EBARA EFQT8 User Manual

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Self Priming Trash Pump

Model EFQT-8

Installation, Operation and Maintenance Manual

Ebara Fluid Handling

Ebara International Corporation

TABLE OF CONTENTS
INTRODUCTION...........................................................................................	Pg. 03
WARNING – SECTION A..........................................................................	Pg. 04
INSTALLATION – SECTION B....................................................................	Pg. 05
Pump Dimensions......................................................................	Pg. 05
PREINSTALLATION INSPECTION.................................................	Pg. 06
POSITIONING PUMP......................................................................	Pg. 06
Lifting..........................................................................................	Pg. 06
Mounting.....................................................................................	Pg. 06
Clearance...................................................................................	Pg. 06
SUCTION AND DISCHARGE PIPING.............................................	Pg. 06
Materials.....................................................................................	Pg. 06
Line Configuration......................................................................	Pg. 07
Connections to Pump.................................................................	Pg. 07
Gauges.......................................................................................	Pg. 07
SUCTION LINES..............................................................................	Pg. 07
Fittings........................................................................................	Pg. 07
Strainers.....................................................................................	Pg. 07
Sealing.......................................................................................	Pg. 07
Suction Lines in Sumps..............................................................	Pg. 07
Suction Lines Positioning...........................................................	Pg. 08
DISCHARGE LINES.........................................................................	Pg. 08
Siphoning...................................................................................	Pg. 08
Valves.........................................................................................	Pg. 08
Bypass Lines..............................................................................	Pg. 09
AUTOMATIC AIR RELEASE VALVE...............................................	Pg. 10
Theory of Operation...................................................................	Pg. 10
Air Release Valve Installation.....................................................	Pg. 10
ALIGNMENT....................................................................................	Pg. 11
Coupled Drivers..........................................................................	Pg. 12
V-Belt Drives..............................................................................	Pg. 12
OPERATION – SECTION C.........................................................................	Pg. 14
PRIMING..........................................................................................	Pg. 14
STARTING.......................................................................................	Pg. 14
Rotation......................................................................................	Pg. 14
OPERATION....................................................................................	Pg. 15
Lines With a Bypass...................................................................	Pg. 15
Lines Without a Bypass..............................................................	Pg. 15
Leakage......................................................................................	Pg. 15
Liquids Temperature and Overheating.......................................	Pg. 15
Strainer Check............................................................................	Pg. 16
Pump Vacuum Check.................................................................	Pg. 16
STOPPING.......................................................................................	Pg. 16
Cold Weather Preservation........................................................	Pg. 16
BEARING TEMPERATURE CHECK...............................................	Pg. 16
EBARA Fluid Handling	1

TABLE OF CONTENTS (Continued)

TROUBLESHOOTING – SECTION D ………………………............	Pg. 18
PUMP MAINTENANCE AND REPAIR – SECTION E………..........	Pg. 21
PERFORMANCE CURVE………………………………………..........	Pg. 21
Pump Model …………………………………………………..........	Pg. 22
PARTS LISTS.................................................................................	Pg. 23
Repair Rotating Assembly…………………………………...........	Pg. 24
PARTS LISTS.................................................................................	Pg. 25
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY…............	Pg. 26
Back Cover and Wear Plate Removal……………………...........	Pg. 26
Suction Check Valve Removal……………………………...........	Pg. 26
Rotating Assembly Removal………………………………...........	Pg. 26
Impeller Removal……………………………………………..........	Pg. 27
Seal Removal………………………………………………….........	Pg. 28
Shaft and Bearing Removal and Disassembly…………….........	Pg. 28
Shaft and Bearing Reassembly and Installation…………..........	Pg. 29
Seal Installation…………………………......................................	Pg. 30
Impeller Installation………………………………………............	Pg. 33
Rotating Assembly Installation……….……………………...........	Pg. 33
Suction Check Valve Installation…………………………............	Pg. 34
Back Cover Installation……………………………………............	Pg. 34
PRESSURE RELIEF VALVE MAINTENANCE.............................	Pg. 34
Final Pump Assembly...............................................................	Pg. 35
LUBRICATION............................................................................	Pg. 35
Seal Assembly .........................................................................	Pg. 35
Bearings....................................................................................	Pg. 35
Power Source............................................................................	Pg. 35

EBARA Fluid Handling

INTRODUCTION

This Installation, Operation, and Maintenance manual is designed to help you get the best performance and longest life from your EBARA pump.

This pump is a EFQT Series, semi-open impeller, self priming centrifugal model with a suction check valve.

The pump is designed for handling mild industrial corrosives, mud or slurries containing large entrained solids. The basic material of construction is gray iron, with ductile iron impeller and steel wearing parts.

If there are any questions regarding the pump or its applications which are not covered in this manual or in other literature accompanying this unit, please contact your EBARA distributor, or write:

EBARA Fluid Handling

1651 Cedar Line Drive

Rock Hill, SC 29730

For information or technical assistance on the power source, contact the power source manufacture’s local dealer or representative.

The following are used to alert maintenance personnel to procedures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel:

DANGER!

Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure required and the injury which will result from failure to follow procedure.

CAUTION!

Hazards or unsafe practices could result in minor personal injury or product or property damage. These instructions describe the requirements and the possible damage which could result from failure to follow the procedure.

NOTE

Instructions to aid in installation, operation, and maintenance or which clarify a procedure.

EBARA Fluid Handling

SAFETY – SECTION A

These warnings apply to EFQT series basic pumps. EBARA has no control over or particular knowledge of the power source which will be used. Refer to the manual accompanying the power source before attempting to begin operation.

WARNING!

After the pump has been positioned, make certain that the pump and all piping connections are tight, properly supported and secure before operation.

WARNING!

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Disconnect or lock out the power source to ensure that the pump will remain inoperative.

3.Allow the pump to cool if overheated.

4.Check the temperature before opening any covers, plates, or plugs.

5.Close the suction and discharge valves.

6.Vent the pump slowly and cautiously.

7.Drain the pump

WARNING!

Do not operate the pump without the guards in place over the rotating parts.

Exposed rotating parts can catch clothing, fingers, or tools, causing severe injury to personnel.

WARNING!

Do not remove plates, covers, gauges, pipe plugs, or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to cool before servicing.

WARNING!

Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed discharge valve, pump components will deteriorate, and the liquid could come to a boil, pressure, and cause the pump casing to rupture or explode .

WARNING!

This pump is designed to handle mild industrial corrosives, mud or slurries containing large entrained solids. Do not attempt to pump volatile, corrosive, or flammable materials which may damage the pump or endanger personnel as result of pump failure.

WARNING!

Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or damage to equipment. Suction and discharge hoses and piping must be removed form the before lifting

EBARA Fluid Handling

INSTALLATION – SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position and arrange the pump and piping.

Most of the information pertains to a standard static lift application where the pump is positioned above the level of liquid to be pumped.

If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the specific application.

Since the pressure supplied to the pump is critical to performance and safety, be sure to limit incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve.

For further assistance, contact your EBARA distributor or EBARA Fluid Handling.

Pump Dimensions

See Figure 1 for the approximate physical dimensions of this pump.

OUTLINE DRAWING

Figure 1 Pump Model EFQT-8

EBARA Fluid Handling

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested before shipment from the factory. Before installation, inspect the pump for damage which may have occurred during shipment. Check as follows:

a.inspect the pump for cracks, dents, damaged threads, and other obvious damage.

b.Check for and tighten loose attaching fasteners. Since gaskets tend to shrink after drying, check for loose hardware at mating surfaces.

c.Carefully read all warnings and cautions contained in this manual or affixed to the pump, and perform all duties indicated. Note the direction of rotation indicated on the pump. Check that the pump shaft rotates counterclockwise when facing the back cover plate assembly/impeller end of the pump.

CAUTION!

Only operate this pump in the direction indicate by the arrow on the pump body and on the accompanying decal. Refer to ROTATION in OPERATION, Section C.

d.Check levels and lubricate as necessary. Refer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and perform duties as instructed.

e.If the pump and power source have been stored for more than 12 months, some of the components or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump service.

If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your EBARA distributor or the factory to determine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.

EBARA Fluid Handling

POSITIONING PUMP

Lifting

Use lifting equipment with a capacity of at least

6.002 pounds (2722 Kg). This pump weighs approximately 1201 pounds (545 Kg), not including the weight of accessories and base. Customer installed equipment such as suction and discharge piping must be removed before attempting to lift.

CAUTION!

The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit is improperly wrapped around the pump.

Mounting

Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mounting is essential for proper operation.

The pump may have to be supported or shimmed to provide for level operation or to eliminate vibration.

Clearance

When positioning the pump, allow a minimum clearance of 40 inches (1000 mm) in front of the back cover to permit removal of the cover and easy access to the pump interior.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely affected by increase suction lift, discharge elevation and friction losses. See the performance curve and operating range shown on Page 21 to be sure your overall application allows pump to operate within the safe operation range.

Materials

Either pipe or hose maybe used for suction and discharge lines: however, the materials must be compatible with liquid being pumped.

If hose is used in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended.

Line Configuration

Keep suction and discharge lines as straight as possible to minimize friction losses. Make minimum use of elbows and fittings, which substantially increase friction loss. If elbows are necessary, use the long radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it exactly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or couplings.

Lines near the pump must be independently supported to avoid strain on the pump which could cause excessive vibration, decrease bearing life, and increased shaft and seal wear. If hose-type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.

Gauges

Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings.

SUCTION LINES

To avoid air pockets which could affect pump priming, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped: if the line slopes down to the pump at any point along the suction run, air pockets will be created.

EBARA Fluid Handling

Fittings

Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be installed with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not normally used in suction lines, but if a valve is used, install it with the horizontal to avoid air pockets.

Strainers

If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.

If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.

This pump is designed to handle up to 3 inch (76 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift; all connections in the suction line should be sealed with pipe dope to ensure an airtight seal. Follow the sealant manufacturer’s recommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.

Suction Lines in Sumps

If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 ½ times the diameter of the suction line.

If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suction inlet because the inflow will carry air down into the sump, and air entering the suction line will reduce pump efficiency.

If it is necessary to position inflow close to the suction inlet, install a baffle between the inflow and the in suction lines, it must be the rigid-wall, reinforced type to prevent collapse under suction. Using piping couplings in suction lines is not recommended. Suction inlet at a distance 1 ½ times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.

If two suction lines are installed a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a distance equal to at least 3 times the diameter of the suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows Recommended minimum submergence vs. velocity.

NOTE

The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).

VELOCITY (FT./SEC.)= QUANT. (G.P.M)x.321 OR	G.P.M. x 4085
AREA	D²
VELOCITY (M./SEC.)= FLOW (M./MIN)x21.22 OR	FLOW (M³/SEC.)
DIAMETER IN MM²	AREA IN M²

Figure 2 Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lower than of the liquid being pumped unless a siphon breaker is used in the line. Otherwise, a siphoning action causing damage to the pump could result.

Valves

If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.

With high discharge heads, it is recommended that a throttling valve and a system check valve be installed in the discharge line to protect the pump from excessive shock pressure and reverse rotation when it is stopped.

EBARA Fluid Handling

CAUTION!

If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.

Bypass Lines

Self-priming pumps are not air compressors. During the priming cycle, air from the suction line must be vented to atmosphere on the discharge side. If the discharge line is open and a check valve has been installed in the discharge line, the discharge side of the pump must be opened to atmospheric pressure through a bypass line installed between the pump discharge and the check valve. A self-priming centrifugal pump will not prime if there is sufficient static liquid head to hold the discharge check valve closed.

NOTE

The bypass line should be sized so that it does not affect pump discharge capacity; however, the bypass line should be at least 1 inch in diameter to minimize the chance of plugging.

In low discharge head applications (less than 30 feet or 9 meters), it is recommended that the bypass line be run back to the wet well, and locate 6 inches below the water level or cut-off point of the level pump. In some installations, this bypass line may be terminated with a six-to-eight foot length of 1 ¼ inch ID. smooth-bore hose; air and liquid vented during the priming process will then agitate the hose and break up any solids, grease, or other substances likely to cause clogging.

CAUTION!

A bypass line that is returned to a wet well must be secured against being drawn into the pump suction inlet.

It is also recommended that pipe unions be installed at each 90º elbow in a bypass line to ease disassembly and maintenance.

In high discharge head applications (more than 30 feet), an excessive amount of liquid may be bypassed and forced back to the wet well under the full working pressure of the pump; this will reduce overall pumping efficiency. Therefore, it is recommended that an EBARA Automatic Air Release Valve be installed in the bypass line.

EBARA Automatic Air Release Valves are reliable, and require minimum maintenance. See

AUTOMATIC AIR RELEASE VALVE in this section for installation and theory of operation of the Automatic Air Release Valve. Contact EBARA Fluid Handling for selection of an Automatic Air Release Valve to fit your application.

If the installation involves a flooded suction such as below-ground lift station, a pipe union and manual shut-off valve may be installed in the bleed line to allow service of the valve without shutting down the station, and to eliminate the possibility of flooding. If a manual shut-off valve is installed anywhere in the air release piping, it must be a full-opening ball type valve to prevent plugging by solids.

DANGER!

If a manual shut-off valve is installed in a bypass line, it must not be left closed during operation. A closed manual shut-off valve may cause a pump which has lost prime to continue to operate without reaching prime, causing dangerous overheating and possible explosive rupture of the pump casing. Personnel could be severely injured.

Allow an over-heated pump to cool before

servicing. Do not remove plates, covers, gauges, or fittings from an overheated pump. Liquid within the pump can reach boiling temperatures, and vapor pressure within the pump can cause parts being disengaged to be ejected with great force. After the pump cools, drain the liquid from the pump by removing the casing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.

EBARA Fluid Handling

AUTOMATIC AIR RELEASE VALVE

When properly installed and correctly adjusted to the specific hydraulic operating conditions of the application, the EBARA Automatic Air Release Valve will permit air to escape through the bypass line, and then close automatically when the pump is fully primed and pumping at full capacity.

Theory of Operation

Figures 3 and 4 show a cross-sectional view of the Automatic Air Release Valve, and a corresponding description of operation.

Figure 3. Valve in Open Position

During the priming cycle, air from the pump casing flows through the bypass line, and passes through the Air Release valve to the wet well (Figure 3).

WARNING!

Some leakage (1 to 5 gallons [3.8 to 19 liters] per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills.

When the pump shuts down, the spring returns the diaphragm to its original position. Any solids that may have accumulated in the diaphragm chamber settle to the bottom and are flushed out during the next priming cycle.

NOTE

The valve will remain open if the pump does not reach its designed capacity or head. Valve closing pressure is dependent upon the discharge head of the pump at full capacity. The range of the valve closing pressure is established by the tension rate of the spring as ordered from the factory. Valve closing pressure can be further adjusted to the exact system requirements by moving the spring retaining pin up or down the plunger rod to increase or decrease tension on the spring. Contact your EBARA distributor or EBARA Fluid Handling for information about an Automatic Air Release Valve for your specific application.

Air Release Valve installation

The Automatic Air Release Valve must be independently mounted in a horizontal position and connected to the discharge line of the self-priming centrifugal pump (see Figure 5).

Figure 4 Valve in Closed Position

NOTE

When the pump is fully primed, pressure resulting from flow against the valve diaphragm compresses the spring and closes the valve (Figure 4). The valve will remain closed, reducing the bypass of liquid to 1 to 5 gallons (3.8 to 19 liters) per minute, until the pump loses its prime or stops.

If the Air Release Valve is to be installed on a staged pump application, contact the factory for specific installation instructions.

EBARA Fluid Handling

CLEAN-OUT	DISCHARGE PIPE
COVER
INSTALL AIR RELEASE VALVE
IN HORIZONTAL POSITION

90 LONG RADIUS

ELBOW SUPPORT BRACKET

BLEED LINE 1"

(25,4MM) DIA. MIN.

(CUSTOMER FURNISHED)

EXTEND 6" (152,4MM) BELOW LIQUID

LEVEL SURFACE

	DISCHARGE PIPE
	SELF-PRINING
	CENTRIFUGAL
SUCTION	PUMP
LINE
	DRAIN LINE
	WET WELL OR SUMP

Figure 5 Typical Automatic Air Release Valve Installation

The valve inlet must be installed between the pump discharge port and the non-pressurized side of the discharge check valve. The valve inlet is it at the large end of the valve body, and is provided with standard 1-inch NPT pipe threads.

The valve outlet is located at the opposite end of the valve, and is also equipped with standard 1-inch NPT pipe threads. The outlet should be connected to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the inlet piping, or larger. If piping is used for the bleed line, avoid the use of elbows whenever possible.

NOTE

It is recommended that each Air Release Valve be fitted with an independent bleeder line directed back to the wet well. However, if multiple Air Release Valves are installed in a system, the bleeder lines may be directed to a common manifold pipe. Contact your EBARA distributor or EBARA Fluid Handling for information about installation of an Automatic Air Release Valve for your specific application.

ALIGNMENT

The alignment of the pump and its power source is critical for trouble-free mechanical operation. In either a flexible coupling or V-belt driven system, the driver and pump must be mounted so that their shafts are aligned with and parallel to each other. It is imperative that alignment be checked after the pump and piping are installed, and before operation.

NOTE

Check Rotation, Section C, before alignment of the pump.

When mounted at the EBARA factory, driver and pump are aligned before shipment. Misalignment will occur in transit and handling. Pumps must be checking alignment, tighten the foundation bolts. The pump casing feet and/or pedestal feet, and the driver mounting bolts should also be tightly secured.

EBARA Fluid Handling

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