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P81875G
User Manual
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Bell & Gossett P81875G User Manual

INSTRUCTION MANUAL
381875
REVISION G
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
Series HSC and HSC-S Base Mounted Centrifugal Pumps
DESCRIPTION
The HSC and HSC-S Series centrifugal pumps are frame mounted pumps which feature – high efficiency, rugged con­struction, compact design, foot mounted volute, center drop out coupler, and regreasable bearings. These features, along with the horizontal split case, make installation, operation, and service easy to perform.
PUMP APPLICATION
The standard HSC and HSC-S Series centrifugal pump’s bronze fitted construction make it ideal for service with the following liquids: unheated domestic and fresh water, boiler feed water, condensate, hydronic cooling or heating, pressure boosting, general pumping and benign liquids.
For other applications contact your local B&G representative.
OPERATIONAL LIMITS
Unless special provisions have been made for your pump by Bell & Gossett, the operational limits for HSC and HSC-S Series Pumps are as follows:
Maximum Working Pressure,
Listed on pump nameplate.
SEAL OPERATING LIMITS
Standard Self Flushing Mechanical Seals
BUNA-PH Limitations 7-9; Temperature Range -20 to +225°F EPT-PH Limitations 7-11; Temperature Range -20 to +250°F For use on closed or open systems which are relatively free of dirt and/or other abrasive particles.
PUMP IDENTIFICATION
Bell & Gossett pumps are designated by a series of numbers such as Series HSC and HSC-S. The pump nameplate gives identification and rating information as identified in Illustration 1.
Permanent records for this pump are kept by the serial number and it must be used therefore with all correspondence and spare parts orders.
Illustration 1 – The Rating Plate
2
ADDITIONAL SAFETY REQUIREMENTS:
NYLON SLING, CHAIN OR WIRE ROPE
CHOKER HITCH AROUND BEARING FRAME
ELECTRICAL SAFETY:
MECHANICAL SAFETY:
WARNING: Electrical Shock Hazard
Electrical connections to be made by a qualified electrician in accordance with all applicable codes, ordi­nances, and good practices. Failure to follow these in­structions could result in serious personal injury or death, or property damage.
WARNING: Electrical Overload Hazard
Three phase motors must have properly sized heaters to provide overload and undervoltage protection. Single phase motors have built-in overload protectors. Failure to follow these instructions could result in serious personal injury or death, or property damage.
THERMAL SAFETY:
WARNING: Extreme Temperature Hazard
If pump, motor, or piping are operating at extremely high or low temperatures, guarding or insulation is re­quired. Failure to follow these instructions could result in serious personal injury or death, or property damage.
PUMP LOCATION
Locate the pump so there is sufficient room for inspection, main­tenance and service. If the use of a hoist or tackle is needed, allow ample head room.
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing. Failure to follow these instructions could result in serious personal injury or death, or property damage.
WARNING: Excessive System Pressure Hazard
The maximum working pressure of the pump is listed on the nameplate, do not exceed this pressure. Do not use air to hydrotest pump. Failure to follow these instructions could result in serious personal injury or death, or property damage.
WARNING: Excessive Pressure Hazard
Volumetric Expansion
The heating of water and other fluids causes volumetric expansion. The associated forces may cause failure of sys­tem components and release of high temperature fluids. This will be prevented by installing properly sized and located compression tanks and pressure relief valves. Failure to follow these instructions could result in serious personal injury or death, or property damage.
WARNING: Falling Objects Hazard
Eyebolts or lifting lugs, if provided, are for lifting only the components to which they are attached. Failure to fol­low these instructions could result in serious personal injury or death, or property damage.
If lifting base pump is required, use a nylon string, chain, or wire rope, hitch around both bearing supports. If lifting of the entire pump is required, do so with slings placed under the base rails as shown.
The best pump location for sound and vibration absorption is on a concrete floor with subsoil underneath. If the pump loca­tion is overhead, special precautions should be undertaken to reduce possible sound transmission. Consult a sound specialist.
If the pump is not on a closed system, it should be placed as near as possible to the source of the liquid supply, and located to permit installation with the fewest number of bends or elbows in the suction pipe.
COMPRESSION TANK SHOULD BE LOCATED ON THE SUCTION SIDE OF THE PUMP
B&G REDUCING
COLD
WATER
SUPPLY
4
VALVE
FROM BOILER
CHILLER OR CONVERTER
B&G ROLAIRTROL
AIR SEPARATOR
ISOLATION
VALVE
SUPPLY
TO SYSTEM
B&G CIRCUIT
SETTER
B&G TRIPLE DUTY
VALVE
Illustration 3
The installation must be evaluated to determine that the Net Positive Suction Head Available (NPSHA) meets or exceeds the Net Positive Suction Head Required (NPSHR), as stated by the pump performance curve. See page 9 for more details on proper suction piping installation.
IMPORTANT
Do not install and operate Bell & Gossett Pumps, 3D Valves, Suction Diffusers, etc., in closed systems unless the system is constructed with properly sized safety devices and control devices. Such devices include the use of properly sized and located pressure relief valves, compression tanks, pressure con­trols, temperature controls, and flow controls as appropriate. If the system does not include these devices, consult the respon­sible engineer or architect before making pumps operational.
General HSC and HSC-S Instructions
INTRODUCTION
1. Purpose of Manual
This manual is furnished to acquaint you with some of the practical ways to install, operate, and maintain this pump. Read it completely before doing any work on your unit and keep it handy for future reference.
Equipment cannot operate well without proper care. To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.
2. Warranty
Refer to your local representative for warranty coverage.
3. Pump Identification
All pumps are designated by Serial Number, Model Number, and Size. This information is stamped on an identification plate which is mounted on the pump. Refer to pump identifi­cation in specific instruction section of this manual for detailed information.
4. Installation
5. Receiving Pump
Check pump for shortages and damage immediately upon arrival. (An absolute must.) Prompt reporting to the carrier’s agent with notations made on the freight bill, will expedite satisfactory adjustment by the carrier.
Pumps and drivers normally are shipped from the factory mounted and painted with primer and one finish coat. Couplings may be either completely assembled or have the coupling hubs mounted on the shafts and the connecting members removed. When the connecting members are removed, they will be packaged in a separate container and shipped with the pump or attached to the base plate.
Shafts are in alignment when the unit is shipped; however, due to shipping, the pumps may arrive misaligned and, therefore, alignment must be established during installation. Bell & Gossett has determined that proper and correct alignment can only be made by accepted erection practices. Refer to the fol­lowing paragraphs on “Foundation,” “Base Plate Setting,” “Grouting Procedure,” “Alignment Procedure” and “Doweling.”
6. Temporary Storage
If the pump is not to be installed and operated soon after arrival, store it in a clean, dry place having slow, moderate changes in ambient temperature. Rotate the shaft periodically to coat the bearings with lubricant and to retard oxidation, corrosion, and to reduce the possibility of false brinelling of the bearings.
7. Location
The pump should be installed as near the suction supply as possible, but no less than five suction diameters (refer to page 9, suction and discharge piping section) with the shortest and most direct suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction line) should not exceed the limits for which the pump was sold.
The pump must be primed before starting. Whenever possible, the pump should be located below the fluid level to facilitate priming and assure a steady flow of liquid. This condition pro­vides a positive suction head on the pump. It is also possible to prime the pump by pressurizing the suction vessel.
When installing the pump, consider its location in relation to the system to assure that sufficient Net Positive Suction Head (NPSH) at pump suction is provided. Available NPSH must always equal or exceed the required NPSH of the pump.
The pump should be installed with sufficient accessibility for inspection and maintenance. A clear space with ample head room should be allowed for the use of an overhead crane or hoist sufficiently strong to lift the unit.
NOTE: Allow sufficient space to be able to dismantle pump without disturbing the pump inlet and discharge piping.
Select a dry place above the floor level wherever possible. Take care to prevent pump from freezing during cold weather when not in operation. Should the possibility of freezing exist during a shut-down period, the pump should be completely drained, and all passages and pockets where liquid might col­lect should be blown out with compressed air.
Make sure there is a suitable power source available for the pump driver. If motor driven, electrical characteristics should be identical to those shown on motor data plate.
8. Foundation
A substantial foundation and footing should be built to suit local conditions. It should form a rigid support to maintain alignment.
The foundation should be poured without interruption to within
1
/2 to 11/2 inches of the finished height. The top surface of the foundation should be well scored and grooved before the concrete sets; this provides a bonding surface for the grout.
5
Foundation bolts should be set in concrete as shown in Illustration 4. An optional 4-inch long tube around the bolts at the top of the concrete will allow some flexibility in bolt align­ment to match the holes in the base plate. Allow enough bolt length for grout, shims, lower base plate flange, nuts and washers. The foundation should be allowed to cure for several days before the base plate is shimmed and grouted.
FOUNDATION
BOLT
WASHER
(OPTIONAL)
PIPE
SLEEVE
BUILT-UP CONCRETE FOUNDATION
Illustration 4 – Foundation
9. Base Plate Setting (Before Piping)
NOTE: This procedure assumes that a concrete foundation
has been prepared with anchor or hold down bolts extending up ready to receive unit. It must be understood that pump and motor have been mounted and rough aligned at the factory. If motor is to be field mounted, consult factory for recommenda­tions. Bell & Gossett cannot assume responsibility for final alignment.
NOTE: TO KEEP SHIMS IN
ALLOW 1" FOR SHIMS. PLACE ON BOTH SIDES OF ANCHOR BOLTS.
APPROX.
1" GAP
LEVELING OF PUMP BASE ON CONCRETE FOUNDATION.
Illustration 5 – Setting Base Plate and Grouting
PLACE ALLOW GROUT TO FLOW AROUND HOLD DOWN LUGS.
GROUT
CONCRETE FOUNDATION
GROUT ONLY TO TOP OF BASE RAIL.
PUMP BASE RAIL
a. Use blocks and shims under base for support at anchor
bolts and midway between bolts, to position base approximately 1" above the concrete foundation, with studs extending through holes in the base plate.
b. By adding or removing shims under the base, level and
plumb the pump shaft and flanges. The base plate does not have to be level.
c. Draw anchor nuts tight against base, and observe pump
and motor shafts or coupling hubs for alignment. (Tem­porarily remove coupling guard for checking alignment.)
6
d. If alignment needs improvement, add shims or wedges at
appropriate positions under base, so that retightening of anchor nuts will shift shafts into closer alignment. Repeat this procedure until a reasonable alignment is reached.
NOTE: Reasonable alignment is defined as that which is mutually agree upon by pump contractor and the accepting facility (final operator). Final alignment procedures are cov­ered under “Alignment Procedures.”
e. Check to make sure the piping can be aligned to the pump
flanges without placing pipe strain on either flange.
f. Grout in base plate completely (See “Grouting Procedure”)
and allow grout to dry thoroughly before attaching piping to pump. (24 hours is sufficient time with approved grouting procedure.)
10. Grouting Procedure
Grout compensates for uneven foundation, distributes weight of unit, and prevents shifting. Use an approved, non-shrinking grout, after setting and leveling unit (See Illustration 5).
a. Build strong form around the foundation to contain grout.
b. Soak top of concrete foundation thoroughly, then remove
surface water.
c. Base plate should be completely filled with grout.
d. After the grout has thoroughly hardened, check the founda-
tion bolts and tighten if necessary.
e. Check the alignment after the foundation bolts are
tightened.
f. Approximately 14 days after the grout has been poured or
when the grout has thoroughly dried, apply an oil base paint to the exposed edges of the grout to prevent air and mois­ture from coming in contact with the grout.
11. See ANSI/OSHA Coupler Guard Removal/Installation
(next page)
12. Alignment Procedure
NOTE: A flexible coupling will only compensate for small
amounts of misalignment. Permissible misalignment will vary with the make of coupling. Consult coupling manufacturer’s data when in doubt.
Allowances are to be made for thermal expansion during cold alignment, so that the coupling will be aligned at operating temperature. In all cases, a coupling must be in alignment for continuous operation. Even though the coupling may be lubri­cated, misalignment causes excessive wear, vibration, and bearing loads that result in premature bearing failure and ultimate seizing of the pump. Misalignment can be angular, parallel, or a combination of these, and in the horizontal and vertical planes. Final alignment should be made by moving and shimming the motor on the base plate, until the coupling hubs are within the recommended tolerances measured in total run-out. All measurements should be taken with the pump and motor foot bolts tightened. The shaft of sleeve bearing motors should be in the center of its mechanical float.
NOTE: Proper alignment is essential for correct pump opera­tion. This should be performed after base plate has been properly set and grout has dried thoroughly according to instructions. Final alignment should be made by shimming driver only. Alignment should be made at operating temperatures.
WARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury or death and property damage.
11. ANSI/OSHA COUPLER GUARD
INNER GUARD
ATTACH SUPPORT BRACKET TO BEARING HOUSING
THIS OPTION USED IN PLACE OF SPACER WHERE OVERALL LENGTH OF GUARD EXCEEDS 12 INCHES OR GUARD WIDTH IS OVER 10 INCHES ACROSS THE FLATS.
OUTER GUARD
NUT
LOCKWASHER
LOCATE SUPPORT ARM BETWEEN OUTER GUARD ENDS. ALIGN THE ARM WITH HOLES IN THE OUTER GUARD AND HOLES IN THE SADDLE BRACKET.
BRACKET SUPPORT
CAPSCREW
FLAT WASHER
BRACKET SUPPORT
ATTACHES INSIDE HERE
IN LINE WITH BOLT
MOTOR SADDLE BRACKET ATTACH TO MOTOR SADDLE
SPACER WASHER
SUPPORT BRACKET
REMOVAL/INSTALLATION
WARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury or death and property damage.
NOTE: Do not spread the inner and outer guards more than necessary for guard removal or installation. Over spreading the guards may alter their fit and appearance.
Removal
a. Remove the two capscrews that hold the outer (motor side)
coupler guard to the support bracket(s).
b. Spread the outer guard and pull it off the inner guard.
c. Remove the capscrew that holds the inner guard to the
support bracket.
d. Spread the inner guard and pull it over the coupler.
Installation
a. Check coupler alignment before proceeding. Correct if
necessary.
b. Spread the inner guard and place it over the coupler.
c. With the inner guard straddling the support bracket, install a
capscrew through the hole (or slot) in the support bracket and guard located closest to the pump. Do not tighten the capscrew.
d. Spread the outer guard and place it over the inner guard.
e. Install the outer guard capscrews by following the step
stated below which pertains to your particular pump:
i. For pumps with a motor saddle support bracket: Ensure
the outer guard is straddling the support arm, and install but do not tighten the two remaining capscrews.
ii. For pumps without a motor saddle support bracket:
Insert the spacer washer between the holes located closest to the motor in the outer guard, and install, but do not tighten, the two remaining capscrews.
f. Position the outer guard so it is centered around the shaft,
and so there is less than a 1/4" of the motor shaft exposed. On guards that utilize a slotted support bracket, the inner guard will have to be positioned so there is only a 1/4" of the pump shaft exposed.
g. Holding the guard in this position, tighten the three
capscrews.
ANSI/OSHA Coupling Guard Exploded View for Typical Series HSC and HSC-S Pump Installation
7
Method 1 – Straight Edge Alignment for Standard Sleeve Type Coupler with Black Rubber Insert (See Illustration 6A)
1
Before aligning the coupler, make sure there is at least
/8" end
clearance between the sleeve and the two coupler halves.
1. Check angular misalignment using a micrometer or caliper. Measure from the outside of one flange to the outside of the opposite flange at four points 90° apart. DO NOT ROTATE COUPLER. Misalignment up to
1
/64" per inch of
coupler radius is permissible.
2. At four points 90° apart (DO NOT ROTATE COUPLER), measure the parallel coupler misalignment by laying a straight edge across one coupler half and measuring the gap between the straight edge and opposite coupler half. Up to a
1
/64" gap is permissible.
STRAIGHT EDGE
FEELER GAGE
ANGULAR ALIGNMENT PARALLEL ALIGNMENT
INCORRECT ALIGNMENT
STRAIGHT EDGE
FEELER GAGE
CORRECT ALIGNMENT
Method 2 – For Orange Hytrel Inserts, 3500 RPM Operation, or All Other Coupler Types (See Illustration 6B)
a. Make sure each hub is secured to its respective shaft and
that all connecting and/or spacing elements are removed at this time.
b. The gap between the coupling hubs is set by the manufac-
turer before the units are shipped. However, this dimension should be checked. (Refer to the coupling manufacturer’s specifications supplied with the unit.)
c. Scribe index lines on coupling halves as shown in
Illustration 5B.
d. Mount dial indicator on one hub as shown for parallel align-
ment. Set dial to zero.
e. Turn both coupling halves so that index lines remain
matched. Observe dial reading to see whether driver needs adjustment (See paragraph i below).
f. Mount dial indicator on one hub as shown for angular align-
ment. Set dial to zero.
g. Turn both coupling halves so that index lines remain
matched. Observe dial reading to see whether driver needs adjustment (See paragraph i below).
h. Assemble coupling. Tighten all bolts and set screw(s). It
may be necessary to repeat steps c through f for a final check.
i. For single element couplings, a satisfactory parallel mis-
alignment is .004"T.I.R., while a satisfactory angular mis­alignment is .004"T.I.R. per inch of radius R (See Figure 5B).
Final Alignment
Final alignment cannot be accomplished until the pump has been operated initially for a sufficient length of time to attain operating temperature. When normal operating temperature has been attained, secure the pump to re-check alignment and compensate for temperature accordingly. See Alignment Section.
Illustration 6A – Checking Alignment (Method 1)
PARALLEL ALIGNMENT
ANGULAR ALIGNMENT
Illustration 6B – Checking Alignment (Method 2)
DIAL INDICATOR
INDEX LINE
R
RESILIENT SEPARATOR
DIAL INDICATOR
WARNING: Rotating Components Hazard
Do not operate pump without all guards in place. Failure to follow these instructions could result in serious personal injury or death and property damage.
OPTIONAL Alignment Procedure
If desired, the pump and motor feet can be doweled to the base after final alignment is complete. This should not be done until the unit has been run for a sufficient length of time and alignment is within the tolerance. See Doweling Section.
CAUTION: Extreme Temperature and/or
Flying Debris Hazard
Eye protection and gloves required. Failure to follow these instructions could result in property damage and/or moder­ate personal injury.
NOTE: Pump may have been doweled to base at factory.
8
9
13. DOWELING
CHECK VALVE
GATE VALVE
INCREASER
CORRECT
C OF PIPE
SUCTION PIPE INSTALLED WITH A GRADUAL RISE TO PUMP
L
LEVEL
AIR POCKET
INCORRECT
AIR POCKET
INCORRECT
AIR POCKET
INCORRECT
GRADUAL RISE TO PUMP
NO AIR POCKETS
CORRECT
NO AIR POCKETS
GRADUAL RISE TO PUMP
ECCENTRIC REDUCER
CORRECT
DISTANCE PLUS ECCENTRIC REDUCER STRAIGHTENS FLOW
CORRECT
PATH OF WATER
INCORRECT
Dowel the pump and driving unit as follows:
a. Drill holes through diagonally opposite feet and into the
base. Holes must be of a diameter diameter of the dowel pins. Clean out the chips.
b. Ream the holes in feet and base to the proper diameter for
the pins (light push fit). Clean out the chips.
c. Insert pins to be approximately flush with feet.
14. SUCTION AND DISCHARGE PIPING
General
When installing the pump piping, be sure to observe the fol­lowing precautions:
Piping should always be run to the pump.
Do not move pump to pipe. This could make final alignment impossible.
Both the suction and discharge piping should be supported independently near the pump and properly aligned, so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe hangers or other supports at necessary intervals to provide support. When expansion joints are used in the piping system, they must be installed beyond the piping supports closest to the pump. Tie bolts should be used with expansion joints to prevent pipe strain. Do not install expan­sion joints next to the pump or in any way that would cause a strain on the pump resulting from system pressure changes. It is usually advisable to increase the size of both suction and discharge pipes at the pump connections to decrease the loss of head from friction.
Install piping as straight as possible, avoiding unnecessary bends. Where necessary, use 45-degree or long sweep 90-degree fitting to decrease friction losses.
Make sure that all piping joints are air-tight.
Where flanged joints are used, assure that inside diameters match 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 be pumped.
Suction Piping
When installing the suction piping, observe the following precautions (See Illustration 7).
The sizing and installation of the suction piping is extremely important. It must be selected and installed so that pressure losses are minimized and sufficient liquid will flow into the pump when started and operated. Many NPSH (Net Positive Suction Head) problems can be attributed directly to improper suction piping systems.
Friction losses caused by undersized suction piping can increase the fluid’s velocity into the pump. As recommended by the Hydraulic Institute Standard ANSI/HI 1.1-1.5-1994, suc­tion pipe velocity should not exceed the velocity in the pump suction nozzle. In some situations pipe velocity may need to be further reduced to satisfy pump NPSH requirements and to control suction line losses. Pipe friction can be reduced by using pipes that are one to two sizes larger than the pump suction nozzle in order to maintain pipe velocities less than 5 feet/second.
1
/64 inch less than the
10
Illustration 7 – Suction Pipe Installations
(Piping Supports Not Shown)
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