor driven, the electricalcharacteristics of the power source should be identical tothose shown on motor data plate.

FOUNDATIONThe foundation must be substantial enough to absorbvibration. (Hydraulic Institute Standards recommendsthe foundation weigh at least five (5) times the weight ofthe pump unit.) It must form a permanent and rigidsupport for the baseplate. This is important inmaintaining the alignment of a flexibly coupled unit.

Foundation bolts of the proper size should be embeddedin the concrete to a depth of eight (8) to twelve (12)inches and locked with either a hook around areinforcing bar or alternatively, a nut and washer at thebottom. The bolts should have a sleeve around them atleast six (6) times the bolt diameter in length and at leasttwo (2) bolt sizes larger in I.D. If a nut and washer areused for locking, the washer should have an O.D. two(2) sizes larger than the sleeve. Foundation bolts shouldbe sized .125" less than the anchor bolt holes in thebase.

The foundation should be poured to within .75" - 1.5"of the finished height. (See Fig. 8) Freshly pouredfoundations should be allowed to cure for severaldays before the unit is set in place and grouted.

SETTING THE BASEPLATEPump units are checked at the factory for align ability torequired tolerances.

Due to flexibility of an ungrouted base and handling inshipment, it should not be assumed that the unit is inalignment when it is placed on the rough foundation.

If these directions are followed, the required alignmentshould be readily achieved.

Initial or rough alignment must be done prior to grouting ofbaseplate. Rough alignment is designated as .020" TIR(Total Indicator Reading) parallel alignment and .009" TIRper inch of radius angular alignment (See ALIGNMENTPROCEDURE). Use blocks at anchor bolts and midwaybetween to position bottom of base at finished height(See Fig. 9) with foundation bolts extending through holesin the baseplate. Metal wedges with a small taper may beused in lieu of blocks and shims.

Fig. 8

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3If the unit has a non-flexible coupling (e.g. Falk Gearcoupling), the coupling halves should be disconnected;this is generally not necessary on flexible type couplings(e.g. Wood’s Sure-Flex coupling).

Tighten up all pump and motor bolts to assure they havenot loosened or a “soft foot” has occurred due to basedistortion in shipment. A “soft foot” causes a change inthe alignment when unloosening one bolt.

If the driver is being field installed, it should be centered inits bolt holes with shims added to bring the driver intorough alignment with the pump. (The pump may have tobe moved also.)

�! CAUTIONDo not exceed six (6) shims, using as thick ashim as possible, otherwise “sponginess” or“soft foot” will result. Place thin shims inbetween thick shims.

Level and plumb the pump shaft, coupling faces andflanges by adding or removing shims between the blocksand the bottom of the base. Hand tighten the anchor boltnuts at first. Being very careful not to distort the base,snug down the nuts with a wrench. The non-flexiblecoupling should not be reconnected until the alignmentoperation has been completed.

NOTE: The baseplate does not have to be level.

After foundation bolts are lightly torqued, recheckalignment requirements once more. Followrequirements outlined at the beginning of this section.If alignment must be corrected, add or remove shimsor wedges under the baseplate.

The unit can then be grouted. (See Fig. 9)

Grout compensates for the uneven foundation.Together with the baseplate, it makes a very rigidinterface between the pump and the foundationdistributing the weight over the length of the base andpreventing shifting.

Use an approved, non-shrinking grout such asEmbeco 636 or 885 by Master Builders, Cleveland,Ohio or equivalent.

GROUTING PROCEDURE1. Build a strong form around the foundation to

contain the grout.

2. Soak the top of the foundation thoroughly, thenremove surface water.

3. The baseplate should be completely filled withgrout and, if necessary, temporarily use air relieftubing or drill vent holes to remove trapped air.

4. After the grout has thoroughly hardened(approximately 24 hours), tighten the foundationbolts fully.

5. Check the alignment after the foundation boltsare tightened.

6. Approximately fourteen (14) days after the grouthas been poured and the grout has thoroughlydried, apply an oil base paint to the exposededges of the grout to prevent air and moisturefrom coming in contact with the grout.

Fig. 9

ALIGNMENT PROCEDUREProper rough alignment must be made during unitsetting and grouting. See previous section.

There are two forms of misalignment between thepump shaft and the driver shaft as follows:

1. Angular misalignment — shafts have axisconcentric at intersection, but not parallel.

2. Parallel offset misalignment — shafts have axisparallel, but offset.

The necessary tools for checking alignment are: (1) astraight edge and a taper gauge or set of feeler gaugesor, (2) a dial indicator with mounting magnet andextension bars.

Check and correct for angular misalignment beforecorrecting parallel alignment. Final alignment should bemade by moving and shimming the motor on its base untilthe coupling hubs are within the recommended tolerancesmeasured in total run out. All measurements should be

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taken with the pump and driver bolts tightened. Finalalignment check should be made after the unit hasattained its final operating temperature.

Method 1 - Using straight edge and taper gauges orfeelers (Fig. 10):

Proceed with this method only if satisfied that faceand outside diameters of the coupling halves aresquare and concentric with the coupling bores. If thiscondition does not exist or elastomeric couplings donot make this method convenient, use Method 2.

Check for angular alignment by inserting the taper orfeeler gauges between the coupling faces at 90°intervals. The unit is in angular alignment when thesefour (4) measurements are the same, or withinrecommended tolerances.

Check for parallel alignment by placing a straightedge across both coupling rims on all four sides. Theunit is in parallel alignment when the straight edgerests evenly across both coupling rims in all four (4)positions.

Method 2 - Dial Indicators (Fig. 11):

A dial indicator can be used to attain more accuratealignment.

Fasten the indicator stand or magnetic base to thepump half of the coupling and adjust the assemblyuntil the indicator button is resting on the other halfcoupling periphery.

Set the dial to zero and chalk mark the coupling halfwhere the button rests. Also place a separatorbetween the coupling halves so bearing slack doesnot affect the readings. (Chalk and separators are notnecessary on the elastomeric couplings that have notbeen disconnected.) Rotate both shafts by the sameamount; i.e., all readings must be made with thebutton on the chalk mark.

The dial readings will indicate whether the driver hasto be raised, lowered or moved to either side.Accurate alignment of shaft centers can be obtainedwith this method even where faces or outsidediameters of the coupling are not square or concentricwith the bores. After each adjustment, recheck bothparallel and angular alignments.

NOTE: Gross deviations in squareness orconcentricity may cause rotation unbalanceproblems and if so must be corrected.

Permissible Coupling Misalignment:

Parallel: Single element coupling:

.004" TIR (4 mils)

Double element (spacer) coupling:

.060" TIR per foot of spacer length

Angular: Single element coupling:

.004" TIP per inch of radius

Double element (spacer) coupling:

.002" TIR per inch of radius

Fig. 10

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3

SUCTION AND DISCHARGE PIPINGThe introduction of pumpage into a piping system which isnot well designed or adjusted may cause strain on thepump, leading to misalignment or even impeller rubbing.Since slight strain may go unnoticed, final alignment shouldbe done with the system full and up to final temperature.

Pipe flanges should not impose any strain on the pump.This can be checked by a dial indicator. Any strain must becorrected by adjustments in the piping system.

When installing the pump piping, be sure to observe thefollowing precautions:

Piping should always be run to the pump.

Do not move the pump to pipe. This could make finalalignment impossible.

Both the suction and discharge piping should beindependently anchored near the pump and properlyaligned so that no strain is transmitted to the pump whenthe flange bolts are tightened. Use pipe hangers or othersupports at necessary intervals to provide support. Whenexpansion joints are used in the piping system they must beinstalled beyond the piping supports closest to the pump.Tie bolts and spacer sleeves should be used withexpansion joints to prevent pipe strain. Do not installexpansion joints next to the pump or in any way that wouldcause a strain on the pump resulting from system pressurechanges. When using rubber expansion joints, follow therecommendations of the Technical Handbook on RubberExpansion Joints and Flexible Pipe Connectors. It is usually

advisable to increase the size of both suction and dischargepipes at the pump connections to decrease the loss of headfrom friction.

Install piping as straight as possible, avoiding unnecessarybends. Where necessary, use 45° or long radius 90° fittingsto decrease friction losses.

Make sure that all piping joints are air-tight.

Where flanged joints are used, assure that inside diametersmatch properly.

Remove burrs and sharp edges when making up joints.

Do not “spring” piping when making any connections.

Provide for pipe expansion when hot fluids are to bepumped.

DOWELINGPump units may, if desired, (or required inspecification) be doweled on diagonally opposite feet.This should not be done until the unit has been run for

a sufficient length of time and alignment is within theabove alignment tolerance.

Fig. 11

Fig. 12

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Suction PipingWhen installing the suction piping, observe the followingprecautions. (See Fig. 13)

The sizing and installation of the suction piping isextremely important. It must be selected and installed sothat pressure losses are minimized and sufficient liquidwill flow into the pump when started and operated.

Many NPSH (Net Positive Suction Head) problemscan be directly attributed to improper suction pipingsystems.

Suction piping should be short in length, as direct aspossible, and never smaller in diameter than thepump suction opening. A minimum of five (5) pipediameters between any elbow or tee and the pumpshould be allowed. If a long suction pipe is required, itshould be one or two sizes larger than the suctionopening, depending on its length.

�! CAUTIONAn elbow should not be used directly before thesuction of a double suction pump if its plane isparallel to the pump shaft. This can cause anexcessive axial load or NPSH problems in the pumpdue to an uneven flow distribution. (See Fig. 12) Ifthere is no other choice, the elbow should havestraightening vanes to help evenly distribute theflow.

Eccentric reducers should be limited to one pipe sizereduction each to avoid excessive turbulence andnoise. They should be of the conical type. Contourreducers are not recommended.

When operating on a suction lift, the suction pipeshould slope upward to the pump nozzle. A horizontalsuction line must have a gradual rise to the pump.Any high point in the pipe can become filled with airand prevent proper operation of the pump. Whenreducing the piping to the suction opening diameter,use an eccentric reducer with the eccentric side downto avoid air pockets.

NOTE: When operating on suction lift neveruse a concentric reducer in a horizontalsuction line, as it tends to form an air pocket inthe top of the reducer and the pipe.

Fig. 13 shows some correct and incorrect suctionpiping arrangements.

When installing valves in the suction piping, observethe following precautions:

1. If the pump is operating under static suction liftconditions, a foot valve may be installed in thesuction line to avoid the necessity of priming eachtime the pump is started. This valve should be ofthe flapper type, rather than the multiple springtype, sized to avoid excessive friction in thesuction line. (Under all other conditions, a checkvalve, if used, should be installed in the dischargeline. See Discharge Piping.)

2. When foot valves are used, or where there areother possibilities of “water hammer”, close thedischarge valve slowly before shutting down thepump.

3. Where two or more pumps are connected to thesame suction line, install gate valves so that anypump can be isolated from the line. Gate valvesshould be installed on the suction side of allpumps with a positive pressure for maintenancepurposes. Install gate valves with stemshorizontal to avoid air pockets. Globe valvesshould not be used, particularly where NPSH iscritical.

4. The pump must never be throttled by the use of avalve on the suction side of the pump. Suctionvalves should be used only to isolate the pumpfor maintenance purposes, and should always beinstalled in positions to avoid air pockets.

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9

3

Discharge PipingIf the discharge piping is short, the pipe diameter canbe the same as the discharge opening. If the piping islong, the pipe diameter should be one or two sizeslarger than the discharge opening. On long horizontalruns, it is desirable to maintain as even a grade aspossible. Avoid high spots, such as loops, which willcollect air and throttle the system or lead to erraticpumping.

A check valve and an isolating gate valve should beinstalled in the discharge line. The check valve,placed between pump and gate valve, protects thepump from excessive back pressure, and preventsliquid from running back through the pump in case ofpower failure. The gate valve is used in priming andstarting, and when shutting the pump down.

Pressure GaugesProperly sized pressure gauges should be installed inboth the suction and discharge nozzles in the gaugetaps provided. The gauges will enable the operator toeasily observe the operation of the pump, and alsodetermine if the pump is operating in conformancewith the performance curve. If cavitation, vaporbinding, or other unstable operation should occur,widely fluctuating discharge pressure will be noted.

Fig. 13

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STUFFING BOX LUBRICATIONContaminants in the pumped liquid must not enter thestuffing box. These contaminants may cause severeabrasion or corrosion of the shaft, or shaft sleeve, andrapid packing or mechanical seal deterioration; theycan even plug the stuffing box flushing and lubricationsystem. The stuffing box must be supplied at all timeswith a source of clean, clear liquid to flush andlubricate the packing or seal. The most importantconsideration is to establish the optimum flushingpressure that will keep contaminants from the stuffingbox cavity. If this pressure is too low, fluid beingpumped may enter the stuffing box. If the pressure istoo high, excessive packing or seal wear may result;and extreme heat may develop in the shaft causinghigher bearing temperatures. The most desirablecondition, therefore, is to use a seal water pressure15-20 psig above the maximum stuffing box pressure.

If the pump system pressure conditions vary, packingadjustment becomes difficult. Consideration should begiven to using a mechanical seal. (See MechanicalSeals.)

PackingStandard pumps are normally packed before ship-ment. If the pump is installed within 60 days aftershipment, the packing will be in good condition with asufficient supply of lubrication. If the pump is storedfor a longer period, it may be necessary to repack thestuffing box. In all cases, however, inspect thepacking before the pump is started.

NOTE: Packing adjustment is covered in theMAINTENANCE SECTION of this manual.

On some applications, it is possible to use internalliquid lubrication (pumped liquid) to lubricate packing.Only when all of the conditions prevail, can this bedone:

1. Liquid is clean, free from sediment and chemicalprecipitation and is compatible with sealmaterials.

2. Temperature is above 32° F and below 160° F.

3. Suction pressure is below 75 psig.

4. Lubrication (pumped liquid) has lubricatingqualities.

5. Liquid is non-toxic and non-volatile.

When the liquid being pumped contains solids or isotherwise not compatible with packing materials, anoutside supply of seal liquid should be furnished. Ingeneral, external-injection liquid (from an outsidesource) is required when any of the above conditionscannot be met.

The standard stuffing box consists of rings of packing(see assembly section for number of rings), a sealcage (optional), and a gland. A shaft sleeve whichextends through the box and under the gland isprovided to protect the shaft.

A tapped hole is supplied in the stuffing box directlyover the seal cage to introduce a clean, clear sealingmedium. The stuffing box must, at all times, besupplied with sealing liquid at a high enough pressureto keep the box free from foreign matter, which wouldquickly destroy the packing and score the shaftsleeve.

Only a sufficient volume of sealing liquid to create adefinite direction of flow from the stuffing box inwardto the pump casing is required, but the pressure isimportant. Apply seal water at a rate of approximately.25 GPM at a pressure approximately 15 to 20 psigabove the suction pressure. (Approximately one (1)drop per second.)

One recommended method to minimize error inregulating flushing water is a “Controlled PressureSystem.” (Fig. 14) Most important is the pressurereducing valve adjusted to a value slightly exceedingthe maximum stuffing box operating pressure(assuming it is reasonably constant). A flow indicatingdevice will serve to indicate a failing of the bottompacking rings allowing leakage in the pump.

External sealing liquid should be adjusted to the pointwhere the packing runs only slightly warm, with a veryslow drip from the stuffing box. Excess pressure froman external source can be very destructive to packing.More pressure is required, however, for abrasiveslurries than for clear liquids. Examination of theleakage will indicate whether to increase or decreaseexternal pressure. If slurry is present in the leakage,increase the pressure until only clear liquid drips fromthe box. If the drippage is corrosive or harmful topersonnel, it should be collected and piped away.

A common error is to open the external piping valvewide and then control the drippage by tightening thepacking gland. Actually, a combination of bothadjustments is essential to arrive at the optimumcondition. The life of packing and sleeve depends onthis careful control more than any other factor.

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3

Mechanical SealsMechanical seals are preferred over packing on someapplications because of better sealing qualities andlonger serviceability. Leakage is eliminated when aseal is properly installed, and normal life is muchgreater than that of packing on similar applications. Amechanical shaft seal is supplied in place of a packedstuffing box when specifically requested. The changefrom packing to an alternate arrangement may bemade in the field by competent service personnel.

Just as with packing, the mechanical seal chambermust be supplied, at all times, with a source of clean,clear liquid to flush and lubricate the seal. The mostimportant consideration is to establish the optimumflushing pressure that will keep contaminants from theseal cavity. If this pressure is too low, fluid beingpumped may enter the stuffing box. If the pressure istoo high, excessive seal wear may result.

When contaminants are present in the pumpage, anexternal source of clean seal water must be supplied.Supply approximately .25 GPM at a pressureapproximately 15 to 20 psig above the suctionpressure.

Fig. 14 shows the recommended “Controlled PressureSystem” for a mechanical seal. Seal water enters theseal chamber, lubricates the seal face, and exits intothe pump itself. Positive flow in the seal water lineindicates adequate seal water pressure.

Cartridge SealsFollow the appropriate lubrication directions formechanical seals given in this section. Most cartridgeseals provide flushing connections on their glands.Use the cartridge seal gland flushing taps (if provided)for your seal water connections instead of the stuffingbox tap. The quench taps on the glands (if present)are normally only used in chemical applications.Consult seal manufacturer’s literature for moredetailed information.

Cyclone SeparatorIf the fluid being pumped contains sediment and thereis no external, clean water source available to flushthe mechanical seals, a cyclone separator can beused to remove most of the sediment from the liquidbeing pumped so it can be used to flush the seals.The separator is placed in the seal water piping lineand removes the sediment to an external drain(normally back to the pump suction line).

Fig. 14

PumpCasing

OPERATIONPRE-START CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Flushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24OPERATIONAL CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . 24SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25FREEZE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25FIELD TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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PRE-START CHECKSBefore the initial start of the pump, make the followinginspections:

1. Check alignment between pump and driver. See thesection on alignment for alignment requirements.

2. Check all connections to motor and starting devicewith wiring diagram. Check voltage, phase, andfrequency on motor nameplate with line circuit.

3. Check suction and discharge piping and pressuregauges for proper operation.

4. Turn rotating element by hand to assure that it rotatesfreely.

5. Check stuffing box adjustment, lubrication, andpiping.

6. Check driver lubrication.

7. Assure that pump bearings are properly lubricated.

8. Assure that coupling is properly lubricated, if required.

9. Assure that pump is full of liquid and all valves areproperly set and operational, with the discharge valveand the suction valve open. Purge all air from top ofcasing.

10. Check rotation. Be sure that the driver operates in thedirection indicated by the arrow on the pump casingas serious damage can result if the pump is operatedwith incorrect rotation. Check rotation each time themotor leads have been disconnected.

PRIMINGIf the pump is installed with a positive head on thesuction, it can be primed by opening the suctionvalve, and loosening the vent plug on the top of thecasing (Do not remove), allowing air to be purgedfrom the casing.

If the pump is installed with a suction lift, priming mustbe done by other methods such as foot valves,ejectors, or by manually filling the casing and suctionline.

�! CAUTIONUnder either condition, the pump must becompletely filled with liquid before starting. Thepump must not be run dry in the hope it willprime itself. Serious damage to the pump mayresult if it is started dry.

FLUSHINGNew and old systems should be flushed to eliminate allforeign matter. Heavy scale, welding splatter and wire orother large foreign matter can clog the pump impeller.This will reduce the capacity of the pump causingcavitation, excessive vibration, and/or damage to closeclearance parts (wear rings, seals, sleeves, etc.)

FILLINGVents should be located at the highest point so entrainedgases and air can escape. However, if the gases areflammable, toxic, or corrosive they should be vented to anappropriate place to prevent harm to personnel or otherparts of the system. Pipe hangers and anchors should bechecked to make sure they are properly set to take theadditional weight of the pumpage.

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13

STARTING1. Close drain valves.

2. Open fully all valves in the suction and dischargelines.

3. Turn on seal water to the stuffing box. (If pumpedfluid is dirty or if leaking of air is to be prevented,these lines should be always left open.)

4. Prime the pump.

NOTE: If the pump does not prime properly,or loses prime during start-up, it should beshutdown and the condition corrected beforethe procedure is repeated.

5. Start the pump driver (turbines and engines mayrequire warming up; consult the manufacturer’sinstructions).

6. When the pump is operating at full speed, checkto see that the check valve has opened up. Checkvalve must open 5 seconds or less after start-upto prevent damage to pump by operating at zeroflow.

7. Adjust the liquid seal valves to produce therecommended pressure for either the mechanicalseal or packed stuffing box.

OPERATIONAL CHECKLIST

1. Driver/Pump RotationCheck rotation each time the motor leads havebeen disconnected. Be sure that the driveroperates in the direction indicated by the arrow onthe pump casing. Rough operation and extremevibration can result if the pump is operated in thewrong direction.

2. Stuffing Box AdjustmentMake stuffing box packing gland and lubricationadjustments.

3. FlowAn accurate measurement of flow rate(volume/time) is difficult in the field. Venturimeters, flow nozzles, orifice plates, or timing thedraw down in the wet well are all possiblemethods. Record any reading for future reference.

4. PressureCheck and record both suction and dischargepressure gauge readings for future reference.Also, record voltage, amperage per phase,kilowatts if an indicating wattmeter is available,and pump speed.

5. TemperatureCheck and record bearing temperatures using athermometer. Temperature should not exceed180° F.

NOTE: Just because bearing housings are toohot to touch does not mean that they arerunning too hot for proper operation.

6. Vibration and SoundThe acceptable vibration level of a centrifugalpump depends on the rigidity of the pump and thesupporting structure. Recommended values forvibration can vary between .20 ips (inches persecond) velocity to .60 ips velocity depending onthe operating characteristics and the structure.Refer to the Centrifugal Pump section of theHydraulic Institute Standards for a completedescription and charts on various pumps.

Field sound levels are difficult to measurebecause of background noise from piping, valves,drivers, gears, etc. Follow recommendations inthe Hydraulic Institute Standards.

All drains should be closed when filling the system.Filling should be done slowly so that excessive velocitiesdo not cause rotation of the pumping elements whichmay cause damage to the pump or its driver. Theadequacy of the anchors and hangers may be checkedby mounting a dial indicator off of any rigid structure not

tied to the piping and setting the indicator button on thepump flange in the axial direction of the nozzle. If theindicator moves, as the filling proceeds, the anchors andsupports are not adequate or set properly and should becorrected.

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SHUTDOWNThe following steps will take care of most normalshutdowns of the pump, i.e. maintenance. Make anyfurther adjustments of process piping, valves, etc., asrequired. If the pump is to be removed from service foran extended period of time, refer to the sections onstorage and freeze protection.

1. Shut down the driver. (Consult manufacturer’sinstructions for special operations.)

2. Close suction and discharge valves.

3. Close seal liquid valves. (If pumped liquid is dirty,or if in leakage is to be prevented, these linesshould always be left open, except when thepump is completely drained.)

4. Open drain valves as required.

FREEZE PROTECTIONPumps that are shut down during freezing conditionsshould be protected by one of the following methods.

1. Drain the pump; remove all liquid from the casing.

2. Keep fluid moving in the pump and insulate orheat the pump to prevent freezing.

�! CAUTIONIf heat is used to keep the pump from freezing,do not let the temperature rise above 150° F.

PREVENTIVE MAINTENANCE

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GENERAL MAINTENANCE ANDPERIODIC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27MAINTENANCE TIME TABLE. . . . . . . . . . . . . . . . . . . . . . . . . 27MAINTENANCE OF FLOODED PUMPS . . . . . . . . . . . . . . . . . . . 28LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Grease Lubrication of Bearings . . . . . . . . . . . . . . . . . . . . . . . 28Periodic Addition of Grease. . . . . . . . . . . . . . . . . . . . . . . . . 29Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Oil Lubrication of Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 29Coupling Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SEALING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Packing (Non-Asbestos) . . . . . . . . . . . . . . . . . . . . . . . . . . 30Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

GENERAL MAINTENANCE & PERIODIC INSPECTIONOperating conditions vary so widely that torecommend one schedule of preventativemaintenance for all centrifugal pumps is not possible.Yet, some sort of regular inspection must be plannedand followed. We suggest a permanent record bekept of the periodic inspections and maintenanceperformed on your pump. This recognition ofmaintenance procedure will keep your pump in goodworking condition, and prevent costly breakdowns.

One of the best results to follow in the propermaintenance of your centrifugal pump is to keep a

record of actual operating hours. Then, after apredetermined period of operation has elapsed, thepump should be given a thorough inspection. Thelength of this operating period will vary with differentapplications, and can only be determined fromexperience. New equipment, however, should beexamined after a relatively short period of operation.The next inspection period can be lengthenedsomewhat. This system can be followed until amaximum period of operation is reached which shouldbe considered the operating schedule betweeninspections.

MAINTENANCE TIME TABLE

EVERY MONTHCheck bearing temperature with a thermometer, not byhand. If bearings are running hot (over 180° F), it maybe the result of too much or too little lubricant. Ifchanging the lubricant and/or adjusting to proper leveldoes not correct the condition, disassemble and inspectthe bearings. Lip seals bearing on the shaft may alsocause the housing to run hot. Lubricate lip seals tocorrect this condition.

EVERY 3 MONTHSCheck the oil on oil lubricated units. Check greaselubricated bearings for saponification. This condition isusually caused by the infiltration of water or other fluidpast the bearing shaft seals and can be noticedimmediately upon inspection, since it gives the grease a

whitish color. Wash out the bearings with a cleanindustrial solvent and replace the grease with the propertype as recommended.

EVERY 6 MONTHSCheck the packing and replace if necessary. Use thegrade recommended. Be sure the seal cages arecentered in the stuffing box at the entrance of thestuffing box piping connection.

Take vibration readings on the bearing housings.Compare the readings with the last set of readings tocheck for possible pump component failure (e.g.bearings).

Check shaft or shaft sleeve for scoring. Scoringaccelerates packing wear.

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MAINTENANCE OF FLOOD DAMAGED PUMPSThe servicing of centrifugal pumps after a floodedcondition is a comparatively simple matter undernormal conditions.

Bearings are a primary concern on pumping units.First, dismantle the frame, clean and inspect thebearings for any rusted or badly worn surfaces. Ifbearings are free from rust and wear, reassemble andrelubricate them with one of the recommendedlubricants. Depending on the length of time the pumphas remained in the flooded area, it is unlikely thatbearing replacement is necessary; however, in theevent that rust or worn surfaces appear, it may benecessary to replace the bearings.

Next, inspect the stuffing box, and clean out any foreignmatter that might clog the box. Packing that appears tobe worn, or no longer regulates leakage properly shouldbe replaced. Mechanical seals should be cleaned andthoroughly flushed.

Couplings should be dismantled and thoroughlycleaned. Lubricate the coupling with one of the couplingmanufacturer’s recommended lubricants whererequired.

Any pump that is properly sealed at all joints andconnected to both the suction and discharge shouldexclude outside liquid. Therefore, it should not benecessary to go beyond the bearings, stuffing box, andcoupling when servicing the pump after flood damage.

LUBRICATION

GREASE LUBRICATIONOF BEARINGSGrease lubricated ball bearings are packed with greaseat the factory and ordinarily will require no attentionbefore starting, provided the pump has been stored in aclean, dry place prior to its first operation. The bearingsshould be watched the first hour or so after the pumphas been started to see that they are operating properly.

A lithium based NLGI-2 grade grease should be used forlubricating bearings where the ambient temperature isabove -20° F. Grease lubricated bearings are packed atthe factory with Mobilux EP No. 2 grease. Otherrecommended greases are Texaco Multifak EP-2 andShell Alvania EP-2.

Greases made from animal or vegetable oils are notrecommended due to the danger of deterioration andforming of acid. Do not use graphite.

In greasing anti-friction bearings, the use of highpressure equipment is not only unnecessary, but isactually undesirable unless used with great care. Highpressure may damage the bearings or seals, causeunnecessary loss of grease, create a danger ofoverheating due to over greasing, and produce unsightlyconditions around the bearing. Excess grease is themost common cause of overheating. Adequatelubrication is assured if the level of grease is maintainedat about the capacity of the bearing and 1/3 to 1/2 of the

Check alignment of pump and driver. Shim up units ifnecessary. If misalignment reoccurs frequently, inspectthe entire piping system. Unbolt piping at suction anddischarge flanges to see if it springs away, thereby indicatingstrain on the casing. Inspect all piping supports forsoundness and effective support of load. Correct asnecessary.

EVERY YEARRemove the upper half of the casing. Inspect the pumpthoroughly for wear, and order replacement parts ifnecessary.

Check wear ring clearances. Replace when clearancesbecome three (3) times their normal clearance or when asignificant decrease in discharge pressure for the same flowrate is observed.

See Engineering Data Section for standard clearances.

Remove any deposit or scaling. Clean out stuffing boxpiping.

Measure total dynamic suction and discharge head as atest of pump performance and pipe condition. Record thefigures and compare them with the figures of the last test.This is important, especially where the fluid being pumpedtends to form a deposit on internal surfaces. Inspect footvalves and check valves, especially the check valve whichsafeguards against water hammer when the pump stops.A faulty foot or check valve will reflect also in poorperformance of the pump while in operation.

NOTE: The above time table is based on theassumption that after startup, the unit has beenconstantly monitored and such a schedule wasfound to be consistent with operation, as shown bystable readings. Extreme or unusual applicationsor conditions should be taken into considerationwhen establishing the maintenance intervals.

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cavity between the bearing and grease fitting. Any greateramount will, as a rule, be discharged by the seal or ventand be wasted.

The importance of proper lubrication cannot be overemphasized. Lubrication frequency depends upon thespeed, size and type of bearing, and operatingtemperature or environmental conditions. Generally, thesmaller the bearing and faster the speed, the morefrequent the interval for relubrication with grease. It isrecommended that a certain amount of grease be addedat intervals of three to six months to replace the smallquantity of grease lost between grease flushing intervals.For average bearing housing designs, one (1) ounce ofgrease will be sufficient at these intervals. For larger orsmaller bearing housings this amount may have to beadjusted.

Unfortunately, there is not a grease available which willnot harden over time and become less suitable for itspurpose due to oxidation. Therefore, it is good practice toremove all the old grease about once a year andthoroughly clean the bearings. This should be doneduring major overhauls. After gaining experience witheach individual pump and its operating characteristics, therelubrication and flushing intervals may be adjustedaccordingly. Keep good records and add grease atregular intervals. Then adjustments can be made after thefirst overhaul, if necessary.

PERIODIC ADDITION OF GREASEGrease lubricated ball bearings are packed with grease atthe factory. Store the pump in a clean, dry place prior toits first operation.

If one is uncertain about the amount of grease in abearing at relubrication intervals, the safe rule is to addgrease slowly (one ounce at a time) as the bearingoperates (if this is safe). Remember, a ball or rollerbearing in most applications is assured of adequatelubrication if the level of grease is maintained at about thecapacity of the bearing and 1/3 to 1/2 of the cavitybetween the bearing and grease fitting. Any greateramount will, as a rule, be discharged by the seals or ventand be wasted. Excess grease is the most commoncause of overheating of the bearings. Remove vent plugsfor the first 24 hours of operation after regreasing.

BEARING TEMPERATURENormally the maximum desirable operating temperaturefor ball bearings is 180° F. Special designs may havehigher limits. Should the temperature of the bearing framerise above the limit, the pump should be shut down todetermine the cause. A bearing frame which feels hot tothe touch of the hand is not necessarily running hot.Check with an accurate temperature measuring device tobe sure.

OIL LUBRICATION OF BEARINGSOil lubricated pumps are installed with Trico oilers.(See Fig. 15) The oilers keep the oil level in thehousings constant at proper level.

After the pump has been installed, flush the housingto remove dirt, grit, and other impurities that may haveentered the bearing housing during shipment orinstallation. Then refill the housing with properlubricant. (The housing must be filled using the Tricooiler.) The oil level will be maintained by the Tricooiler. (See the SERVICE section for the properinstructions.)

A Mobil Oil, DTE Medium, or equal, meeting thefollowing specification will provide satisfactorylubrication. Similar oils can be furnished by all majoroil companies. It is the responsibility of the oil vendorto supply a suitable lubricant.(1) Saybolt viscosity at 100° F . . . . . . . . 215 SSU-240 SSU

(2) Saybolt viscosity at 210° F . . . . . . . . . . . . . .49 SSU

(3) Viscosity index, minimum . . . . . . . . . . . . . . . . 95

(4) API gravity . . . . . . . . . . . . . . . . . . . . . .28-33

(5) Pour point, maximum . . . . . . . . . . . . . . . . +20° F

(6) Flash point, minimum . . . . . . . . . . . . . . . . 400° F

(7) Additives. . . . . . . . . . . . . Rust & Oxidation Inhibitors

(8) ISO viscosity . . . . . . . . . . . . . . . . . . . . . . 46

NOTE: Oils from different suppliers should notbe mixed. Engine oils are not recommended.

The oil should be a non-foaming, well refined, goodgrade, straight cut, filtered mineral oil. It must be freefrom water, sediment, resin, soaps, acid and fillers ofany kind.

Fig. 15

18

In installations with moderate temperature changes,low humidity, and a clean atmosphere, the oil shouldbe changed after approximately 1000 hours ofoperation. The oil should be inspected at this time todetermine the operating period before the next oilchange. Oil change periods may be increased up to2000-4000 hours based on an 8000 hour year. Checkthe oil frequently for moisture, dirt or signs of“breakdown”, especially during the first 1000 hours.

�! CAUTIONDo not over oil; this causes the bearings to runhot. The maximum desirable bearing housingoperating temperature for all ball bearings is180° F. Should the temperature of the bearingframe exceed 180° F (measured bythermometer) shut down pump to determinethe cause.

COUPLING LUBRICATIONFlexible couplings (Wood’s Sure-Flex or Falk Toruscoupling for instance) provide smooth transmission ofpower. There is no rubbing action of metal againstrubber to cause wear. Couplings are not affected byabrasives, dirt or moisture. This eliminates the needfor lubrication or maintenance, and provides cleanand quiet performance.

If other type couplings are used, follow maintenanceinstructions of coupling manufacturer.

SEALING INFORMATION

PACKING (NON-ASBESTOS)On packed pumps the packing is installed prior toshipment. All packings used are the highest gradematerial. Before pump is put into operation check thecondition of the packing. If pump is installed within sixty(60) days after shipment the packing will be in goodcondition with a sufficient supply of lubrication. If pump isstored for a longer period it may be necessary to repackthe stuffing box. In all cases, however, we recommend aninspection of the packing before pump is started.

The standard pump packing is made from braidedacrylic yarn impregnated with graphite.

A soft, well-lubricated packing reduces stuffing boxresistance and prevents excessive wear on the shaft orshaft sleeve. Many brands of packing on the market havethe desired qualities. Standard packing is John CraneStyle 1340, or equal.

When a pump with fiber packing is first started it isadvisable to have the packing slightly loose withoutcausing an air leak. As the pump runs in, gradually tightenthe gland bolts evenly. The gland should never be drawnto the point where packing is compressed too tightly andno leakage occurs. This will cause the packing to burn,score the shaft sleeve and prevent liquid from circulatingthrough the stuffing box cooling the packing. The stuffingbox is improperly packed or adjusted if friction in the boxprevents turning the rotating element by hand. A properlyoperated stuffing box should run lukewarm with a slowdrip of sealing liquid. After the pump has been inoperation for some time, and the packing has been inoperation for some time, and the packing has beencompletely run-in, drippage from the stuffing boxes shouldbe at least 40 to 60 drops per minute. This will indicateproper packing and shaft sleeve lubrication and cooling.

NOTE: Eccentricity of the shaft or sleevethrough the packing could result in excessleakage that cannot be compensated for.Correction of this defect is very important.

Packing should be checked frequently and replaced asservice indicates. Six months might be a reasonableexpected life, depending on operating conditions. It isimpossible to give any exact predictions. A packing toolshould be used to remove all old packing from the stuffingbox. Never reuse old and lifeless packing or merely addsome new rings. Make sure the stuffing box is thoroughlycleaned before new packing is installed. Also check thecondition of the shaft or sleeve for possible scoring oreccentricity, make replacements where necessary.

New packing (non-asbestos) should be placed carefullyinto the stuffing box. If molded rings are used, the ringsshould be opened sideways and the joints pushed intothe stuffing box first. The rings are installed one at a time,each ring seated firmly and the joints staggered at about a90° rotation from each preceding joint.

If coil packing is used, cut one ring to accurate size witheither a butt or mitered joint. An accurately cut butt joint issuperior to a poor fitting mitered joint. Fit the ring over theshaft to assure proper length. Then remove and cut allother rings to the first sample. When the rings are placedaround the shaft a tight joint should be formed. Place thefirst ring in the bottom of the stuffing box. Then installeach succeeding ring, staggering the joints as describedabove, making sure each ring is firmly seated.

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If your pump is supplied with seal cages (optional)make sure they are properly located in the stuffingboxes under the sealing water inlets. The function ofthe seal cage is to establish a liquid seal around theshaft, prevent leakage of air through the stuffing boxand lubricate the packing. If it is not properly located itserves no purpose.

MECHANICAL SEALSGeneral instructions for operation of the variousmechanical sealing arrangements are included below.It is not feasible to include detailed instructions for allmechanical seals in this booklet because of thealmost unlimited number of possible combinationsand arrangements. Instead, seal manufacturer’sinstructions will be included as a separate supplementto this book, where required.

a. Mechanical seals are precision products andshould be treated with care. Use special carewhen handling seals. Clean oil and clean partsare essential to prevent scratching the finelylapped sealing faces. Even light scratches onthese faces could result in leaky seals.

b. Normally, mechanical seals require no adjustmentor maintenance except routine replacement ofworn or broken parts.

c. A mechanical seal which has been used shouldnot be put back into service until the sealing faceshave been replaced or relapped. (Relapping isgenerally economical only in seals two inches insize and above.)

Four important rules which should always be followedfor optimum seal life are:

1. Keep the seal faces as clean as possible.

2. Keep the seal as cool as possible.

3. Assure that the seal always has properlubrication.

4. If seal is lubricated with filtered fluid, clean filterfrequently.

20

Problem Items Probable Cause Remedy

No LiquidDelivered

1 Lack of prime. Fill pump and suction pipe completely with liquid.

2 Loss of prime. Check for leaks in suction pipe joints and fittings; vent casing to removeaccumulated air. Check mechanical seal or packing.

3 Suction lift too high (a negative suctiongauge reading).

If there is no obstruction at inlet and suction valves are open, check for pipefriction losses. However, static lift may be too great. Measure with mercurycolumn or vacuum gauge while pump operates. If static lift is too high, liquidto be pumped must be raised or pump lowered.

4 System static head too high.Check with factory to see if a larger impeller can be used; otherwise, cut pipelosses or increase speed — or both, as needed. But be careful not toseriously overload driver.

5 Speed to low. Check whether motor is directly across-the-line and receiving full voltage.Frequency may be too low. Motor may have an open phase.

6 Wrong direction of rotation.Check motor rotation with directional arrow on pump casing. If rotation iscorrect with arrow, check the relationship of the impeller with casing. (Thiswill require removing casing upper half.)

7 No rotation. Check power, coupling, line shaft and shaft keys.

8 Impeller loose on shaft. Check key, locknut and set screws.

9 Impeller completely plugged. Dismantle pump and clean impeller.

10 System head or required discharge headtoo high.

Check pipe friction losses. Large piping may correct condition. Check thatvalves are wide open.

NotEnoughLiquidDelivered

11 Air leaks in suction piping.

If liquid pumped is water or other non-explosive and explosive gas or dustis not present, test flanges for leakage with flame or match. For suchliquids as gasoline, suction line can be tested by shutting off or plugginginlet and putting line under pressure. A gauge will indicate a leak with adrop of pressure.

12 Air leaks in stuffing box. Replace packing and sleeves if appropriate or increase seal lubricantpressure to above atmosphere.

13 Speed too low. See item 5.

14 Discharge head too high. See item 10.

15 Suction lift too high. See item 3.

16 Impeller partially plugged. See item 9.

17 Cavitation; insufficient NPSHA (Net PositiveSuction Head Available).

a. Increase positive suction head on pump by lowering pump or increasingsuction pipe and fittings size.

b. Sub-cool suction piping at inlet to lower entering liquid temperature.c. Pressurize suction vessel.

18 Defective Impeller and/or wear rings. Inspect impeller and wear rings. Replace if damaged or vane sectionsare badly eroded or if wear ring clearance is 3 times normal.

19 Foot valve too small or partially obstructed.Area through ports of valve should be at least as large as area of suctionpipe (preferably 1.5 times). If strainer is used, net clear area should be3 to 4 times area of suction pipe.

20 Suction inlet not immersed deep enough.If inlet cannot be lowered or if eddies through which air is sucked persistswhen it is lowered, chain a board to suction pipe. It will be drawn intoeddies, smothering the vortex.

21 Wrong direction of rotation.

Symptoms are an overloaded driver and about one third rated capacity frompump. Compare rotation of motor with directional arrow on pump casing.If rotation is correct with arrow, impeller may have to be turned 180º. (seeCHANGING ROTATION)

22 System head too high. See item 4.

23 Defective mechanical seal. Repair or replace seal.

NotEnoughPressure

24 Speed too low. See item 5.

25 Air leaks in suction piping or stuffing box. See item 11.

26 Mechanical defects. See item 18.

27 Vortex at suction inlet. See item 20.

28 Obstruction in liquid passages. Check to see if suction and discharge valves are fully open. Dismantlepump and inspect passages and casing. Remove obstruction.

29 Air or gases in liquid.May be possible to over rate pump to a point where it will provide adequate pres-sure despite condition. Better provide gas separation chamber onsuction line near pump and periodically exhaust accumulated gas. See item 17.

TROUBLE SHOOTINGBetween regular maintenance inspections, be alert for signs of driver or pump trouble. Common symptoms arelisted below. Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN.

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Problem Item Probable cause Remedy

PumpOperatesFor aShortTime,ThenStops

30 Insufficient NPSHA. See item 17

31 System head too high. See items 4 & 10.

PumpTakesToo MuchPower

32 Head lower than rating; thereby pumping toomuch liquid. Machine impeller’s O.D. to size advised by factory, or reduce speed.

33 Cavitation. See item 17.

34 Mechanical defects. See items 18, 19, 21, and 23.

35 Suction inlet not immersed. See item 20.

36 Liquid heavier (in either viscosity or specificgravity) than allowed for.

Use larger driver. Consult factory for recommended size. Test liquidfor viscosity and specific gravity.

37 Wrong direction of rotation. See item 6.

38 Stuffing box glands too tight. Release gland pressure. Tighten reasonably. If sealing liquid doesnot flow while pump operates, replace packing.

39 Casing distorted by excessive strains fromsuction or discharge piping.

Check alignment. Examine pump for rubbing between impeller andcasing. Replace damaged parts. Re-pipe pump.

40 Shaft bent due to damage — throughshipment, operation, or overhaul.

Check deflection of rotor by turning on bearing journals. Totalindicator run-out should not exceed .002" on shaft and .004"on impeller wearing surface.

41 Mechanical failure of critical pump parts. Check wear rings and impeller for damage. Any irregularity in theseparts will cause a drag on shaft.

42 Misalignment. Realign pump and driver.

43 Speed may be too high Check voltage on motor. Check speed versus pump nameplate rating.

44 Electrical defectsThe voltage and frequency of the electrical current may be lower thanthat for which motor was built, or there may be defects in motor. Themotor may not be ventilated properly do to a poor location.

45 Mechanical defects in turbine, engine or othertype of drive exclusive of motor. If trouble cannot be located consult factory.