Download - Aurora Pump Maintenance
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Aurora PumpsAurora Pumps
Installation & Maintenance Tool
Kit 101
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Installation and MaintenanceInstallation and Maintenance
To ensure proper operation of any pumpingsystem, it is imperative that the pump
should be installed to the pump
manufacturers specifications, operated in
the proper manner and maintained to ensure
continued performance. Above all the pumpshould always be operated or worked on in
a safe manner.
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Maintenance Tool KitMaintenance Tool Kit
Safety Base Installation
Coupling Alignment
Piping Alignment
Grouting
Stuffing Boxes Packing
Mechanical Seals Anti-Friction Bearings
Sleeve Bearings
Checking Rotation
Starting of Pump
Looking for Trouble Conclusion
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SafetySafety
When working on a pump or any piece of rotatingequipment the following safeguards should be put
in place:
Wear safety glasses. Wear a hard hat, (this is important to not only to protect
from falling items, but as a bump hat as well).
Do not wear any loose fitting clothing or jewelry whichcan catch on the equipment.
Long hair should always be tied back.
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Safety ContinuedSafety Continued
System safeguards should also be put in place: Lock out the electrical power to the pump if you are
going to be working on the pump or checking the
alignment.
Notify authorities or building operators that you are
there to do maintenance or operate the pump.
Only operate the pump with coupling guard in placeand with all controller doors in the closed and secured
position.
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Base InstallationBase Installation
Alignment-Base mounted units come fromthe factory with pump and motors on a
common base. These units were properly
aligned at the factory but most likely have
shifted during shipping. To ensure proper
operation of the pumping units the baseshould be mounted on the foundation and
leveled to allow for proper alignment.
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Leveling the BaseLeveling the Base
The pump should be installed on the foundationwith the pump/motor coupling halvesdisconnected. The coupling should not bereconnected until the alignment process has beencompleted.
Wedge type shims should be used to level thebase. These will left in place during the groutingprocedure.
A gap of .5 to .75 should be maintained between
the base and foundation to allow grout to fill inunder the base.
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Typical Base/FoundationTypical Base/Foundation
InstallationInstallation
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Typical Base/FoundationTypical Base/Foundation
InstallationInstallation
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Coupling AlignmentCoupling Alignment
Flexible couplings are not designed to compensatefor misalignment of the pump and motor
combination. Alignment must be checked for the
following: Axial Alignment-Spacing between coupling halves.
Parallel Alignment-Proper side to side, up and down
alignment between coupling halves. Angular Alignment-Face to face alignment of the
coupling halves.
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Aligning the couplingAligning the coupling
In all cases, the coupling should be alignedto the manufacturers specifications.
Failure to comply will not only void the
warranty, but can also create a hazardous
situation.
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Examples of couplingExamples of coupling
misalignmentmisalignment
Parallel
Angular
Axial
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Methods of coupling alignmentMethods of coupling alignment
In many cases, using astraight edge is the
recommended
procedure for aligninga coupling. This
applies mainly to
rough finished, closedcoupled, elastomeric
couplings.
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Methods of coupling alignmentMethods of coupling alignment
For angular alignment,
and also axial
alignment, calipers
and feeler gages arethe most popular
methods of alignment.
Again follow themanufacturers
instructions.
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Methods of coupling alignmentMethods of coupling alignment
In many cases a dial
indicator is used. This
can be used to check
both parallel andangular adjustment.
This method is used
commonly with allmetallic couplings and
spacer type couplings.
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Methods of coupling alignmentMethods of coupling alignment
Example of dial
indicator and ID
calipers or
micrometers for spacercoupling alignment.
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Methods of coupling alignmentMethods of coupling alignment
Example of aligning a
metal grid type
coupling. Distance
between the shafts isalways a consideration
when doing coupling
alignment.
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Coupling AlignmentCoupling Alignment After initial installation of the pump, several
factors may disturb the coupling alignment:
Loose nuts or bolts on the pump or driver.
Pipe strain on the pump.
Temperature changes in high temperature applications.
Settling, seasoning, or springing of the foundation.
Shifting of the building or floor.
Alignment verification should be doneperiodically and especially when there is any workdone on the pump or driver.
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Piping AlignmentPiping Alignment
Piping alignment is often overlooked duringthe installation and maintenance of a pumpunit. The pump is not designed to support
the forces and moments of a piping system.In fact just the opposite. All piping, suctionand discharge, should be supported and
restrained near the pump. If an expansionjoint is used there should a pipe anchorbetween the pump and the expansion joint.
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Piping Alignment ContdPiping Alignment Contd
Connections
All connections should use proper mating. E.g. a flat
face flange should use a flat face companion flange and
gasket.
All connections should make up easily. If force is
required to line up bolt holes etc than that force will
be transferred to the pump. Pipe strain can cause the
pump to bind as many of the tolerances are very close.
All connections shall be secure to prevent leakage or
the entrance of air into the system.
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GroutingGrouting
Once the base has been leveled, thecoupling has been aligned, and the piping
has been connected and supported, it is
important to grout the base.
The base should be entirely grouted with
foundation bolts being tightened 48 hoursafter grouting.
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Stuffing BoxesStuffing Boxes Stuffing boxes are designed to be used with
packing, with or without a lantern ring. Thelantern ring assists in lubricating the packing.Make sure that the lantern ring is placed where it
receives the maximum fluid. In externally flushedpumps at the flush line connection, and at theinternal groove on internally flushed pumps.
If the liquid being pump is gritty or dirty, it isusually recommended that a outside source ofclean liquid is used to flush the stuffing box.
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PackingPacking Packing should be the type recommended by the pump
manufacturer. Packing rings are split and should be installed at 90 degree
intervals so that they do not provide a channel for the water
to pass through the stuffing box. Packing should not be overly compressed as this can cause
damage to the shaft sleeve.
Packing should only be compressed with the packinggland, and only when the pump is filled with fluid. A slightadjustment should be made at that time to stop the flow ofwater. In some cases with high suction pressure this may
not be possible.
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PackingPacking When the pump is started the packing gland should be
adjusted to reduce the flow to about 1 drop per second.Tightening of the gland should be done equally to avoid
binding or uneven pressure of the packing on the sleeve.
Packing when replaced should always be replaced as a set. Never add more than specified amount of rings to a pump.
When working on older pumps take caution when
changing out the packing as older pumps may haveasbestos packing in them. Always make sure that any
packing in stock is the non-asbestos type.
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Mechanical SealsMechanical Seals Mechanical seals are the most typical and efficient
way of sealing a pump.
Mechanical seals require no adjustment, butshould be checked periodically for leaks, toprevent a catastrophic seal failure.
In the event of the pump running dry it is
recommended that the seals be changed, as theyare lubricated by the fluid being pumped in mostcases and will more than likely be damaged.
Take great care in keeping the seal faces cleanduring installation to prevent seal failure.
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Sleeve BearingsSleeve Bearings Sleeve bearings are typically used in vertical
pumps.
These pumps are lubricated either by:
Product
Grease
Outside Source, (water or oil)
It is imperative that the bearings are alwayslubricated.
Greasing the bearings should only be done when
the pump is idle, never while the pump isoperating.
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AntiAnti--Friction BearingsFriction Bearings In most cases of failures with anti-friction
bearings, it is too much oil or grease that causesmost failures. Oil and grease should be checked atinstallation and checked periodically thereafter.
For grease lubricated bearings a high grade anti-friction grease should be used and in no casesshould a graphite grease be used.
Oil lubricated bearings should be used in a methodand amount as recommended by the manufacturer.
Record keeping of lubrication of the pump is agood practice.
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Checking RotationChecking Rotation With all electric motor driven pumps it is
imperative to check rotation of the motor driver.
This should be done at start up and anytime that
the motor or controller is re-connected. This should always be done with the coupling
disconnected. On a close coupled pump a mark
should be made on any visible shafting. A qualified electrician should make the changes to
the wiring to ensure proper rotation.
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Starting a PumpStarting a Pump The pump should only be started with the pump
fully primed. If an automatic air release valve isnot furnished the air should be bled out of thepump manually.
In a negative suction application the pump shouldbe primed manually from an outside source orwith a vacuum pump.
The position of all suction and discharge valves inthe system should be noted. It is imperative thatthe suction valve be in the fully open position.
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Starting a Pump ContdStarting a Pump Contd When starting a pump good record keeping should
be maintained. It is a good practice to record all of
the following, where possible, for future reference:
Flow Pressure
Temperature of fluids
Temperature of bearings Pump vibration levels
Pump noise levels
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Looking for TroubleLooking for Trouble No discharge:
Pump not primed or suction closed.
Speed too low.
System head too high. Wrong rotation or impeller on backwards.
Air leak on the suction or through stuffing box.
Broken shaft. Insufficient minimum submergence, (vertical pumps)
Blockage in impeller.
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Looking for TroubleLooking for Trouble Insufficient Discharge:
Wear rings or impeller wear.
Insufficient NPSH.
Impeller installed backwards or wrong rotation. Suction valve not opened completely.
System head is too high.
Speed too low.
Blockage in impeller.
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Looking for TroubleLooking for Trouble
Insufficient Pressure: Speed too low.
System head less than anticipated.
Worn impellers or wear rings.
Impeller diameter smaller than specified.
Wrong rotation or impeller installed backwards. Blockage in impeller.
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Looking for TroubleLooking for Trouble Cavitation can be caused by many things. It
is the point of operation where entrained airis in the pump casing and air can damage
the innards of a pump. Examples of causes: Insufficient NPSH
Open system like a cooling tower with high
suction losses allowing a vortex or suction ofair into the pump.
Blockage in a closed loop system.
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ConclusionConclusion Proper installation and maintenance will
ensure long life performance of your pumpoperating system.
Proper record keeping will help youmaintain your pump and measure yourpumps performance.
Proper safety and maintenance are keys toyour pumps overall successful operation.