manual : std: is-5120: series: vcp

DOC. NO. : VP-MM-VCP-03/0

MANUAL FORInstructions on Installations,

Operation and Maintenance of Type VCPPump applicable for 2+1 Bearing with

single driving head

Manufactured by :Varat Pump & Machinery Pvt. Ltd.

20, NETAJI SUBHAS ROADKOLKATA – 700 001

WEST BENGALINDIA

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DOC NO.:VP-MM-VCP-03/0

Contents

PointNo.

Description PageNo.

1.0 General 31.1 Model Coverage 31.2 Storage 31.3 Long Storage 32.0 Installation 32.1 Location 32.2 Foundation 32.3 Handling 42.4 Leveling 42.5 Flexible Coupling 42.6 Alignment 52.7 Misalignment 52.8 Grouting 82.9 Piping 82.10 Suction Pipe 82.11 Delivery Pipe 82.12 Vacuum Equalizing Line 82.13 Foot Valve 102.14 Stuffing Boxes and Packing 102.15 Lubrication 112.16 Ball Bearing 112.17 Priming 113.0 Preparation of Pump Starting 124.0 Starting and Stopping of the Pump 125.0 Bearing 136.0 Lubricant 137.0 Stuffing Box 148.0 Gasket 149.0 Coupling 1410.0 Guide Ring / Wearing Ring 1411.0 Shaft Sleeve 1412.0 Spare Parts 1413.0 Trouble Shooting 1514.0 Maintenance 1714.1 Daily Checks 1714.2 Periodical Maintenance 1715.0 Overhauling 1715.1 Dismantling of Pump 1715.2 Reassembling of Pump 18

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1.1 The Operation & Instruction Manual is required to read carefully who will work on this Pump sets. Theworking Instruction should be followed strictly so that damages to the equipment, specially for the Pumpis avoided. This book let covers instructions for following Models of VARAT Centrifugal Back Pull OutProcess Pump Model:

40VCP2, 40VCP3, 40VCP3N, 50VCP1, 50VCP2, 50VCP3, 65VCP3, 65VCP3M, 65VCP3N,80VCP1, 80VCP1K, 80VCP2, 100VCP2,

1.2 When the pumps are received sometime before the use of the pump it should be located in dry place. Thecoupling should be rotated once in a month to prevent pilling of bearing surfaces.

1.3 When the pumps kept idle for a period after one use, it should be cleaned properly and overhauling shouldbe made before long storage.

Unauthorized Modes of OperationTo ensure operational reliability and safety of the pump / unit supplied, the machine shall be usedexclusively in accordance with its designated use as described in the following sections. The limitsstated in the data sheet must not be exceeded under any circumstances.

Unauthorized Modification and Manufacture of Spare PartsModifications or alterations of the machine are only permitted after consultation with the manufacturer.Original spare parts and accessories authorised by the manufacturer ensure safety. The use of otherparts can invalidate any liability of the manufacturer for consequential damage.

2.1 LOCATION

The pump should be located as near the liquid source as possible. This will minimise the suction lift andpump will give better performance.Ample space should be provided on all the sides so that the pump can be inspected while in operation andcan be serviced conveniently whenever required.

2.2 FOUNDATION

The foundation should be sufficiently substantial to absorb any vibration and to form a permanent rigidsupport for the base plate. This is important in maintaining the alignment of a direct connected unit. Aconcrete foundation on a solid base is advisable. Foundation bolts of the proper size should be embeddedin the concrete located by a drawing or template. A pipe sleeve about two and one-half diameter largerthan the bolt should be used to allow movement for the final position of the foundation bolts.

1.0 GENERAL

2.0 INSTALLATION3.0

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2.3 HANDLING

The pump set should be properly handled and slung for transport. Do not thread the ropes through theeyebolt on the Motor or Pump during handling complete set. During handling do not remove the blankrubber gasket provided on the suction and discharge nozzles. Lifting equipment must be able toadequately support the entire assembly. Hoist bare pump using suitable slings under the outboard end ofthe bearing frame and under the suction flange.

Warning : Pump and Components are heavy. Failure to properly lift and support equipment couldresult in serious physical injury or damage to pumps

2.4 LEVELLING

When the unit is received with the pump and driver mounted on the base plate, it should be placed on thefoundation and the coupling halves disconnected. The coupling should not be reconnected until allalignment operations have been completed. The base plate must be supported evenly and placed closed tothe foundation bolt. In each case, the supports should directly under the part base plate carrying thegreatest weight and spaced closely enough to give uniform support. A gap of about 25 to 50 mm should beallowed between the base plate and foundation of grouting. Supporting will be such that it will not bedistorted or sprung by the uneven distribution of the weight. Adjust the wedges until the shafts of thepump and driver are in level. Check the coupling faces, suction and discharge flanges for the horizontalor vertical position by means of spirit level.

2.5 FLEXIBLE COUPLING

A flexible coupling will not compensate for misalignment of the pump and driver shafts. The purpose ofthe flexible coupling is to compensate for temperature changes and to permit the movement of the shaftswithout interference with each other while transmitting power from the driver to the pump.

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2.6 ALIGNMENT

Pumps and drivers that are supplied by the manufacturers, mounted on a common base plate areaccurately aligned before despatch. All base plates are flexible to some extent and alignments are likely tobe disturbed during transit to some extent and therefore must not be relied upon to maintain the factoryalignment. Re-alignment is necessary after the complete unit has been leveled on the foundation and againafter the grout has set and foundation bolts have been tightened. The alignment must be checked after theunit is piped up and re-checked periodically.

2.7 MISALIGNMENT

There are two types of misalignment between the Pump shaft and the driver shaft:(a) Angular misalignment: Shafts with axis concentric but not parallel.(b) Parallel misalignment: Shafts with axis Parallel but not concentric.

The unit can then be grouted by soft concrete under the edges.

DIAL GAUGE ALIGNMENT

An approved method for putting the coupling halves in final accurate alignment is by the use of a dialindicator. Check the alignment by straight edge and fillers as accurately as possible as described above.Fasten the indicator to the pump half of the coupling with the indicator button resting on the other half ofthe coupling periphery (FIG 3). Set the dial to the 0 and chalk mark the coupling half beside where thebottom rests. For any check, top or bottom or sides, rotate both shafts by the same amount i.e. all readingson the dial must be made with bottom beside the chalk mark. The dials reading will indicate whether thedriver has to be raised or lowered or moved to either side. Accurate alignment of shaft center can beobtained with this method.

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ALIGNMENT OF SPACER TYPE COUPLING

Where a spacer type coupling is used between the pump and driver, it is may not be possible to align thecouplings to the pump and driver exactly as described above. To align unit with a floating coupling,remove the spacer between the pump and driver. Use a magnetic stand and place the dial indicator asgiven in FIG 4, make a chalk mark of the coupling half beside where the bottom rest and set the dial toZero. To check for parallel alignment, rotate both shafts be the same amount i.e. all readings are madewith the bottom beside the chalk mark. After parallel alignment has been obtained change the indicator soit bears against the face of the same coupling half and follow the same procedure to check angularalignment that were used for parallel alignment. The angular alignment may also to check by using insidemicrometer as shown in FIG 4. After final alignment is obtained, insert the spacer and bolt the couplinghalves.

ALIGNMENT CRITERIAGood alignment is attained when readings as specified in this section have been achieved with pump anddriver at operating temperatures (final alignment). Table 1 shows maximum allowable Total IndicatorReading (T.I.R.) for parallel and angular misalignment.

Maximum AllowableParallel and Angular Misalignment

GroupMaximum Allowable Misalignment

Parallel Angular

All0.05 mm(.002 in.)

0.03 degrees[0.125 mm/cm (.0005in. /in.) of coupling

face diameter]

NOTE A: For electrical motros, motor shaft initial (cold) parallel vertical alignment settings shouldbe 0.05-0.10mm (.002-0..4 in) lower than pump shaft.

NOTE B: For other drivers (turbines, engine etc.), follow driver manufacturers’ recommendation.

ALIGNMENT TROUBLESHOOTINGProblem Probable Cause Remedy

Cannot obtain horizontal (Side-to-Side)alignment, angular or parallel

Driver feet bolt bound.Loosen pump hold down bolts and slidepump and driver until horizontal lignmentis achieved.

Baseplate not leveledproperly, probablytwisted.

Determine which corner(s) of thebaseplate are high or low and adjustleveling screws at the appropriatecorner(s) and realign.

Cannot obtain vertical (Top-to-Bottom)alignment, angular or parallel

Base plate not leveledproperly, probablybowed.

Determine if center of baseplate shouldbe raised or lowered and correct byadjusting leveling screws equally at thecenter of the baseplate.

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2.8 GROUTINGWhen the alignment is correct, the foundation bolts should be tightened evenly but not too firmly.Working soft concrete under the edges can then grout the unit. Foundation bolts should not be fullytightened until the grout is hardened, usually 48 hours after pouring.

2.9 PIPINGBoth suction and delivery pipes and accessories should be independently supported near the pump so thatwhen the flange bolts are tightened no strain will be transmitted to the pump casing. It is usually advisableto increase the size of both suction and delivery pipes at the pump nozzles in order to decrease the loss ofhead from friction and for the same reason piping should be arranged with as minimum bends as possible,as these should be made with a long radius wherever possible. The pipe lines should be free from scales,welding residuals etc., and have to be mounted in such way that they can be connected to suction anddelivery flanges without any stress on the pump. Adequate supports should be given to pipe lines so thatthe weight of the pipelines does not fall on the pump. The use of minimum number of the bends and otherfittings will minimise the friction losses.

2.10 SUCTION PIPEThe suction pipe should be as short as possible. This can be achieved by placing the pump close to theliquid to be pumped. The suction pipe must be kept free from air leaks. This is particularly importantwhen the suction lift is high. A horizontal suction line must have a gradual rise towards the pump. Anyhigh point in the pipe will be filled with air and thus prevent proper operative of the pump. A concentrictaper piece should not be used in a horizontal suction line as it forms an air pocket in the top of the reducerand the pipe. Use an eccentric per piece (FIG 5).The end of the suction pipe must be well submerged to avoid whirlpools and ingress of air but must bekept clear of any deposits of mud, silt grit etc. The pipe must be clear from any side of wall by at least450mm. The end of the suction pipe should be provided with a strainer of sufficient open area.

2.11 DELIVERY PIPEA check (non-return) valve and a gate or sluice valve (regulating valve) should be installed in thedischarge line. The check valve placed between the pump and the gate valve is to protect the pump fromexcessive pressure and to prevent water running back through the pump in case of failure of the drivingmachine i.e.-excessive backpressure.Discharge piping should be provided with a sluice valve to control the discharge, if required. The valve isused in primary, starting and when shutting down the pumps. If increaser is used on the discharge side toincrease the size of discharge piping they should be placed between the check valve and pump.

2.12 VACCUM EQUALIZING LINE (AND LIQUID LINE) (SEE FIGURE 6)

If the pump draws from system under vacuum a equalizing pipe min 25 NB must be carried from thehighest point of the suction line, however, as close to the suction flange of the pump as, to the top of thefeed tank to keep gas bubbles that might have been entrapped in the flow from entering the pump. Theline should be fitted with an isolating valve, which should be closed only for maintenance work on thepump set.Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air and in the case ofpumps with packed stuffing box It is convenient to tap the sealing liquid from the delivery line above thenon-return valve.

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2.13 FOOT VALVE

It is advisable to install a foot valve to facilitate priming of pump. Foot valve should have sufficient clearpassage for water. Care must be taken to prevent foreign matter from being drawn into the pump orchoking the foot valve and for this purpose an efficient strainer should be provided.

2.14 STUFFING BOXES AND PACKING

Stuffing boxes should be carefully cleaned and the packing placed in them. Be sure that sufficientpacking is placed at the back of the water seal cage. If the water to be pumped is dirty or gritty, sealingwater should be piped to the stuffing boxes from clean outside source of supply in order to preventdamage to the packing and shaft. In placing the packing, each packing ring should be cut to the properlength & ends at 450 so that ends come into correct contact with one another but do not overlap. Thefollowing packing rings are then inserted into the packing compartment one by one making sure that thebutt joint of each ring is offset by 900 approx. in relation to the butt joint of the preceding ring. Thesucceeding rings of packing should be placed in the Stuffing Box so that the joints of the several rings ofpacking are staggered and cutting the shaft. If the stuffing box is not properly packed, friction in stuffingbox prevents turning the rotor by hand. On starting the pump, Stuffing Box Packing should be left slightlyloose without causing an air leak, and if it seems to leak instead of putting too much pressure on the gland,put some heavy oil in the stuffing box until the pump works properly and then gradually tighten up thegland. The packing should be occasionally changed. Cutting of the packing rings to correct length &ends at 450 most important so that ends come into correct contact with one another.

MECHANICAL SEAL (MOSTLY APPLICABLE FOR SINGLE BALANCE SEAL)

Since mechanical seals are made in a wide variety of designs, the instruction for the specific seal must becarefully studied and followed exactly. A Mechanical Seal is a precision device and must be treatedaccordingly. If any leakage is found, observe carefully whether it is found from:-1) Between shaft & sleeve or2) Between stuffing box flange and sleeve or3) Between stuffing box and seal coverFor clause no.1 PTFE gaskets & ‘O’ ring (Item no. 03 & 17) are to be replaced. For clause no.2 ifadequate leakage from the sleeve surface is found then after inspection of the seal face damage,compression of the seal is to be increased. Unscrewing 4 nos.align screws for holding rotary part on thesleeve, you have to slide the seal rotary part towards the stationary part and tightening the 4 nos. alignscrew can do this. You have to keep the compression of the seal about 3 to 4 mm. If the leakage is littlethen it is normally through the `O’ Ring provided inside the rotary seal. The ring may be required to bereplaced. For clause no.3 tighten the 4 nos. gland nut (No. 35), if any further leakage found then sealcover ‘O’ ring/gasket (No.13) is to be replaced.

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2.15 LUBRICATION

Pump is usually provided with a special auto feed oil lubrication pot. Initially fill up oil at the drivinghead through the breather port. The oil pot provided at the side of driving head, is to be removed, duringinitial filling. When oil just comes out from the port then replace the oil pot and stop the oil fillingthrough the breather part. Lift the oil pot as explained in the figure 7 and fill up oil at the pot. Release thepot and find that due to spring action pot will take its place. Oil level inside the pot will decreaseautomatically until the pre-determined required level is reached. The repetition of the process of oil potfilling is required if you find the pot empty. Never fill up oil through others part of oil pot, which maycause excess filling of lubricating oil. This will result in excess rise of temperature of the bearing.

Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigradeabove ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Explained withbelow figure. The Bearing Housing should be filled with oil of any one of the following types andspecification :

Indian Oil Servosystem 46Hindustan Petroleum Enklo 46Bharat Petroleum Bharat Hydrol 68

2.16 BALL BEARING

Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as guideto relubrication periods under normal conditions.Quarterly when on continuous duty.Half yearly when on eight-hour per day duty.The bearings and housings should be completely cleaned and recharged with fresh oil after 2500 hours orthe nearest pump overhaul time.

2.17 PRIMING

No pumping action occurs unless the pump casing is filled with liquid. Pump casing and suction pipe musttherefore be completely filled with the liquid and thus all air removed before the pump is started. Severaldifferent priming methods can be used depending on the kind of installation and service involved.

(1) Liquid level above pump level.Pump is set below liquid level of source of supply so that liquid always flows to pump underpositive head.

(2) Priming with Foot Valve.(a) When pump is installed on suction lift with foot valve at the end of suction line, fill pump

with water from some outside source till all air is expelled and water flows through airvent or filled up up to Delivery flange of Pump.

(b) When there is liquid under some pressure in the discharge pipe, priming can be effectedby bypassing the pressure liquid around the check and gate valve. Provide one stop cockat bypass line. Of course, the initial priming must be effected from some outside source.

NOTE: In this case, the foot valve must be capable of withstanding pump pressure and possiblesurge.

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(3) Priming by ejector: An ejector operated by steam, compressed air or water under pressure andconnected to air vent on top of casing can be used to remove air from and prime the pump onsuction lift installations.

(4) Priming by dry vacuum pump: A hand or power pump sucks in all the air from the casing and thesuction pipe, and thus primes the system

After the pump and the drive are mounted, the plant should be prepared for starting. The followingrules should be observed before starting the pump:

The pins or pad should be inserted into the coupling or placement of spacer for spacer coupling not beforemaking sure of the correct rotation of drive motor. In case of the drive rotating in the wrong direction, theconnection of two cable conductors supplying the current to the motor should be interchange in case ofDOL starting.

Check presence of oil in bearings and correct location of water deflector on shafts that ensure flashing,quenching, and lubrication in case of mechanical seal as well as if required as per design.

Gland packing should be tightly stuffed, but not over tightened. The sealing packing should be tightenedto such an amount as to allow the pumping liquid to seek to the outside. Over tightening of sealingpacking causes quick wear out of shaft sleeves, increases its friction and lowers the efficiency factor of thewhole plant.

Check the free rotation of pump rotor, turning it by hand to verify any major obstruction or friction withwearing parts.

Check the proper order of suction and pressure pipelines, tightening of flanges, fittings of inlet valve andpresence of drain plug.

Check the correct direction of rotation of pump and drive. The pump rotor should rotate according todirection of rotation marked on pump.

Getting reasonably sure of the proper order of the whole plan and its readiness for operation, the suctionpipe should be primed with water / liquid. Arrangement for priming funnel and three ways connection ofpressure gauge with air-cock after delivery flange but before delivery sluice valve is required.

The pump is being filled up (Primed) until the air-cock produces water jet without air bubbles. Then theprimary funnel, air-cock and sluice valve is required to be closed. After all these operation and checking,the pump is ready for starting.

The pump should be loaded gradually, when the drive is engaged. When the prime movers attain fullspeed, the regulating sluice valve should be smoothly opened. This will avoid overloading of the drive.

On the other hand it should be kept in mind that a lengthy operation with completely close sliding valve islikewise to be avoided, since this causes unnecessary heating of the liquid in the pump.

3.0 PREPARATION OF PUMP STARTING:

4.0 STARTING AND STOPPING OF THE PUMP:

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By controlling the sliding valve the required flow and head may be obtained. After setting of pressuregauge at required point, check ampere consumption. If found value exceeds required value, pump shouldbe stopped

Generally the pump is supplied with 2 nos. anti-friction ball bearings or angular contact ball bearing at DEand 1 no ball or self align roller bearing at NDE according to the load factor of pump. Bearings are ofSKF/NBC/RHP/ equivalent make.

Bearings are normally oil lubricated. Bearing temperature is permissible to rise 40 degree Centigradeabove ambient temperature. For oil lubrication, oil should be maintained in the oil pot. Level is maintainin bearing housing. Explained with below figure. The Bearing Housing should be filled with oil of anyone of the following types and specification :

Indian Oil Servosystem 46Hindustan Petroleum Enklo 46Bharat Petroleum Bharat Hydrol 68

Procedure :

Unscrew vent plug. Pour in oil through the vent plug aperture after having hinged down the reservoir ofthe constant level oiler until oil appears in the vertical portion of the connection elbow of the constantlevel oiler (see figure below). Then fill the reservoir of the constant level oiler with oil and snap it backsmartly into the operation position. Screw vent plug in again. After a short time has elapsed, checkwhether the oil level in the reservoir has sunk. The reservoir should always remain filled.

6.0 LUBRICANT:

5.0 BEARING:

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Stuffing Boxes are extra deep and suitable soft packing and/or for single balance mechanical seal.Mechanical seal must be over oiled before starting the pump after long time storage. Soft-packing stuffingboxes reduce the flow of leakage liquid at the clearance gap between casing and shaft protection sleevewhen the pressure inside the pump is higher than atmospheric. Conversely, on pumps which operate onsuction lift, the soft-packed stuffing box prevents the ingress of air into the pump.

Compressed asbestos packing gasket for joining of volute casing is used. However, packing gasketsuitable to handle corrosive liquid and high temperature fluid is supplied against specific requirements.

Normally star type spider coupling with spacer is used. Other type of coupling may be supplied againstspecific requirements.

Replaceable throat bush as guide ring and wearing ring for protection of both side of impeller provided atcasing cover (optional) and Volute Casing of pumps.

Replaceable sleeve for protecting the shaft and for Balance seal step sleeve is being provided. Sleeve isextended beyond seal cover or gland flange.

One set Anti-friction bearing, Wearing Ring, Shaft Sleeve, Gland Packing/ Mechanical seal, Sleevegasket, Gasket for Impeller nut, Lantern ring, and Gasket & “O” ring set must always be kept with theactual users of the pump to ensure uninterrupted service from the pump.

7.0 STUFFING BOX:

8.0 GASKET

9.0 COUPLING

10.0 GUIDE RING / WEARING RING

11.0 SHAFT SLEEVES

12.0 SPARE PARTS

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SL.NO. DEFECTS CAUSES REMEDY1. Pump does

not deliverliquid.

(1)Insufficient quantity ofwater/water not filled in pumpcasing

(1) Fill up pump casing withclear water or liquid to bepumped.

(2) Incorrect direction ofrotation.

(2) Change the direction ofrotation of prime mover.

(3) Pump is clogged. (3) Check up Impeller mayclog. Clean Suction pipe andStrainer.

(4) Pump speed too low. (4) Check up speed of primemover and adjust.

(5) Suction Lift too high. (5) Reduce Suction Lift.(6) Leakage in Suction Pipe. (6) Prevent leakage in suction

Pipe.(7) Incorrect layout of SuctionLine.

(7) Correctly install theSuction Line.

(8)Valve in Suction Line notopen properly.

(8) Check up the opening ofline valve.

(9) Shaft Sleeve & Glandpacking worn and air leaks.

(9) Replace Shaft-Sleeve &Gland Packing.

(10) Delivery liquid too viscous. (10) Liquid viscosity to bechecked & corrected.

(11) Incorrect selection of pumpfor operating condition.

(11) Replace the pump with asuitable designed capacity.

2. Flow notadequate.

(1) Speed too low. (1) Check up speed of primemover and adjust.

(2) Leakage in Suction sidefitting and piping

(2) Prevent leakage in suctionpipe and fittings.

(3) Discharge Head too high.Excessive high back pressure.

(3) Check up vertical headobstruction of frictionallosses. Adjust duty point.

(4) Pump Casing or Piping arenot vented carefully.

(4) Fill up the pump casing/vented pressure pipe.

(5) Rubber Flap Valve clogged. (5) Check up rubber Flapassembly & leakage frompump casing.

(6) Leakage through seal and airleaks.

(6) Check Mechanical Sealunit and rectify/replace ifrequired.

(7) More clearance betweenImpeller and Wearing Plate.

(7) Measure the clearancebetween Impeller and WearingPlate and adjust by usingproper Packing.

(8) Suction lift too high orsuction pipe too long.

(8) Avoid High Suction liftand Suction piping.

(9) formation of air pocket (9) After piping layout fit avent valve

(10) Supply line or Impellerpassage obstruction

(10) Remove deposit in pipingand inside of Impeller

13.0 TROUBLE SHOOTING

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SL.NO.

DEFECTS CAUSES REMEDY

3. Pumptakes morePower.

(1)Opening Voltage is too low. (1) Provide required voltage(2) Specific gravity of liquid ishigher than specified.

(2) Reduce speed if possible.

(3) Motor running on two phase (3) Rectify defective phase(4) Speed too high. (4) Check and correct the speed.(5) Head/Back pressure less thanrating.

(5) Provide minimum head. Adjustduty point

(6) Shaft Bent (6) Check and replace the Shaft.(7) Misalignment of the set. (7) Correct the alignment.

4. Ratedpressurenotdeveloped.

(1) Prime mover not running at ratedspeed.

(1) Check the speed of Prime moverand correct it.

(2) Leakage through Gland Packing. (2) Replace Gland Packing.(3) Too much clearance betweenImpeller and Wearing plate.

(3) Measure the clearance betweenImpeller and Wearing plate andadjust by using proper packing.

5. Pumpvibratesand makesmorenoise.

(1) Pump casing not filled withWater/Liquid (it is only possibleonly during priming time).

(1) Fill up the pump casing.

(2) Suction lift too high. (2) Reduce the suction lift or installthe Foot valve.

(3) Mis- alignment (3) Correct the alignment.(4) Foundation not rigid (4) Check up the foundation bolt.(5) Shaft bent (5) Replace the shaft(6) Bearing Worn out (6) Check & replace Bearing.(7) Lack of Lubrication (7) Lubricate the Bearings.(8) Pump operating at very lowcapacity.

(8) Reduce total head.

6. Bearingshave shortlife.Increase inBearingTemperature

(1) Misalignment (1) Correct the alignment.(2) Shaft bend (2) Check the shaft condition.(3) Excessive Oil or lack of oil. (3) Check up lubrication.(4) Dirty water getting into Bearings. (4) Protect bearing neatly.(5) Pump is on vibration in the pipeline

(5) Check pipe line & ensure properfixing of pipe line. Reduce distanceof piping support. Fix pipe lineusing anti vibration material.

7. Excessivepressure

(1)Speed is too high than rated RPM (1) Adjust speed to the rated RPM

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Preventative maintenance schedule are the periodical checks and precautions by which possibilities offailures and breakdowns are made very remote.

14.1 Daily ChecksPressure gauge readingBearing temperatureLeakage through stuffing boxNoise and vibrationVoltage and currentConstant flow of cooling water.

14.2 Periodical MaintenanceReplace the oil for bearing lubrication.Change of stuffing box packing.Check the alignment of the pump set.Calibrate the measuring instruments.Check the sealing and cooling connections etc.

Normally the pump will be due for overhauling after about 3000 working hours. Pump dismantling andassembling should be done by skilled personal. Special attention should be given to continuous runningpumps & advice is to keep stand by pump for emergency services.

15.1 DISMANTLING OF PUMP: (Refer cross section drawing with list of component.)

1. Remove Coupling Guard, Pressure Gauge, Oil Pot, Cooling Pipe, Flash Pipe and other fittings asapplicable. Drain out pumping liquid by removing casing drain plug (Item.26) and drain out oil fromBearing Housing by removing plug (Item.42)

2. The Design advantage of this BPO pumps is, dismantling of pump can be done without disturbing thepipe line connected to suction or delivery flange. If spacer type coupling is provided than remove bothside spacer bolt (Item.21) by unscrewing it and then remove the spacer of the coupling (Item. 24).Remove support foot (Item 45) by unscrewing the bolt (Item.46) and removing bolt & nut of baseframe fixed with it the support leg.

3. Unscrew and remove the nut from the stud (Item 29) for casing and take out the Driving Headassemble with impeller and shaft along with bearing housing without disturbing the pump casing.Take assistance of forcing screw if provided for removal of Casing Cover from Casing(Item no.03).Special care may be taken during removal of casing cover to save the casing gasket.

4. To dismantle dynamic assembly, first unlock the lock washer (Item no.03) of impeller lock nut (ifapplicable) and remove impeller lock nut (Item 01) by unscrewing it. Remove lock washer (Optional).Now pull out the Impeller (Item 04) from shaft and take out the Impeller key (Item no.05).

5. In case of mechanical seal don’t disturb the gland nut (Item 35). After removal of impeller take out theguide ring/throat bush (Item no.08) unscrewing 4 numbers screw(Item 07). For gland packed pumpremove gland flange (Item no.34) and then take out Stuffing Box Packing (Item 31) and Lantern Ring(Item 30) one by one after removal of Throat Bush for Mechanical Seal application, take out sleevewith mechanical seal rotating assembly from non-driving end. This is major advantage of our

14.0 MAINTENANCE

15.0 OVERHAULING

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mechanical seal design that you can remove the rotating part of seal without disturbing the stuffingbox. Remove key for sleeve (optional) before removal of the sleeve.

6. Remove Casing Cover (Item no.28) with stuffing Box (Item no.11) (along with gland flange formechanical seal pump) from the driving head by removing the bolt (Item 33). In special case for fewmodel casing cover and stuffing box are integrally casted.

7. For mechanical seal pumps remove seal cover fitted with stationary parts of mechanical seal fromstuffing box by unscrewing 4 Nos. gland nut (Item no.35). Take out the mating rings (stationary seal)from the seal cover along with seal secondary ‘O’ ring for inspection of stationary face & ‘O’ringcondition.

8. Remove align screw (Item no.22) provided at coupling, take out pump coupling half & Key forcoupling (Item no.23).

9. Remove both side baring cover (Item 39&53) by unscrewing bolt (Item no.38&49) provided for it.Remove both side oil seal (Item no.41&52) from bearing covers.

10. Carefully take out the pump shaft (Item no.20) together with bearings (item no.43) towards drivingend. In few model NDE bearing provided self align cylindrical rotter type instead of ball bearingproviding a cieclip inside NDE housing. Check the condition of NDE bearing housing circlip andreplace it if required (Applicable for self align cylindrical bearing if provided at NDE.) RemoveNDE roller case of cylindrical roller bearing from housing.

11. Unlock bearing lock washer (Item no.51) and remove bearing lock nut (Item no 50) by unscrewing itbefore removal of the bearing from the shaft. Pull out D.E. bearings (Item no 47) from the shaft andtake out NDE bearing (Item no.43) or the inner race of the cylindrical roller bearing as applicable.

12. Check wearing ring provided at casing and casing cover (optional) (Item no. 02 & 06) and if requiredreplaced it. Wearing ring may be provided with cod screw. Pull out the wearing rings after removingthe cod screw if provided.

13. After removal of all above pump parts it is necessary to check up properly for any wear and tear and ifany part is found to be worn out, the same should be replaced or rectified. Special care should betaken for check up of Wearing ring, Sleeve, Throat Bush, Mechanical Seal, Lantern Ring, BearingsGasket & ‘O’ Ring.

15.2 Reassembling of Pump:

1. The pump should be reassembled in accordance with the rules of sound engineering practice. Beforereassembling all parts are to be cleared and it is advised to paint all the parts which are withoutmachined faces. Paints should be dry before reassembling. Bearings are to be cleaned with petrol.All machined faces should be rubbed with suitable Lubricant, Lubricant to be applied on screwedcomponents also.

2. Reassembly proceeds in reverse sequence to dismantling. Fit driving end bearings (Item no.43) withthe pump shaft (2 nos. Bearing to be fitted back to back if supplied with angular contact ball bearingsas applicable) lock with lock washer clip after slipped on lock washer (Item no.50) and screwed onbearing lock nut (Item no.51) firmly fix up of lock washer. After tightening of bearing fold the lockwasher peak to lock the nut . NDE ball bearing (Item no.43) or inner ring of self-align bearing fornon-driving end is to be fitted with the shaft. For oil lubrication don’t apply any grease to theBearings. If bearings are not replaced then provide few drops of oil at bearings. For NU series selfalign bearing only outer ring of N.D.E. roller bearing to be inserted at N.D.E. bearing housing afterproviding the circlip at inside bose of NDE housing.(Bearing & Inner ring may be preheated on oil

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bath to 800C before fixing at shaft).

3. Insert the pump shaft with bearing assembly from driving end inside bearing housing keeping properdirection of shaft. Fixed up bearing at its position by a press fit.

4. Fix up bearing cover at driving end (Item no.53) and other bearing cover (Item no.39) at non-drivingend. Don’t forget to replace Bearing Cover Gasket (Item no.40&48) and the Oil Seal inside BearingCover (Item no.41&52) before insert it. Put coupling key (Item no.23) at shaft, fit pump half couplingand tighten the coupling grub screw (Item no.21).

5. For balance mech. seal pump gland flange is to be fitted with stationary part (Item no.15) of the sealby hand press fit providing ‘O’ ring (Item no.14) for it. At first stuffing box(Item no.11) is to be fittedwith Casing Cover (Item no.28). Then the gland flange (Item no.34) along with the stationary seal isto be fitted with stuffing box tightening the Gland Nut (Item no.35). Provide gasket /’O’ ring (Itemno.13) before placement of seal cover. Also check for ‘O’ ring (item no.36) and if required replace it.

6. Now fixed up casing cover (Item no.28) with bearing housing (Item no.18) i.e. driving head-shaftassembly and tighten the stud-nut/bolt (Item no.33) as applicable.

7. Before mounting the seal on the sleeve measure the distance of seal face from setting face of throatbush and additional compression to be required at about 3 to 4mm. Sleeve may be provided with aseparate key / lock screw (Item no.36) for locking it. Provide key if applicable after placement of thesleeve. Provide guide ring /Throat Bush (Item no.08) and tight 4nos screw (Item no.07) to fix upthroat bush from NDE.

8. Put impeller key(Item no.05) to shaft and PTFE gasket(if applicable) between sleeve and impeller andfix up the impeller on the shaft. Tighten the impeller lock nut. Provide a lock washer (if applicable)between impeller and nut and lock the nut by lock it by folding the tooth of washer after full tight.

9. Now the assembly is ready to fit with volute casing providing one recommended ring gasket(Itemno.27).Fit all oil pot, seal flash pipe, pressure gauge and other fittings applicable. This completes the re-assembling.

10. While ordering the spares please inform us your pump sl. No. along with item no. and Cross Sectiondrg. no.

Recommended Stock of Spare Parts for two years of Operation

Item No. DesignationNumber of Pumps (including standby pumps)

2 3 4 5 6 8 10 and moreQuantity of spares parts

42 Pump Shaft 1 1 2 2 2 3 30%01 Impeller 1 1 1 2 2 3 30%37 Bearing (DE) 1 1 2 2 3 4 50%34 Bearing (NDE) 1 1 2 2 3 4 50%12 Guide Ring 1 1 2 2 2 3 30%19 Stuffing Box Packing/Mechanical

Seal2 2 3 3 3 4 40%

06 Wearing Ring 2 2 3 3 3 4 50%08 Wearing Ring 2 2 3 3 3 4 50%14 Shaft Sleeve 2 2 3 3 3 4 50%09 Casing Gasket 4 6 8 8 9 12 150%11,13,16,26,29 Other secondary seal like ‘O’ Ring 4 6 8 8 9 12 150%

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manual : std: is-5120: series: vcp

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