Flowserve Byron Jackson Type M User Manual

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Byron Jackson Type M Double Mechanical Seal Submersible Pumping Unit

USER INSTRUCTIONS: INSTALLATION, OPERATION, MAINTENANCE

PCN=85392711 1042.293/9 • Edition June 2004

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

CONTENTS

PAGE

INTRODUCTION AND SAFETY ...................5

1.1 About the product and these user

instructions........................................... 5

1.2 CE marking and approvals ..................5

1.3 Disclaimer............................................5

1.4 Copyright ............................................. 6

1.5 Duty conditions....................................6

1.6 Safety................................................... 6

1.6.1 Safety symbols................................6

1.6.2 General safety instructions..............7

1.6.3 Personnel qualification, training

and protective clothing ....................7

1.6.4 Authorized and prohibited use.........7

2 TRANSPORT AND STORAGE.....................9

2.1 Consignment receipt and

unpacking ............................................ 9

2.2 Transport ........................................... 10

2.2.1 Safety instructions.........................10

2.2.2 Equipment and personnel

required ........................................ 10

2.2.3 Transport of the motor................... 10

2.2.4 Transport of the pump bowl

assembly....................................... 11

2.3 Storage and shipping......................... 12

2.4 Recycling and end of product life ...... 13

3 DESCRIPTION.............................................14

3.1 Configurations.................................... 14

3.1.1 General Description.......................14

3.1.2 Main Components.........................14

3.1.3 Motor serial number ...................... 14

3.5 Electrical requirements.......................17

3.5.1 General electrical requirements.... 17

3.5.2 Motor protection............................ 18

3.5.3 Short circuit protection .................. 18

4 INSTALLATION AND

UNINSTALLATION..................................... 19

4.1 Fitter ...................................................19

4.2 Equipment and personnel required....19

4.2.1 Equipment and tools supplied

with motor ..................................... 19

4.2.2 Equipment and tools to be

supplied by operator ..................... 19

4.2.3 Personnel required........................ 21

4.3 Hydraulic connection..........................21

4.4 Installation..........................................23

4.4.1 Safety instructions......................... 23

4.4.2 Sequence of installation................ 23

4.4.3 Prepare installation site................. 23

4.4.4 Arrange components for

installation..................................... 24

4.4.5 Inspect components...................... 25

4.4.6 Install motor .................................. 26

4.4.7 Install coupling.............................. 27

4.4.8 Install pump bowl assembly.......... 30

4.4.9 Install impeller............................... 32

4.4.10 Vent motor..................................... 33

4.4.11 Install power cable ........................ 35

4.4.12 Fasten the power cable to the

cable guard................................... 39

4.4.13 Install riser pipe, fasten power

cable to riser pipe.......................... 40

4.4.14 Connect power cable to

terminal box .................................. 43

4.4.15 Connect terminal box to main

power supply ................................. 43

4.5 Uninstallation......................................45

4.5.1 Safety instructions......................... 45

4.5.2 Uninstallation ................................ 45

3.2 Design of major parts.........................14

3.3 Performance and operating limits......15

3.3.1 Normal operating conditions..........15

3.3.2 Design changes ............................15

3.4 Preconditions at the installation

site .....................................................16

3.4.1 Survey of well................................ 16

3.4.2 Crooked well .................................16

3.4.3 Development of the well................16

3.4.4 Suction and submergence

requirements.................................16

3.4.5 Effect of pumping sand..................16

3.4.6 Effect of air or gas.........................16

3.4.7 Oxidizing and corrosive effects

of chemicals, air and gases...........16

5 COMMISSIONING STARTUP,

OPERATION AND SHUTDOWN................ 46

5.1 Safety instructions..............................46

5.2 Direction of rotation............................46

5.3 Starting the pump...............................46

5.3.1 First-time start-up of the pump...... 46

5.3.2 Normal start-up of the pump ......... 47

5.4 Running or operation..........................47

5.4.1 Performance and operating

limits ........................................ 47

5.4.2 Motor operation............................. 48

5.4.3 Starting frequency......................... 48

5.5 Stopping and shutdown......................49

Page 3 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

6 MAINTENANCE ..........................................50

6.1 Safety instructions .............................50

6.2 Maintenance schedule....................... 50

6.3 Working substances and auxiliary

agents................................................51

6.4 Motor maintenance............................ 51

6.5 Pump maintenance............................51

6.6 Pump test run .................................... 51

6.7 Periodic testing of motor and pump... 52

6.8 Electrical tests of the motor ...............53

6.8.1 Insulation test................................ 53

6.8.2 Continuity testing...........................53

6.9 Spare parts........................................ 54

6.9.1 Recommended spares and

consumable items ......................... 54

6.9.2 Ordering spare parts ..................... 54

6.9.3 Storage of spare parts................... 54

6.10 Tools for repair and maintenance...... 55

7 FAULTS, CAUSES AND REMEDIES.........56

8 PARTS LIST AND DRAWINGS..................59

9 CERTIFICATION.........................................60

10 OTHER RELEVANT DOCUMENTATION

AND MANUALS ..........................................61

10.1 Change notes ....................................61

10.2 Abbreviations..................................... 61

11 GLOBAL CONTACT POINTS, EU CE

MARKER AND SERVICE CONTACTS ......62

12 APPENDIX...................................................63

12.1 Scope of delivery ...............................64

12.2 Data sheet .........................................65

12.3 Tightening torques............................. 66

12.4 Safety data sheet for motor oil...........67

Page 4 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

1 INTRODUCTION AND SAFETY

1.1 About the product and these user instructions

NOTE These user instructions must always

be kept close to the product's operating location of operation or directly with the product so that they are available to the operating personnel at any time.

ned, developed and

Flowserve's products are d manufactured with state-of-the-art technologies in modern facilities. The pumping unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements.

Flowserve is committed to continuous quality im-

ent a

provem formation about the product in its installation and operation or about its support products, repair and diagnostic services.

These instructions are intended to facilitate familiarization Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.

NOTE These instructions should be read

These user instructions outline the general proce-

that must be observed to ensure long, trou-

dure ble free performance of the pumping unit. However, it is assumed that plant personnel are familiar with the basic principles and tools involved in the installation, operation and maintenance of a pumping unit. Successful pumping unit operation is dependent on careful study of these user instructions

nd being at service for any further in-

with

the product and its permitted use.

prior to ins and maintaining the equipment in any region worldwide.

The equipment must not be put into

ce until all the conditions relat-

serv ing to safety, noted in the instructions, have been met.

esig

alling, operating, using

and a well planned and observed maintenance program.

In these user instructions, the numbers in brackets

umbers, e. g.: shaft button screw

are item (806-2). Refer to the drawings in Chapter 8 "Parts list and drawings", Page 59, for the position of the respective item.

1.2 CE marking and approvals

It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC) and Pressure Equipment Directive (PED).

Where applicable, the Directives and any addi-

ovals cover important safety aspects

tional App relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable, this document incorporates information relevant to these Directives and Approvals.

To check if the approvals apply and if the product itself is CE marked, check markings and the Certification, see Section 9 "Certification", Page 60.

the seri

al number plate

1.3 Disclaimer

Information in these user instructions is believed to be reliable. In spite of all the efforts o Flowserve Pump Division to provide sound and all necessary information the content of these use instructions may appear insufficient and is not guaranteed by Flowserve as to its completeness or accuracy.

Flowserve manufactures products according to International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure continued product quality and performance in use.

As Flowserve cannot test parts and accessories

ced from other vendors the incorrect installa-

sou tion of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Flowserve's warranty. In addition, any modification of

Page 5 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Flowserve products or removal of original components may impair the safety of these products in their use.

1.4 Copyright

1.5 Duty conditions

This product has been selected to meet the specifications of your purchaser order. The acknowledgement of these conditions has been sent separately to the purchaser. A copy should be kept with these user instructions.

NOTE The product must not be operated

beyond the parameters specified fo the application.

If there is any doubt as to the suitability of the product for the application intended, contact Flowserve fo advice, quoting the serial number.

If the conditions of service on your purchase order are changed (for example liquid pumped, temperature or duty) it is requested that the user seeks our written agreement before start up.

1.6 Safety

1.6.1 Safety symbols

These user instructions contain specific safety symbols where non-observance of an instruction would cause hazards.

Safety symbol and safety word

DANGER This symbol indicates an

This symbol indicates a

CAUTION This symbol indicates a

The following symbols may be added to the above symbols

CAUTION This word indicates a situation

NOTE This sign is not a safety symbol

This symbol indicates a

Table 1 Safety symbols in these user instructions

Meaning

imminent hazardous situation. The situation, if not avoided, will

result in death or serious injury.

potentially hazardous situation. The situation, if not avoided,

could result in death or serious injury.

potentially hazardous situation. The situation, if not avoided,

could result in minor or moderate injury.

which, if not avoided, could damage the equipment.

but indicates an important instruction in the assembly process.

potentially hazardous situation due to hazardous and toxic fluid.

The situation, if not avoided, could result in death or serious injury.

This symbol indicates a potentially hazardous situation due to strong magnetic field.

The situation, if not avoided, could result in death or serious injury to persons with pacemaker implant.

Further, the situation could damage instruments and stored data sensitive to magnetic fields.

potentially hazardous situation in an explosive atmosphere according to ATEX.

The situation, if not avoided in the hazardous area, could cause an explosion.

Page 6 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

1.6.2 General safety instructions

NOTE Always follow

• legal regulations

• plant regulations

• these user instructions

concerning safety.

Absolutely heed all information placed directly on the pumping unit and given in Chapter 12.2 "Data sheet", as for example

• rotation arrow

• labeling of connections

• rating plate.

Danger of injury by

• knocking against parts, tools o

equipment

• jamming fingers or hands in o

between parts, tools or equipment

• dropping parts, tools or equipment on parts of the body.

DANGER

ll work on the electrical system may only be performed by qualified electricians!

All work on the hydraulic connections may only be performed by qualified fitters.

Protective clothing

During transport, installation and removal of the pumping unit, all personnel must wear

• helmet

• safety boots

•

protective gloves

During operation of the pumping unit at the control center, all personnel must wear

•

protective gloves

NOTE Also follow

• legal regulations

• plant regulations

concerning protective clothing.

1.6.3 Personnel qualification, training and protective clothing

Personnel qualification and training

All personnel involved in the operation, installation, inspection and maintenance of the pumping unit must be qualified and authorized to carry out the work involved.

If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer / supplier to provide applicable training.

Always co-ordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws and regulations.

1.6.4 Authorized and prohibited use

The safe operation of the pumping unit can only be guaranteed if it is operated as authorized.

The only authorized utilization of the pumping unit is to pump water from a well. The pumping unit is to be operated submerged in water.

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

By not heeding this user instructions, product liability is rendered void.

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Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Non-authorized utilization of the pumping unit includes:

• operating the pumping u

nit in a known mal-

functioning state

• operating the pumpin

g unit in conditions other than those given in Chapter 3.3.1 "Normal operating conditions", Page 15.

• making modifications of the pumping unit that are not auth

orized by Flowserve

• using spare parts that are not authorized by Flowse

rve.

CAUTION Alterations to the pumping unit are

only

permitted a

fter written permis-

sion by Flowserve. Only use spare parts that have been

autho

rized b

y Flowserve.

Flowserve is not liable for any dam-

ause

age c

d by the use of parts ob-

tained from third parties.

Page 8 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpack-

ing

A submersible pumping unit consists of

• Motor

• Pump bowl assembly

• Non-return valve

• Powe

• Riser pipe

• Cable or bracket to fasten the motor power

• Wellhead (surface plate)

• Terminal box or jun

• Tools for inst

NOTE Not all components or sub-

Flowserve generally ships the pumping unit in two packa

• Main compon

• Tools described in

All components and parts are suitably protective

ppe

wra ate.

The motor is shipped nearly completely filled with oil, with mounted outside of the motor to allow thermal expansion and contraction of the motor oil.

r cable

(discharge column)

cabl

e onto the riser pipe

ction box

allation and maintenance.

assemblies

of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c

omponen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12 "Scope of delivery".

ents described in Chapter 3.1.2

"Main Components", Page 14.

Chapter 4.4.4 ”Arrange

components for installation", Page 24.

d, crated or mounted on skids as appropri-

oil expansion bag (shipping bladder)

The power cable, if included in the delivery, is ship

ped on a reel with a sh

ipping cap or other pro-

tective covering installed to protect the connectors. Immediately after receipt of the equipment

1. Uncrate all parts. Check all crates, boxes and wrappings for any

accessorie

s or spare parts which may be packed separately with the equipment or attached to side walls of the box or equipment.

2. Check the scope of delivery.

• Che

ck the delivery against the delivery

and shippi

ng documents for its com-

pleteness.

Each product has a unique serial num-

at this number corresponds

ber. Ch

eck th

with that advised.

NOTE Make sure you can always quote

each par

's serial number in correspondence and when ordering spare parts or further accessories.

• Ins

pect the delivery for trans

damage.

Immediately report any shortage and or dam-

age to Flowserve and the ship

ping company.

Claims must be reported in writing within one

month of receipt of the equipment. Flo does not accept latter claims.

3. Check the available power against the res given on the motor data plate and

ment

quire in Chapter 12.2 "Data sheet".

If the equipment is to be stored

• continue with Chapter 2.3 "Storage and ship-

ping", Page 1

If the equipment is to be installed

• contin

ue with Chapter 4.4 "Installation",

Page 23.

portation

wserve

Page 9 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

2.2 Transport

2.2.1 Safety instructions

Transport is the process of moving the pumping unit or its components from the installation site to a storage site, maintenance site or repair site, or vice versa.

During transport, always

• Work carefully to avoid accidents.

• Handle equipment carefully.

• Be sure lifting devices are in good condition

and are capable of safely handling the weights to be lifted.

• Mark and seal off the transport route so that unauthorized personnel do not enter the danger area.

• Take precautions to prevent foreign materials or dirt from entering the working parts of pump and motor.

2.2.3 Transport of the motor

Do not raise or move the motor by the power cables!

CAUTION The motor is a dynamically bal-

anced machine and should be handled accordingly.

Take precautions to prevent foreign materials or dirt from entering the working parts of the motor.

1. Refer to Figure 1. Place hitching line under lifting lugs.

Take care that the hoist has an adequate carrying force. For weight see Chapter 12.2 "Data sheet".

Never step under floating load. Watch for and avoid overhead ob-

structions including power lines.

2.2.2 Equipment and personnel required

Provide the following equipment for the transport:

• Portable crane with adequate carrying force. For weight see Chapter 12.2 "Data sheet.

• Also see Chapter 4.2 "Equipment and personnel required", Page 19.

Flowserve recommends that 2 persons plus 1 crane operator perform the transport.

Figure 1 Hitching line under lifting lugs

Page 10 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

2. Refer to Figure 2.

Place a wire around the motor. The wire is to

be positioned between stator and lower casing, approx. 1/3 from bottom of motor.

Figure 2 Lifting motor for installation

3. Lift the motor horizontally by 2 points.

4. Transport the motor horizontally to the installation or storage site.

5. Carefully lower the motor at the respective site and place it on the floor.

If the motor is to be stored:

• Continue with Chapter 2.3 "Storage and shipping", Page 12.

If the motor is to be installed in a well:

• Continue with Chapter 4 "Installation", Page 19.

2.2.4 Transport of the pump bowl assembly

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

CAUTION Use care to prevent bumping, push-

ing, or scraping of pump bowl assembly parts, especially the shafts, or other machined surfaces.

Take precautions to prevent foreign materials or dirt from entering the working parts of the pump bowl assembly.

NOTE The following description refers to

pumps without auxiliary carriers. Should the pump be delivered on an

auxiliary carrier, refer to the pump manual for transportation instructions.

1. Connect the pump

• directly to the hoists, or

• to the cross-beam

If the motor is to be maintained:

• Continue with Chapter 6 "Maintenance", Page 50.

Page 11 of 68

of a portable crane.

2. By means of the crane, carefully lift the pump and move it to the desired site.

If the pump bowl assembly is to be stored:

• Continue with Chapter 2.3 "Storage and shipping", Page 12.

If the pump bowl assembly is to be installed in a well:

• Continue with Chapter 4 "Installation", Page 19.

If the pump bowl assembly is to be maintained:

• Continue with Chapter 6 "Maintenance", Page 50.

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

2.3 Storage and shipping

For the removal of the pump from the well see Chapter 4.5 "Uninstallation", Page 45, if necessary.

Requirements for the storage area

• Safe

• Clea

• Away from extended p

eriods of direct sunlight

• Well ventilated

• Dry

Air humidity:

................................40 % to 60 %

• Cool Air temperatur

e for motors

originally filled by Flowserve:...+50 °C to -5 °C

CAUTION Always s tore mot or and pump bowl

assembly

separately

Prepare motor for storage or shipping after removing the motor from the well

1. Arrange the motor horizontally.

2. If pump and coupling are to be stored or shipped sep nents on motor shaft.

3. Install power terminal shipping cap (112), power te shipping caps (112-1).

4. If the motor is to be stored in a vertical position, proceed

a. Remove the adapter bracket (808). b. Drill a vent hole in the motor shipping cap

(112-1

If the motor is returned to factory at a

later time, se plug.

5. If the motor is to be returned to the factory,

eed as follows:

pro a. Remove motor half-coupling (529) or mo-

tor one-pie

b. Lubricate shaft with some form of pene-

trating oil.

c. Place coupling and components in motor

ship minal gasket (744-6) and bolt cap securely in place.

arately: Install coupling compo-

nal gasket (744-6), and motor

rmi

as follo

ws:

al the vent hole by a pip

ce coupling (531).

ping cap

(112-1) with its power ter-

d. Elevate motor over a sump or drum to

drain oil a

water from motor.

e. Remove lower casing drain plug (806)

from bottom of motor, then remove vent plugs (806-4 and 806-5) at top of motor and allow motor to fully drain.

f. Replace drain and vent plugs.

Prepare pump bowl assembly for storage or shipping

NOTE Not all components or sub-

assemblies

of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c

omponen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

NOTE The following description refers to

pumps

ithout auxiliary carriers.

Should the pump be delivered on an

auxiliar

carrier, refer to the pump

manual for storage and shipping instructions.

1. Install blocks in the strainer to restrain the pump shaft.

This prevents shaft end float and possible in-

e during handling.

ternal da

mag

2. Make sure the bowl assembly is thoroughly dry.

3. Install suitable covers to seal off all openings.

Page 12 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Store pumping unit

NOTE The following description refers to

pumps without auxiliary carriers. Should the pump be delivered on an

auxiliary carrier, refer to the pump manual for storage and shipping instructions.

Store the pumping unit as follows:

• Motor: Preferably vertically

Filled with oil

• Pump bowl assembly with rubber bearing bushes:

Vertically

• Pump bowl assembly with other than rubber bearing bushes:

Preferably vertically

DANGER Horizontally stored motors and

pump bowl assemblies must be secured against rolling.

ertically stored motors and pump bowl assemblies must be secured by appropriate means in this storage position to prevent tipping over.

• Power cable: Leads protected from moisture

NOTE Do not bend power cable during

storage.

Maintenance during storage

• Storage up to four weeks

At the beginning and end of the storage pe-

riod: Carefully check the motor to be sure there are no signs of oil leakage.

• Storage between 1 and 24 months Maintenance of the motor, every 6 to 8 weeks:

1. Remove the motor shipping cap (112) at

the motor.

3. Mount the motor shipping cap (112) to the motor.

Maintenance of the pump, every 6 to 8 weeks:

1. Remove the discharge housing and the non-return valve for the pump shaft.

2. Turn the pump shaft several times by means of a wrench.

4. Mount the discharge housing and nonreturn-valve to the pump.

• Storage for over 24 months After a storage of more than 24 months, we

recommend a complete visual inspection at our main factory or at your nearest Flowserve representative.

Shipping

Ship motor and pump bowl assembly

• in non-airtight protection film

• in wooden box or similar transport packaging.

2.4 Recycling and end of product life

At the end of the service life of the pumping unit or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and heeding local regulations.

If the product contains substances which are harmful to the environment, these should be removed and disposed of in accordance with local regulations. This also includes the liquids and or gases in the "seal system" or other utilities.

DANGER Make sure that hazardous sub-

stances are disposed of safely and that the correct personal protective equipment is used.

The safety specifications must be in accordance with the local regulations at all times.

Hazardous substances in the pumping unit are

• Motor oil

2. Turn the motor shaft several times by means of a wrench.

Page 13 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

3 DESCRIPTION

3.1 Configurations

3.1.1 General Description

The Flowserve submersible pumping unit is a combination of

• a vertic chanical seal

• a vertical pump bowl a

designed for sustained operation submerged in water.

The

pump bowl assembly. The rotating element of the pump bowl assembly is

driven from the bottom connected to the motor shaft by a coupling.

Power is supplied to the motor through a submarine po

we and extends to the starting equipment. Motor and pump bowl assembly are connected to the riser pipe. The riser pipe is threaded or flanged and coupled in random lengths and the entire unit is coupled to a wellhead assembly.

Each pumping unit has been individually manufac-

ccording to the special requirements of the

tured customer. The technical data is given in Chapter

12.2 "Data sheet".

al, oil filled motor with double me-

ssembly

motor is positioned directly below the

where its extended shaft is

r cable which is fastened to the riser pipe

These user instructions apply only to the componen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

3.1.3 Motor serial number

The motor serial number is on the name plate on the stator.

3.2 Design of major parts

The motor is filled with, lubricated and cooled by a special mineral oil of high dielectric strength.

This oil

• allows high efficiency rotor-stator design,

• provides

qualities, and

• protects the motor from internal corrosion.

CAUTIO

excellent insulation and lubrication

N The oil used in this pumping unit is

specifie

d in Chap

ter 12.2 "Data

sheet". Use of other oil

3.1.2 Main Components

A pumping unit consists of

• Motor

• Pump bowl assembly

• Non-return valve

• Power cable

• Riser pipe

(discharge column)

• Cable or bracket to fasten the motor power cabl

e onto the riser pipe

• Wellhead (surface plate)

• Terminal box or jun

• Tools for inst

ction box

allation and maintenance.

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

• ma

y cause damage to the

pumping unit

• renders Flo

wserve's warranty

void.

The motor does not require periodic oil changes. The oil is circulated within the motor by pumping

action of the

thrust bearing disc. Separation between the motor oil and pump liquid at the shaft exit is maintained by two mechanical seals.

The motor is pressure compensated. The double mechanical seal system uses a pres-

balan

sure

ce process to equalize the pressure differential across the seals, minimizing leakage and providing years of maintenance free service. The inner seal diverts any pumped fluid leakage via a communication line to a storage reservoir at the bottom of the motor. The motor is vented to the well by the balance line. As the oil expands, some oil is pushed out of the motor through the balance tube. As the oil cools down, pumped fluid is drawn back into the lower casing at the bottom of the motor through the balance tube.

Page 14 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

3.3 Performance and operating limits

3.3.1 Normal operating conditions Operating purpose

Submersible pumps serve to transport water under the operating con

ditions described in the following.

tion

Opera

• Operation

wit

hin prescribed voltage tolerance,

see Chapter 12.2 "Data sheet"

• No operation against closed slide valve

• Permissible o

perational range: 50 % to 120 %

of the optimal delivery rate

CAUTION Other uses, operating purposes o

operating conditions must be agreed upon by Flowserve.

Water characteristics

• Water temperature: .............

• Sand content:

......................Maximum 25 mg/l

Also see Chapter 3.4.3 "

well", Page 16, and Chapter 3.4.5 "Effect of pumping sand", Page 16.

• No impuritie

s which could lead to deposits and blockages within the pump or to deposits on the motor surface.

Also see Chapter 3.4.6 "Effect of air or gas",

nd Chapter 3.4.7 "Oxidizing and

16 a

Page corrosive effects of chemicals, air and gases", Page 16.

• No occurrence of water hammer

CAUTIO

N At higher surrounding temperatures

and/or lo

er flow velocities on the

w external motor surfaces, or if there is risk of clogging, special measures for heat dissipation are required.

Inform Flowserve of the surrounding conditio

ns.

See Chapter 12.2

"Data sheet"

evelopment of the

• Observation of the starting frequency

maximum permissible

Installation position

Take the following criteria into account when determinin

• Vertical installation in a

g the installatio

n position and depth:

well above the filter line, so that a perfect flow is guaranteed along the external motor wall.

• Sufficient water cover

• A static wat

er level at least 2 m above the

pump exit

• A dynamic water level above the suction hou

sing, taking into account the required net positive suction head for the pump (see Chapter 12.2 "Data sheet")

• Flow rate (see Cha

• Supply cond

pter 12.2 "Data sheet")

itions of the pumping medium

(dependent upon the installation conditions)

CAUTION The pumping unit should be in-

stalled above the

well filter.

If this is not possible, prevent direct

suction

ithin the filter line by suitable measures (e.g. blind tube in the filter, outer pump mantle, pump with sand protection jacket.

Flo of the p application and confirm its use, i applicable.

Pumping unit

• Corre

ctly selected and adjusted motor protec-

tion

wserve will check the suitability

ump

ing unit for its planned

Page 15 of 68

3.3.2 Design changes

Alternation or addition of the pumping unit may

only take pla

• by Flowserve,

• after written consent by Flowserve.

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

3.4 Preconditions at the installation site

3.4.1 Survey of well

Always sound the well to make sure it is deep enough to permit install consisting of pump bowl assembly and motor. If the exact diameter and depth of the well casing is not known, "cage" the well following the procedure outlined in Chapter 3.4.2 "Crooked well", Page 16.

Experience indicates that many wells have more

stri

that one

ng of casing installed and frequently the lower sections are smaller in diameter than the surface casing. Be certain the submersible pumping unit will pass into the well freely and hang well above of the well bottom.

3.4.2 Crooked well

A well that is known to be crooked and that has not

ly accommodated a pumping unit of com-

previou

s parable size must be "caged" before the submersible pumping unit is installed.

1. Prepare a cage of the same length and di-

the combined motor and pump

ameter a

s bowl assembly, with 12 m to 15 m (40 feet to 50 feet) of the proper size of riser pipe.

2. Lower the cage into the well to the point at h the pumping unit is to be placed.

whi

3. If the cage can be lowered to this point with-

out touching

the inner wall of the well, the

submersible pumping unit can be installed.

3.4.3 Development of the well

Do not use a new pumping unit to develop the well. Developing, surging and freeing the well of sand

are con

idered a part of the well drillers contract and should be accomplished by the use of a test pumping unit.

ation of the pumping unit

maximum well draw-down level, although some installations may require more submergence.

3.4.5 Effect of pumping sand

Flowserve does not guarantee the pumping unit to be resistant

against the erosive action of sand, silt

or other abrasive materials suspended in water. Pumping sand will adversely affect the motor be-

e the vibration produced in a worn pump bowl

cau assembly will be transmitted to the motor and could result in a shortened motor life.

3.4.6 Effect of air or gas

The presence of gases in the water may reduce

city and head of the pumping unit, thus de-

cap creasing the hydraulic performance. Further, air or gas in the water will cause deterioration of materials of the pumping unit sooner than under normal conditions.

3.4.7 Oxidizing and corrosiv e effects of r and gases

chemicals, a

Even if the composition of the pumped water is

n due to chemical analysis, it is not always

know possible to predict the corrosive action of water on the metals of the pumping unit.

In addition to chemicals, water may also contain entrain

ed air or ga

ses that have a definite oxidizing or corrosive action of their own. This action is accentuated by high velocities within the pump. Such conditions are not recognizable in the chemical analysis of the water.

Conforming with the Standards of the Hydraulic Institute of th

e United States and the p

ractice of all reliable pump manufacturers, Flowserve does not guarantee its pumps and motors to be resistant against corrosive or electrolytic action.

Should you require motors or pumps to perform unde

r oxidizi

ng or corrosive conditions, contact

Flowserve for further information.

3.4.4 Suction and submergence requires

ment

Pumping th unit br

e well at a rate at which the pumping

eaks suction will cause pump deterioration. It is suggested that a method be provided for keeping a record of the water level above the suction inlet.

The minimum submergence recommended is 3 m (10

feet) of

riser pipe submergence below the

Page 16 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

3.5 Electrical requirements

3.5.1 General electrical requirements

The Byron Jackson submersible motor is designed for across-line start, eliminating the need for reduced voltage starting equipment. Maximum current inrush when the motor is connected across the line at full voltage will be limited to about 700 % of the rated load current.

Because starting the motor at full voltage results in high starting torque, the motor accelerates to operating speed very rapidly (within 0.8 seconds, typically), and current consumption correspondingly drops to normal. The rated power requirements of the motor are stated on the pump nameplate located on the wellhead.

Allowed combinations of voltage and frequency variations during operation are classified according IEC 60034 as being either Zone A or Zone B (Figure 3) or according NEMA (see Figure 4).

Voltage and frequency limits

0,1

0,08

0,06

0,04

0,02

-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05

-0,02

Voltage Variation p.u.

-0,04

-0,06

-0,08

-0,1

Frequency Variation p.u.

Figure 3 Voltage and frequency limits acc. IEC 60034

Figure 4 Voltage and frequency limits acc. NEMA

The motor is capable of performing its rated torque continuously within Zone A, but need not comply fully with its performance at rated voltage and frequency (see rated point in Figure 3), and may exhibit some deviations. Temperature rises may be higher than at rated voltage and frequency. For conditions at the extreme boundaries of Zone A, the temperature rises and temperatures may exceed the specified limits of temperature rise and temperature by approximately 10 K.

Operation outside Zone A (within Zone B) may exhibit greater deviations from its performance at rated voltage and frequency than in Zone A. Temperature rises may be higher than at rated voltage and frequency and most likely will be higher than those in Zone A. Extended operation at the perimeter of Zone B is not recommended.

Low voltage is a serious problem since the operating motor current is increased, resulting in additional motor heating. However, the motor is designed to operate continuously at 110 % of rated current, so that some reduction in voltage can be tolerated as long as it is not also accompanied by an overload of the motor.

Page 17 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

With variations in voltage, the motor characteristics will, in general, vary as given in Table 2.

Voltage 110 % 90 %

Speed Increase 1 % Decrease 1.5 % Efficiency (full load) Increase 0.5 % Decrease 1 % Power factor (full load) Decrease 3 % No change Current (starting) Increase 11 % Decrease 11 % Current (full load) Decrease 8 % Increase 11 % Temperature Decrease 2 % Increase 5 %

Table 2 Motor characteristics at varying voltage

Rated or full load current refers to the amperage drawn by the motor at nameplate output, frequency and voltage at the motor terminals. The maximum allowable current (except momentarily at start-up) is 110 % of the rated value.

The voltage on all three phases should be evenly balanced as closely as can be read on the usually available commercial voltmeter, because the current unbalance will be in the order of 6 to 10 times the voltage unbalance. Running the motor with the unbalanced voltage will lead to increased temperature and decreased motor life time, and therefore must be avoided.

The value given in Chapter 12.2 "Data sheet", is a standard value for the operating point. If the actual operational current in the operating point of the pump bowl assembly lies under this given value, the switch must be adjusted lower so that there is effective protection and malfunctions can be indicated in time.

DANGER Do not set the motor protection ad-

justment higher than the highest permissible value given in Chapter 12.2 "Data sheet".

Do not test the perfect functioning o a motor protection switch by intentional single-phasing.

3.5.3 Short circuit protection

To prevent short circuiting of the power cable and the motor, safety measures must be taken according to local ordinances.

Guide values for the safety fuse sizes can be taken from Chapter 12.2 "Data sheet".

Poor voltage regulations of an engine-driven generator, if the power is derived from such a source, can be very disadvantageous to the motor. Thus, Flowserve assumes no responsibility for pumping units operated on such equipment unless agreed on in writing.

Also, because of the unpredictable characteristics and past experiences associated with the use of phase converters, Flowserve must void all guarantees for applications that incorporate these devices as a means of obtaining three phase power.

3.5.2 Motor protection

To protect the motor against power overload, an inverse time-lag overload relay must be provided, sensitive to phase failure and which compensates for temperature.

The over current relay for the switchgear and the safety fuses can be adjusted or selected according to Chapter 12.2 "Data sheet".

The adjustment of the motor protection switch (thermally delayed over current relay) must be done according to the value given in Chapter 12.2 "Data sheet".

Page 18 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4 INSTALLATION AND UNINSTALLA-

TION

4.1 Fitter

It is recommended that the services of Flowserve be employed for the installation and initial starting of a Byron Jackson pump.

Such service will ensure the purchaser that the

properly installed, and will provide an

equipm

ent is excellent opportunity for the plant operator to receive special instructions relative to the pumping unit.

4.2 Equipment and personnel re-

quired

4.2.1 Equipment and tools supplied with mo-

tor

Equipment and tools supplied with motor and half coupling

• Hex so

(806-2)

• Hex socket wrench for coupling set screw

(806

• Hex socket wren

cket wrench for shaft button screw

-1) ch for vent plug (806-4) ch for vent plug (806-5)

4.2.2 Equipment and tools to be supplied by opera

tor

Provide the followin

g equipment and tools:

• Lifting Equipment.

Must be of sufficient strength and rigidity to lift the com

lete unit safely, see Table 3,

p Page 20, and of sufficient height to allow clearance between load hook and foundation. For weight see Chapter 12.2 "Data sheet".

• Two pai

rs of corre

• One correc

tly sized column U-plate tly sized motor U-plate (see Figure

ctly sized pipe elevators

5, Page 21 and Table 4, Page 21)

• One 1.2 - 1.8 m (4 - 6 feet) section of column, thread

ed and coupled, to be attached to the top case and used for handling the pump bowl assembly.

Deduct this length from total column length

specifications.

• Colum

n A supply of pipe, in random lengths, threaded

and

pled, of correct size to handle the unit

cou capacity and total weight and of adequate length to set the unit at the correct pumping level in the well. The threading is 8 threads per 25 mm (1 inch) and 19 mm (0.75 inch) taper per foot.

• Aligning jig as

sembly, including the following

parts:

- Shim, shaft adjusting (262-6)

- Shim, shaft adjusting (262-7)

- Button, thrust (130)

- Screw, thrust Button (806-2)

- Washer, coupling lock screw (690-4)

- Screw, coupling lock (806-3)

- Aligning jig (265)

- Coupling, driver (529)

- Key, coupling (676-1)

- Screw, set, coupling (806-1)

• One pai

r of cable re

el stands, with axle

• One portable insulation resistance tester ("Megg

• One clamp

er"), 0 - 100 MΩ / 1000 Volts

-on ammeter

• One volt/ohmmeter

• Components for water level indicating system

• Special ba

nding tool ("Band-it") for cable

bands

• A length of 1.27

cm (0.5 inch) hemp rope and a cable installation wheel. Diameter must be at least 14 times cable outer diameter.

• Ordinary hand tools (mechanical and electrial) used in this kind of work

• Two sets of chain tongs

• Rubber mat and insulated gloves for electrical

work in da

mp conditions

Page 19 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

• An adequate supply of approved thread compounds, as follows

- For installation of the short section of col-

Motors Nominal motor

size

umn pipe, next to top case or top case flange, use only Loctite 277 (Red) & Primer T or equal.

- For remaining column pipe threads, use a

pipe thread compound that is capable of lubricating and sealing.

Column Size Weight per foot in kg (pounds) Empty Full

2-1/2 2.6 (5.8) 3.6 (7.9) 3 3.4 (7.6) 4.9 (10.8) 4 4.9 (10.9) 7.4 (16.4) 5 6.7 (14.8) 10.7 (23.5) 6 8.7 (19.2) 14.4 (31.7) 8 11.3 (25.0) 21.4 (47.2) 10 14.5 (32.0) 30.2 (66.6) 12 20.4 (45.0) 42.6 (93.9)

Bowl Slumps Size Weight in kg (pounds) 1

8MQ 36 (80) 7 (15) 10MQ 79 (175) 17 (37) 11MQ 132 (290) 32 (70) 12MQ 200 (440) 57 (125) 13MQ 284 (625) 79 (175) 15MQ 386 (850) 120 (265)

Cable Volts Size Weight per foot

600

5000

Stage Additional Stage

in kg (pounds)

8 0.14 (0.30) 4 0.35 (0.77)

2 0.50 (1.10) 300MCM 2.00 (4.40) 500MCM 3.08 (6.80)

6 0.41 (0.90) 2 0.54 (1.20) 1/0 1.00 (2.20) 4/0 1.54 (3.40)

10"

12"

14"

17"

21"

Table 3 Component weight chart for calculating

foundation, derrick and hoist loads

Horsepower Weight

in kg (pounds)

7-1/2 211 (465)

10 211 (465) 20 227 (500) 25 249 (550) 30 249 (550) 40 431 (950) 50 431 (950) 60 458 (1 010)

75 458 (1 010) 100 490 (1 080) 125 553 (1 220) 125 915 (2 018) 150 953 (2 100) 175 1 002 (2 210) 200 1 027 (2 265) 125 1 170 (2 580) 150 1 288 (2 840) 200 1 424 (3 140) 250 1 485 (3 273) 300 1 485 (3 273) 300 1 690 (3 725) 350 1 860 (4 100) 400 1 928 (4 250) 450 1 996 (4 400) 500 1 996 (4 400) 600 2 087 (4 600) 600 1 950 (4 300) 800 2 359 (5 200)

1 000 2 767 (6 100) 1 200 3 221 (7 100) 1 500 3 720 (8 200)

Page 20 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Figure 5 Motor U-plate

Nominal motor size

A B C D E 8" 38.10

10" 40.64

12" 45.72

14" 50.80

21" 91.44

Table 4 Motor U-plate chart

Dimensions in cm (inches)

(15)

(16)

(18)

(20)

(36)

0.95 +

0.32 (0.375 +

0.125)

0.95 +

0.32 (0.375 +

0.125)

1.27 +

0.32 (0.500 +

0.125)

1.27 +

0.32 (0.500 +

0.125)

1.27 +

0.32 (0.500 +

0.125)

25.40 (10)

30.48 (12)

35.56 (14)

73.66 (29)

25.40 (10)

53.34 (21)

14.61 +

0.32 (5.750 +

0.125)

18.10 +

0.32 (7.125 +

0.125)

19.05 +

0.32 (7.500 +

0.125)

24.77 +

0.32 (9.750 +

0.125)

42.57 +

0.32 (16.760

+ 0.125)

4.2.3 Personnel required

Flowserve recommends that 2 persons plus 1 crane operator perform the installation or uninstallation procedure.

4.3 Hydraulic connection

Exemplary construction of a water supply system is depicted in Figure 6, Page 22. As this shows a basic arrangement, the actual layout must be suited to local and technical conditions.

DANGER All work on the hydraulic connec-

tion may only be done by qualified fitters.

Page 21 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Figure 6 Scheme of water supply system

Page 22 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4 Installation

4.4.1 Safety instructions

DANGER Before starting any installation work

or removing any parts of the pumping unit, read Chapter 1.6 "Safety", Page 6.

Tighten all screws in accordance with Chapter 12.3 "Tightening torques".

4.4.2 Sequence of installation

Perform the installation in the following order:

1. Prepare installation site, see Chapter 4.4.3, Page 23.

2. Arrange components for installation, see Chapter 4.4.4, Page 24.

3. Inspect components, see Chapter 4.4.5, Page 25.

4. Install motor, see Chapter 4.4.6, Page 26.

5. Install coupling, see Chapter 4.4.7, Page 27.

6. Install pump bowl assembly, see Chapter 4.4.8, Page 30.

7. Install impeller, see Chapter 4.4.9, Page 32.

8. Vent motor, see Chapter 4.4.10, Page 33.

9. Install power cable, see Chapter 4.4.11, Page 35.

10. Fasten the power cable to the cable guard, see Chapter 4.4.12, Page 39.

11. Install riser pipe, fasten power cable to riser pipe, see Chapter 4.4.13, Page 40.

12. Connect power cable to terminal box, see Chapter 4.4.14, Page 43.

13. Connect terminal box to main power supply, see Chapter 4.4.15, Page 43.

4.4.3 Prepare installation site

1. Verify that the wellhead foundation is poured and cured, if made of concrete.

The total load on the wellhead foundation will

consist of the motor, pump bowl assembly, riser pipe (full of water), wellhead assembly and power cable. See Chapter 12.2 "Data sheet", for weights.

2. Verify that open discharge run-off, ditch, etc. for flushing out well and testing unit is provided for.

3. Verify that a log of the well recording depth, straightness, casing variations, standing water level, rated capacity, pumping level, etc., is at the installation site.

4. Ensure that the well diameter is large enough down to the installation depth so that the pumping unit can be fitted without difficulties. See Chapter 3.4.1 "Survey of well", Page 16.

5. Check the dependability of auxiliary equipment, particularly of hoists.

6. Compare the information in Chapter 12.2 "Data sheet" with that on the rating plate on the motor.

7. Ensure that the line voltage (measured between two phases) is equal to the motor voltage according to the rating plate.

The maximum permissible voltage fluctuation

is given in Chapter 12.2 "Data sheet".

Greater voltage and frequency fluctuations

must be reported to Flowserve and be confirmed by Flowserve in written. In case of doubt, ask Flowserve before starting up the pumping unit.

8. Measure the insulating resistance of the motor according to Chapter 6.8.1 "Insulation test", Page 53.

CAUTION If the ascending riser pipe is made

of flanged pipes, the flanges must have recesses for the power cable i the well diameter is narrowly proportioned.

Page 23 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.4 Arrange components fo r installation

Figure 7 Components arranged for installation

Refer to Figure 7. An orderly arrangement of subassemblies will reduce the installation time.

1. Lay out the parts in order of installation, as follows:

• Motor Arranged horizontally.

• Pump bowl assembly Uncrated and arranged horizontally.

• Riser pipes Place all riser pipe sections with coupling

end toward the well.

Check couplings with chain tongs to

make sure they are screwed tight.

Place riser pipe check valve sections so

that each will be installed in the proper sequence.

• Power cable

• Wellhead

• Tools for installation, see Chapter 4.2

"Equipment and personnel required", Page 19.

• U-plate

2. Record the complete motor serial number from the motor, see Chapter 3.1.3 "Motor serial number", Page 14.

NOTE Make sure you can always quote each

part's serial number in correspondence and when ordering spare parts or further accessories.

3. Check motor rating, horsepower, poles, volts, and frequency against job requirements.

Page 24 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.5 Inspect components

1. Remove the nuts (003-3) and lock washers (690-3) to remove the motor terminal shipping cap (112), and gasket (747-10).

2. Verify that motor terminal gland plate (111) and power terminals (019) are clean and free of dirt and foreign matter.

3. Megger the motor for ground and continuity (see Figure 8).

The reading should be 10 MΩ or more.

Figure 8 Megger test

4. Remove the shipping cap from the power cable terminal box.

5. Verify that the terminal box and connectors are clean and free of dirt and foreign matter.

6. Verify that the power terminals (019) at the motor will fit the connectors of the terminal box:

• Refer to Figure 9. Check position of power terminals (019)

against that of connectors.

The terminals (019) and connectors may

be arranged in either an equilateral triangle or a right triangle positioning.

• Check height of terminal against depth of

connector to assure proper engagement.

Figure 9 Arrangement of terminals

7. Mount motor power terminal shipping cap (112), gasket (747-10), lock washers (690-3) and nuts (003-3).

8. Reinstall power cable shipping cap.

9. Verify that all riser pipe threads are clean and free of dirt and foreign matter.

Page 25 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.6 Install motor

Transport the motor to the well site, see Chapter

2.2.3 "Transport of the motor", Page 10.

Never step under floating load. Watch for and avoid overhead ob-

structions including power lines.

1. Install motor U-plate on foundation.

Use to 2 persons to install the U-plate.

Handle the U-plate carefully. Danger of injury by dropping the

U-plate onto parts of the body.

2. Cover the U-plate and foundation with a tarpaulin.

3. Orient the motor horizontally so that the terminal shipping cap is on top.

Remove motor shipping cap (112-1), power

terminal gasket (744-6), nuts (003-8), and lock washers (690-5). Some oil may be present in the shipping cap.

Be certain to put the power terminal gasket

(744-6) in a safe area until it can be stored in the motor shipping cap (112-1).

NOTE The power terminal gasket is not

used in the unit assembly.

Then remove the tools and the power terminal

gasket (744-10) from the power terminal shipping cap.

4. Reinstall motor shaft shipping cap (112-1), nuts (003-8), and lock washers (690-5).

5. Lift the motor as described in Chapter 2.2.3 "Transport of the motor", Page 10.

6. Slowly elevate the motor to vertical position.

7. Center the motor over the well casing opening.

8. Lower the motor to rest on the U-plate.

Refer to Figure 10.

Figure 10 Motor in place on U-plate

9. Remove motor shipping cap (112-1), nuts (003-8), and lock washers (690-5).

10. Cover coupling (529 or 531) and shaft with a clean cloth.

The motor is now ready to receive the coupling.

Page 26 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.7 Install coupling

NOTE Not all components or sub-

assemblies of a pumping unit are neces

sarily supplied by Flowserve

or part of this delivery. These user instructions apply only

to the c

omponen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

The coupling between motor and pump bowl as-

nds on the type of pump bowl assem-

sembly de

bly delivered. Flowserve manufactures two coupling variants for

the Byron Ja

ckson Doubl

• Variant A: Motor half coup

• Variant B: One-pie

e Mechanical Seal Motor:

ling

ce coupling

Both are described in the following. See Chapter

12.1 "Sco

of delivery" to determine the coupling

delivered and follow the respective instructions.

Variant A: Motor half coupling

1. Motor half coupling is factory installed. Refer to Figure 11

washers (690-4), shaft button screw (806-2) and shims (262-6 and 262-7).

7. Remove string from shaft button screw ) which holds shim in place.

(806-2

Verify that the shims (262-6 and 262-7) are

attach

ed to the screw (806-2).

8. Install alignment jig assembly in motor half

pling (265

cou

9. Install cap screw (806-2) and use wrench pro-

vided to tighten screw (80

6-2).

10. Remove the coupling lock screws (806-3) and

shers (690-4).

Set these pieces aside for later use (see

ter 4.4.8 "Install pump bowl assembly",

Cha Page 30).

11. Remove alignment jig (265) and hold for stor-

ping cap (112-1).

age in moto

r ship

12. Clean the motor flange face of any dirt or for-

eign matter.

Verify that the balance line hole in the flange

pen

face is o

and clear.

13. Cover the coupling (529) and shaft with a

n cloth.

clea

The m

otor is now ready to receive the pump bowl

assembly.

2. Clean coupling and shaft, and lightly oil both.

3. Slip coupling on shaft with keyways aligned.

NOTE Do not attempt to force the cou-

pling. If the coupling will not seat freely:

- remove the coupling

- verify that the shaft is free of dirt and foreign matte

- replace the coupling.

4. Insert key (676-1), round end down, in the key

ay.

5. Install socket head set screw (806-1) through

in th

its hole

e coupling (529) to engage its

hole in the shaft.

Use wrench provided to tighten set screw

-1

(806

6. Identify the shaft adjusting button (130), alignmen

t jig (265), screws (806-3) with

Page 27 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Figure 11 Motor half coupling components

Page 28 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Variant B: One-piece coupling

See Figure 12.

1. Clean the coupling (531) and shaft and lightly oil both.

2. Identify the thrust button (130), thrust button screw (806-2) and shaft adjusting shims (262-6 and 262-7) as required. These pieces are factory installed.

3. Insert key (676-1), round end down, in the keyway.

4. Slip coupling (531) on shaft with keyways aligned.

CAUTION Do not force the coupling.

If the coupling will not seat properly, again verify that shaft and coupling are clean.

5. Install the coupling pins (697) into the coupling holes and the thrust button.

The thrust button may need to be rotated to

align holes.

Install the coupling lock screws (806-6), flat

washers (004-1), a nd lock washers (6 90-6) to secure the pins in the coupling.

6. Tighten the thrust button socket head screw (806-2).

7. Rotate the motor shaft and coupling until the pin holes on the coupling are pointed 90 ° from the power terminal shipping cap.

This aligns pin holes in coupling with adapter

bracket to allow pump coupling pin (697-1) to be installed later. Also see Figure 12.

8. Clean the motor flange face of any dirt or foreign matter. Verify that the balance line hole is open and clear.

9. Cover the coupling (531) and shaft with a clean cloth.

Figure 12 Components for one-piece coupling

The coupling is now ready to receive the pump bowl assembly.

Page 29 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.8 Install pump bo wl assembly

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

Lift pump bowl assembly

Never step under floating load. Watch for and avoid overhead ob-

structions including power lines.

NOTE The following description refers to

pumps without auxiliary carriers.

The motor hangs in the well on the U-plate.

1. Disassemble discharge housing or non-return valve from the pump bowl assembly.

2. Install the discharge housing or non-return valve in the short section of riser pipe.

Additional information for threaded riser pipes:

a. Clean the mating pipe threads of the pipe

and the case or flange as shown in Figure 13.

Should the pump be delivered on an auxiliary carrier, refer to the pump manual for lifting instructions.

To transport the pump bowl assembly to the well site see Chapter 2.2.4 "Transport of the pump bowl assembly", Page 11.

1. Connect the pump to two lifting lines of a portable crane.

The attachment points may vary according to

pump type and local requirements.

2. Carefully lift the pump to a vertical position over the well head.

Install pump bowl assembly

The riser pipes are connected among each other by

• threads or

• flanges.

Figure 13 Cleaning riser pipe threads

b. Apply thread locking fluid, e. g. Loctite

242 or DELO 5249/5349 or equivalent, to the threads as shown in Figure 14.

Figure 14 Applying thread locking fluid

Page 30 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

c. Install the pipe using chain tongs. Figure 15 shows the proper method of

applying chain tongs to the flange.

Thereby most of the force is exerted on

the upper flange rather than the on the discharge housing or the non-return valve.

Apply torque approximating the values

given in Table 5.

CAUTION The discharge section may require

modification to provide protective clearance to the flat cable and splice which will be mounted late on the riser pipe just above the pump.

3. Mount the first length of the riser pipe, which should not be longer than 0.5 m, onto the assembled pump bowl assembly.

4. Remove the cable clamps or cable guard from the pump bowl assembly.

5. Remove the cloth from the coupling.

6. Lift the pump bowl assembly above the motor.

7. Check the end float settings that are preadjusted by Flowserve.

Figure 15 Proper method of applying chain tongs

Pipe Torque Torque

Size [Nm] [ft-lbs] 2-1/2 620 500 3 950 700 4 1 220 900 5 1 425 1 050 6 1 625 1 200 8 2 170 1 600 10 2 710 2 000 12 4 070 3 000

Table 5 Torque for riser pipe assembly

Page 31 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.9 Install impeller

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

Flowserve manufactures two impeller variants for the Byron Jackson Double Mechanical Seal Motor:

Figure 16 Verify end float

• Variant A: Closed impeller

• Variant B: Open impeller

Both are described in the following. See Chapter

12.1 "Scope of delivery" to determine the coupling delivered and follow the respective instructions.

Variant A: Closed impeller

1. Refer to Figure 16. Scale from the face of the adapter bracket

(808) to the end of the pump shaft (167) with the shaft down.

2. Remove adapter bracket (808) from bowl assembly.

3. Install adapter bracket (808) on motor top flange, using fasteners for motor shipping cap (112-1).

4. Scale from the face of the motor top case (076) to the face of the shaft adjusting button (130).

5. The distance recorded in step 1 should be

3.175 mm to 6.350 mm (1/8" to 1/4") less than that of step 4.

Variant B: Open impeller

1. Remove adapter bracket (808) from bowl assembly.

2. Install adapter bracket (808) on motor top flange, using fasteners from motor shipping cap (112-1).

3. Remove the pump half coupling (530) or onepiece coupling (531).

4. Provide four pieces of shim stock, each (50.8 mm x 50.8 mm x 0.508 mm (2" x 2" x

0.020") thick, and place each shim 90 degrees apart on the face of the adapter bracket.

5. Lower the pump bowl assembly into the adapter bracket (808) to rest on the shims.

6. Put a feeler gauge through the plug opening in the adapter bracket (808) and check the gap from shaft adjusting button (130) to pump shaft (167).

7. If gap, step 6, is less than 0.0381 mm (0.015") or more than 0.4572 mm (0.018"), the shims beneath the shaft button (130) must be changed.

8. Reinstall the pump half coupling (530) or onepiece coupling (531).

Page 32 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.10 Vent motor

1. Remove the oil vent plugs (806-4) and (806-5) in the flange located at the power terminals and 90° or 180° from the power terminals.

Add oil into the adapter bracket as shown in

Figure 17. See Chapter 12.2 "Data sheet", Page 65, for oil quality.

NOTE Do not add more than two full moto

shipping caps' amount of oil during the venting process. The oil level in the motor will then rise and expel any air in the upper case cavity.

Figure 18 Removing vent plug

Figure 17 Adding oil

2. Continue to add oil until bubble free oil flows from the vent located near the power terminals.

Reinstall vent plug (806-4). Refer to Figure

18.

Continue to add oil until bubble free oil flows

from the vent located 90° or 180° from the power terminals.

Reinstall vent plug (806-5) and tighten to

27 Nm (20 foot pounds). Refer to Figure 18.

Figure 19 Reinstalling vent plug

3. Remove oil vent plug next to power terminals (806-4) and again check for bubble free oil.

Reinstall vent plug (806-4) and tighten to

27 Nm (20 foot pounds).

4. Place power terminal shipping cap (112-2), power terminal gasket (744-7), jig (265), hex socket wrenches (806-1, 806-2, 806-4, and 806-5), and power terminal gasket (744-6) into the motor shipping cap (112-1).

Send to storage. The motor is now ready to receive the pump

bowl assembly.

6. Verify that the pump half coupling (530) or one-piece coupling (531) is securely locked in place

- by the coupling pin (697-1) and retainer

ring (526) on pump half coupling or

Page 33 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

- by the coupling pin (697-1) and the retainer

screws (806-6), flat washers (004-1), and lock washers (690-5) on the one-piece coupling.

Also verify that the coupling bore and motor

shaft are clean and free of dirt and foreign matter.

7. Refer to Figure 20. Lower the bowl assembly to engage

- the jaws of the pump half coupling (530)

and those of the motor half coupling (529) or

- the one-piece coupling bore (531) with the

motor shaft and key (676-1).

9. Remove the adapter bracket pipe plugs (794) to observe, through the pipe plug holes, the alignment of the holes for the half coupling lock screws (806-3).

Install the half coupling lock screws (806-3) in

the half-coupling, with their washers (690-4) and apply torque to the half coupling screws (806-3) according to Table 6.

Unit size [inches]

8 27 20 10 41 30 12 54 40 14 54 40 17 68 50 18 68 50 21 68 50

Table 6 Torque for half coupling screws

Torque [Nm]

Torque [Ft-lbs]

Figure 20 Aligning strainer and adapter

8. Rotate the bowl assembly to line up bolt holes of strainer with those of the adapter (808) and to line up bottom cable guard with power terminal shipping cap (112-2), then lower until flanges butt metal-to-metal.

Install and tighten fasteners (cap screws or

stud nuts with washers).

After tightening, check that lock washers

(806-3) are seated firmly and lock washers (690-4) are compressed.

For one piece couplings, you will now install

the coupling pin (697), coupling lock screws (806-6), lock washers (690-6), and flat washers (004-1) or the retaining rings (526) to retain the coupling pin in its proper position.

10. Reinstall the adapter bracket pipe plugs (609) and tighten firmly.

11. The strainer body has two holes, size 1/8" N.P.T. at 180°. Pour water into one of these holes to fill the adapter bracket (808) until water runs out the other hole. (A 90° street elbow is used for this purpose.)

The pumping unit is now ready for installation of the power cable.

Page 34 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.11 Install power cable

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c

omponen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

• Use a

rope to hold the cable and the power

e installation wheel to support the power

cabl cable.

• Bring the p

ower cable looping up off the power cable reel stand so that the power cable terminal box is suspended over the power terminal shipping cap.

CAUTION Do not strain the power cable or

bend i

sharper than a diameter of 14 times the power cable outer diameter.

Avoid strain on terminal box. Do not use cable installation wheel

pend

to sus

cable above the top of pump bowl assembly until the flat cable guards are securely banded.

In the following, two variants of the power cable

scri

are de

bed:

• Power cable for voltages of 2 300 V and less (metal cl

amp power terminal connector)

• Power cable for voltages of 4 000 V and greate

r (metal housing power terminal con-

nector)

Page 35 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Power cable for voltages of 2 300 V and less (metal clamp power terminal connector)

1. Use the power cable installation wheel to unreel a sufficient length of power cable to pass the bowl assembly.

Elevate the power cable to the approximate

height of the pump bowl assembly and fasten the cable plug to the motor.

CAUTION Do not kink or stretch the powe

cable.

2. Remove the power terminal shipping cap nuts (003-3), washers (690-3) and power terminal shipping cap (112) at the motor.

3. Depending on configuration supplied:

• For flat faced (no rabbet fit) gland plate: Install flat gasket (744-10) over power

terminals (019).

See Figure 21.

4. Remove the shipping cap (023) from the power cable plug (182).

5. Refer to Figure 22.

Slide the metal terminal box clamp (180)

down over the terminal box (182) as far as possible.

Then check gap from bottom face of terminal

box clamp (180) to bottom face of terminal box. This gap should be minimum 0.8 mm (1/32) and maximum 2.4 mm (3/32).

Figure 22 Checking gap, terminal box clamp to terminal

box

Figure 21 Installing power terminal gasket (flat-faced

type shown)

• For gland plate with rabbet fit: First install gasket (744-11) over rabbet

fit on gland plate (111).

Then install gasket (744-10) over the mo-

tor terminals (019).

6. See Figure 23.

Slide the metal clamp (180) up the flat cable

and off the cable plug (182), loosening the clamping screws (806), if necessary.

CAUTION Do not distort the clamp.

Figure 23 Preparing terminal box clamps

Page 36 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

7. See Figure 24. Align plug connectors with the motor power

terminals and push the cable plug (182) down on the motor power terminals (019) to mate with the gland plate (111) and gasket(s) (744-10, 744-11).

Figure 24 Terminal box installed

8. See Figure 25. Slide metal clamp (180) down over terminal

box (182) and gland plate studs (002-1)

9. Install washers (690-3) and nuts (003-3). Tighten the nuts (003-3) alternatively and evenly to bring the clamp (180) firmly metal to metal against the gland plate (111).

Figure 25 Power cable clamp installed

10. Back off the nuts (003-3) two or three turns each and tighten clamping screws (806).

11. Retighten the nuts (003-3) to achieve metalto-metal fit of clamp (180) to gland plate (111).

12. Attach ground wire to rib of pump adapter using terminal, lock washer and cap screw.

13. Using surface end of the power cable, which should be accessible, megger the power cable and motor for ground and continuity.

The megger reading should 10 MΩ or more.

14. When megger test is completed, install a plastic bag over the surface end of the power cable for protection from the weather.

Continue with "Fasten the power cable to the cable guard", Page 39.

NOTE Key and keyway must be engaged

prior to terminal engagement to prevent damage.

Page 37 of 68

The gland nut must be tightened by hand and repeated until seal is accomplished.

Failure to fully engage the plug and receptacle will result in electrical failure.

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Power cable for voltages of 4 000 V and greater (metal housing power terminal connector)

Figure 26 Metal housing power terminal connector

(4 000 V-cable)

1. Remove the power terminal shipping cap nuts (003-3), washers (690-3) and power terminal shipping cap (112) at the motor.

2. Remove the shipping cap (023) from the power cable connector (182).

Place new O-Ring (747-10) into groove of the

terminal gland plate (111) at the motor top case (074).

4. Align the power cable connector (182) with the motor power terminals (019) and push down them down to mate with the gland plate (111) and O-Ring (747-10).

Slight side-to-side movement will aid this en-

gagement.

3. Install the lock washers (690-3) and tighten nuts (003-3) at gland plate studs (002-1).

4. Tighten the nuts alternately and evenly to bring the power cable connector (182) firmly metal to metal against the gland plate (111) at the motor top case (074).

5. Attach ground wire to rib of pump adapter using terminal, lock washer and cap screw.

6. Using surface end of the power cable, which should be accessible, megger the power cable and motor for ground and continuity. The megger reading should 10 MΩ or more.

7. When megger test is completed, install a plastic bag over the surface end of the power cable for protection from the weather.

Continue with "Fasten the power cable to the cable guard", Page 39.

NOTE Key and keyway must be engaged

prior to terminal engagement to prevent damage.

The gland nut must be tightened by hand and repeated until seal is accomplished.

Figure 27 O-ring for metal housing power terminal

connector at motor gland plate (4 000 V-cable)

3. Refer to Figure 27.

Failure to fully engage the plug and receptacle will result in electrical failure.

Page 38 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.12 Fasten the power cable to the cable guard

4. Remove the U-plate.

Use to 2 persons to remove the U-plate.

Handle the U-plate carefully. Danger of injury by dropping the

U-plate onto parts of the body.

5. Install a clamp to hold the pumping unit.

The pumping unit is now ready for the attachment of riser pipe and lowering into the well.

Figure 28 Outer guard and band in place - example

1. Inspect cable guards, particularly their inner

surfaces, for sharp edges that could damage the cable jacket or insulation.

2. Support the cable alongside the pump bowl

assembly with the cable installation wheel without stretching or straining the terminal box.

CAUTION The attachment of the power cable

to the cable guard depends on the type of the pump bowl assembly.

3. Slightly lift the pumping unit.

Page 39 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.13 Install riser pipe, fasten power cable to riser pipe

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c

omponen

ts or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

CAUTION Do not stretch the power cable and

the splices.

During the installation, observe the following pre-

ns:

cautio

• Support the

pumping unit weight with riser

pipe elevator.

• Keep the riser pip

e centered in the well cas-

ing.

• While lowe

ring the riser pipe, hold the power cable flat against the pipe and keep it from dragging across the sharp well casing or flange.

• Avoid loss of power cable l

• Prevent rotation of the riser pi

ength.

pe so that the

power cable does not spiral wrap around it.

• If used or out of round ri

ser pipe is utilized it is recommended to weld a steel strap across each coupling to prevent unthreading during start up or running.

Install the riser pipe(s)

1. Raise power cable installation wheel to 1.5 times the riser pip

e length to facilitate power

cable alignment to riser pipe and well casing.

2. Arrange the random lengths of riser pipe with

g ends facing one direction.

their co

uplin

At five feet in from each pipe end, draw a

chalk ma

rk to set the banding location.

3. Install the riser pipe.

Ensure that the flow direction is upward. If the riser pipes are threaded:

• Clea

n the mating pipe threads of the riser

s shown in Figure 13, Page 30.

pipe a

• Apply thread

locking fluid, e. g. Loctite 242 or DELO 5249/5349 or equivalent, to the threads as shown in Figure 14, Page 30.

• Install the pipe usi Figure 15, Page 31) and apply torque ac-

ng chain tongs (see

cording to Table 5, Page 31.

6. When the motor first enters the water, use the e end of the power cable to megger the

surfa power cable and motor for ground and continuity. The reading should be 10 MΩ or more.

If one or more vertical riser pipe check valves are

to be use

on an installation, each valve, which should have a bleed-back self draining feature, will take the place of a riser pipe coupling.

The recommended installation is as follows:

• One valve: Locate the valve approximately 23 m (75 feet)

above the pu

mp bowl a

ssembly.

• Two valves: Locate the first valve 30 m (100 feet) above

the pump bowl assem

bly.

Locate the second valve at 3/5 of the distance

en fi

betwe

rst valve and the surface support

plate.

Fasten the power cable to the riser pipe

Use "BAND-IT" or equal stainless steel bands and buckles

to fasten the cable guard to the riser pipe.

Pull each steel band tight enough to fasten the ca-

ard

ble gu

onto the riser pipe, but do not over ten-

sion it. Instructions for use of "BAND-IT" materials and

e shown in Figure 29, Page 41, to Figure

tools a

36, Page 42.

Page 40 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Use of BAND-IT steel bands

1. Cut off about 12" of band from the bulk roll.

Figure 29 Use of "Band-It" steel band, step 1

2. Hook one end on the buckle and bring the other end around the object to be banded and through the buckle.

For best results, apply the band twice around.

Double banding develops almost 4 times the grip of single banding.

3. Draw band tight. With the thumb on the band gripper lever, ap-

ply tension with the tool.

Figure 31 Use of "Band-It" steel band, step 3

4. Apply a proper amount of tension. The band gripper lever locks itself under tension.

Figure 30 Use of "Band-It" steel band, step 2

Figure 32 Use of "Band-It" steel band, step 4

Page 41 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

5. Rotate the tool over the buckle, backing of with tension handle throughout the entire course of the bend.

Failure to back off with tension handle

throughout the entire course of bend may result in breaking of band. There is no loss of tension, as the band released is used up in the bend.

Figure 33 Use of "Band-It" steel band, step 5

7. Remove the tool holding the stub of the band down with your thumb.

Figure 35 Use of "Band-It" steel band, step 7

8. Lock the stub by hammering down the buckle ears, thus completing the BAND-IT clamp.

6. Pull the cutter handle to cut the band.

Figure 34 Use of "Band-It" steel band, step 6

Figure 36 Use of "Band-It" steel band, step 8

Page 42 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.4.14 Connect power cable to terminal box

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

DANGER Before completing the electrical con-

nection, review Chapter 3.5 "Electrical requirements", Page 17.

The surface plate assembly is screwed in place and the pumping unit hangs well above the well base.

1. Measure and cut the cable to approximate length for surface make up.

2. Strip the power cable, if necessary.

3. Feed the cable through the packing gland (or glands) in wellhead and then into the terminal box.

4. Connect the terminal box leads to the power cable.

Each lead is to be waterproof.

5. Place the two final supporting cable clamp assemblies 0.9 m to 1.2 m (3 feet to 4 feet) below the wellhead.

6. If the power cable is a 4-conductor cable and the grounding is in the scope of delivery: make the ground wire connection to wellhead with lug, lock washer and cap screw.

7. Lower the wellhead into its correct position and secure it in place.

8. At the terminal box, megger the power cable and motor for ground and continuity.

The reading should be 10 MΩ or more. The pumping unit is now ready for connection to

the power supply.

4.4.15 Connect terminal box to main power supply

NOTE Starting equipment for the pump

bowl assembly is furnished by the customer.

1. Ensure that the rating of the equipment is

used conform to the National Electric Code requirements for high reactance squirrel cage motors.

Make certain that the starter main contacts

are in good condition and are working properly.

Also see that the overload relays are for the

correct full load current.

To ensure that the starter is operated safely,

verify that the panel housing is properly grounded to a ground rod and to the surface plate assembly.

2. Check the no-load voltage at the starter be-

tween all three phases. The voltage values must be equal and must be approximately the same as the voltage rating.

3. Strip back the outer sheath on the cable be-

tween 152 mm and 457 mm (6 " to 18") depending on cable size and panel terminal requirements.

Strip by scoring the sheath, lengthwise with a

knife or tool to the length needed, in several places around the outside.

Do not cut all the way through and damage

the individual conductor insulation.

Grasp a scored segment of the sheath at the

end and peel like a banana.

Repeat this all the way around and cut off the

stripped segments.

4. Strip a short segment of insulation off the end

of each conductor for connection into the starter load terminals.

5. Remove a conduit knock-out in the bottom of

the panel. Install the cable with its gasketed grip in this hole, and connect to the starter load terminals.

6. Ensure that the starter cannot be activated

accidentally.

7. Perform insulation test as described in Chap-

ter 6.8.1 "Insulation test", Page 53.

Insulation resistance must be at least 10 MΩ.

Page 43 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

8. Perform continuity test as described in Chapter 6.8.2 "Continuity testing, Page 53.

9. Connect the terminal box to the power source cable.

The pum

ping unit is now ready to be started.

Page 44 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

4.5 Uninstallation

4.5.1 Safety instructions

DANGER Before starting any installation work

or removing any parts of the pumping unit, read Chapter 1.6 "Safety", Page 6.

Tighten all screws in accordance with Chapter 12.3 "Tightening torques".

DANGER If the area was designated a hazard-

ous location, refer to applicable safety procedures for safe handling of tools, equipment, and test instruments.

CAUTION If the pumping unit is equipped with

a non-return valve without load relieving holes, the pumping unit weight with ascending pipeline und the water column contained within it must be lifted during removal!

If the non-return valve is provided with load relieving hoIes, the weight of the water column does not apply.

4.5.2 Uninstallation

1. Stop the pumping unit operation at the control panel.

2. Measure the power cable leads to check insulation resistance (leads-to-ground) and conductance (lead-to-lead) as directed in Chapter 6.8 "Electrical tests of the motor", Page 53.

b. Disconnect power cable form terminal

box, see Page 43.

c. Uninstall riser pipe and detach power ca-

ble from riser pipe, see Page 40.

If the bands are double wrapped, cut

them properly so that they can be saved

for use as a single band for reinstallation. d. Uninstall power cable, see Page 35. Separate cable from motor and seal the

cable with the original terminal box ship-

ping cover (023). e. Uninstall pump bowl assembly, see

Page 30. f. Uninstall coupling, see Page 27. g. Uninstall motor, see Page 26.

5. Check the riser pipes for need of replacement, particularly the sections between high and low well fluid levels.

6. Inspect any column check valves for wear and proper functioning.

7. Remove the coupling retainer rings, retainer screws, lock washers, and coupling pins. Separate the pump element from the motor between the adapter bracket (808) and the strainer body (564).

8. Megger the motor for ground and continuity. Reading should be 10 MΩ or more.

9. Seal the motor terminals with original power terminal gasket (744-7) and power terminal shipping cap (112-2).

10. If there is water in the motor, elevate motor over a sump or drum. Remove lower casing drain plug (806) from bottom of motor, then remove vent plugs (806-4 and 806-5) at top of motor to drain the water from the motor. Replace drain and vent plugs.

Continue with Chapter 2.3 "Storage and shipping", Page 12.

3. Disconnect the cable at the starter panel. Megger the leads for ground and continuity. Reading should be 10 MΩ.

4. Remove the pumping unit in the reverse order of the installation procedure (see Chapter 4.4 "Installation", Page 23) and place all parts on the floor.

Also consider Chapter 2.2 "Transport",

Page 10. a. Disconnect terminal box from main power

supply, see Page 43.

Page 45 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

5 COMMISSIONING STARTUP, OP-

ERATION AND SHUTDOWN

5.1 Safety instructions

NOTE Before commissioning, operation o

shutdown of the pumping unit, read Chapter 1.6 "Safety", Page 6.

The pumping unit may only be operated

• by trained pe

• in a comple

• completely filled and immersed.

nel,

rson

tely assembled condition, and

5.2 Direction of rotation

The direction of rotation of motor and pump is given in Chapter 12.2 "Data sheet".

5.3 Starting the pump

5.3.1 First-time start-up of the pump

1. Measure insulation resistance (leads-toground turned off to ascertain that not short circuits are present.

CAUTION Do not attempt to start the pumping

2. Verify that balanced three-phase voltage is sup meter and using the voltmeter selector switch.

CAUTION Never attempt to run the pumping

) with power turned off and motor

unit reading of less than 5 MΩ.

lied by taking readings with the line volt-

unit tween two leads.

An imbalance between two leads can cau of imbalance in an amperage and the resultant temperature increase means a decrease in motor life.

Poor voltage regulation of an engine driv tained from such a source, can be very detrimental.

ith an insulation resistance

ith an unbalanced voltage be-

se 6

- 10 times that amount

en gener

ator, if the power is ob-

3. Close the pump discharge valve.

4. Start the motor. The contractor closes and the pump motor

art

CAUTION Do not run the pump for more than

minutes

2 closed.

5. Immediately take current reading using line ammeter.

If the current is in the range of amps at shut-

off (see correct.

If current is about 80 % of shut-off amps, rota-

tion is a. press STOP b. turn off all power c. move isolator handle to OFF d. reconnect motor leads for proper rotation.

Mark the leads so that they can always be

placed corre

6. After verifying proper rotation,

• stop the pum

• open the discharg

• start the pumping unit ag

7. Recheck the current, which should be the full load cu sheet".

Current could also be the same as full load

amps with re would be greatly reduced.

CAUTION If a circuit breaker trips, always wait

During first-time start-up, take notice of the following:

• Whe spe

If after this period the line current is still high

(over twi not attaining the full speed.

Chapter 12.2 "Data sheet"), rotation is

orrect. In this case,

not c

nt as shown in Chapter 12.2 "Data

rre

verse

at leas

n motor is started, it should attain full

ed within 3 seconds.

e normal value), the pumping unit is

with discharge valve

tly any time they are removed.

ping unit.

e valve

ain.

d rotation but head and flow

t 10 minutes be

fore resetting.

Page 46 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

CAUTION In the event the pumping unit does

not attain the full speed, stop the pumping unit and do not attempt to restart it until the trouble is found and corrected.

During normal operation, the current must not ex-

the motor data plate value.

cee

• Measure the line voltag

e between phases

while the pumping unit is pumping.

The readings obtained should not be more

than 10 % a

bove or below the rated motor

voltage.

• In case of malfunction, stop the pumping unit and refe

r to Chapter 7 "Faults, causes and

remedies", Page 56.

5.3.2 Normal start-up of the pump

CAUTION If maintenance has been performed,

Chapter 5.3.1 "First-time start-

follo up of the pump", Page 46.

1. Verify that the control panel door is closed.

2. Verify that balanced three-phase voltage is

lied by taking readings with the line volt-

supp meter and using the voltmeter selector switch.

CAUTION Never attempt to run the pumping

unit

ith an unbalanced voltage be-

tween two leads.

then stop the pumping unit and refer to Chap-

ter 7 "Faults, cau

ses and remedies", Page 56.

5.4 Running or operation

5.4.1 Performance and operating limits

Usually, a pumping unit has been selected and built to perform a maximum efficiency under de fined conditions, see Chapter 3.3 "Performance and operating limits", Page 15.

crease or de-

Changes of these conditions, e.

g. in crease in head, will not cause an noticeable difference in the efficiency.

However, a large variation in head will not only

up as efficiency loss, but as a output, or

show thrust bearing overload.

Water level

• A well shou

ld alway

s be provided with a means for determining the static water level, and pumping level. A good air line, with depth gage, is generally the most simple and practical.

rin

• For monito

g the water level in the well, we recommend water level detectors or water level measuring units.

Sand

• When a pumping unit is first started, a new well may produ

ce considerable amounts of sand, despite the fact it had been sand pumped after drilling.

3. Start the pumping unit. The contractor completes the pump circuit,

and the pump

motor starts.

4. Verify that the pump motor comes up to speed 3

within

seconds as indicated by normal read-

ings of current, voltage, head and flow.

• current exceeds the rated value of the ampe

rage shown in Chapter 12.2 "Data

sheet", or

• voltage varie

s + 10 % or - 10 % from the rated value shown in Chapter 12.2 "Data sheet", or

• head and flo

w are abnormal

Page 47 of 68

The discharge should be throttled back to

e this is cut down to a minimum, then

whe gradually opened up to full discharge as the sand disappears.

This operation may last from a matter of minutes to seve

ral days or lo

nger.

If the sand flow shows no signs of stopping

• rework the well to screen

• install a pumping unit

out the san

with a capacity

d, or

smaller than that of the currently installed unit.

Continued sand pumping will result in in-

p wear which in turn will show up

creased

pum as increased efficiency loss. Too great a wear will run the pump beyond the repair stage and possibly have serious effects on the motor.

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

• Some wells will always produce a small amount of sand at start-up. Therefore, it may be necessary to bypass or trap out this first flow at each start-up, particularly if a closed piping system is used.

• Whe

n a pumping unit is known installed near

to the bottom of a well, a

close check should be kept to make sure that the well does not sand-up (fill in) around the motor.

This is may take place without any noticeable

mping or motor operation. How-

effect in

pu ever, the motor is dependent on adequate cooling from water, and any sand around it would eventually create overheating, resulting in at least shortened life, if not a burnout.

If this problem cannot be cured by well work,

t Flowserve for devices that can be

conta added to the pumping unit to prevent its sanding up.

Hydro-pneumatic pressure system

If the pumping unit is coupled into a hydropneumatic p

ressure system, the set-up must be

designed so that the pumping unit

• does not get "water-logged" (loss of air through water absorption without replac

ment) and

• and does no

t receive too much air at each

start-up.

5.4.2 Motor operation

" the motor before setting a

• Always "me

tripped circuit breaker.

• Wait 10 minutes befo

re restarting the motor.

• Breaking suction and/or inadequate power sup

ply renders warranty void.

• A time de

lay must be installed when any type of automatic system is used in order to prevent starting of the motor while it is spinning backwards due to riser pipe drainback through the pump.

A 3 minute time delay is usually adequate.

This p

ovides a safety measure in the event a failure in the automatic control system creates a rapid recycle series. It also provides a time period for the rotating element of pump and motor to stop, after reverse rotation due to vertical riser pipe drain- back.

the energy created is then dissipated as heat. This condition has been known to have practically "boiled" the water in the well and created an overheating problem for the motor.

• After the pu

mping

unit has operated for a longer period of time, a minimal readjustment of the motor circuit breaker may be required due to changed operating conditions, e. g. sinking of the water level.

CAUTION In no case select a motor protection

adjustme

setting that is greate

nt than the highest permissible value given in Chapter 12.2 "Data sheet".

If the pumping unit has shut-off hand the reason can

not be tra

ced to a positive external source:

1. Switch off the motor.

2. Disconnect the motor from the main power sup

ply

3. Disconnect the power cable leads from the start

4. Measure the insulation resistance of the

ead

power cable l

s to the ground (the well cas-

ing).

CAUTION Never re-set or re-fuse and start a

tor without first measuring the

m insulation resistance the unit.

5.4.3 Starting frequency

The amount of regularly-distributed starts per hour

n from Chapter 12.2 "Data sheet".

must be ta

Higher starting frequencies are only permissible

upon written agre

ment by Flowserve.

Amount of maximum permissible starts in sequence:

• Cold motor............................................2 s

• Warm motor..........................................1 s

tarts tarts

• Rest interval after each cycle .........10 minutes

It is

suggested to protect the motor against non-

permitted reconne

ction by

a time relay.

• A pumping u

nit should n

ot be run at closed

valve for more than 2 minutes as virtually all

Page 48 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

5.5 Stopping and shutdown

To stop the pump, follow the user instructions of the control panel.

NOTE An automatic 10-minute delay be-

fore res ture in the control panel.

art is suggested as a fea-

Page 49 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

6 MAINTENANCE

• all screws and connections that were previously undone are retightened

6.1 Safety instructions

Before maintenance or repair work

DANGER Before commissioning, operation or

shutdown of the pumping unit, read Chapter 1.6 "Safety", Page 6.

Before starting any maintenance o repair work or removing any parts o the pumping unit:

1. Switch off the motor, see Chapter 5.5 "Stopping and shutdown", Page 49.

2. Completely separate the pumping unit from the power supply.

During maintenance or repair work

During maintenance or repair work, avoid polluting water or soil with hazardous substances such as lubricants or cleaning agents. Collect these substances in suitable containers and dispose of the in accordance with the local regulations.

After maintenance or repair work

Immediately after finishing maintenance or repair work and before restarting the pumping unit, ensure that

• all tools and equipment required for maintenance or repair work have been removed from the pumping unit

• all safety devices are replaced and/or operate correctly

• the motor is filled.

6.2 Maintenance schedule

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the components or subassemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

Flowserve submersible pumps are custom designed to operate for extended periods with a minimum of regular maintenance, the frequency and scope of maintenance depending primarily on the conditions of service to which the pump is subject. Periodic dismantling for inspection is not necessary unless excessive wear is indicated or a pump malfunction is suspected.

To determine when major maintenance is required, periodic testing of the pumping unit (as described in Chapter 6.7 "Periodic testing", Page 52) is strongly recommended. This will establish a baseline of performance data indicative on pump condition that will permit scheduling of major maintenance tasks well ahead of the time they become necessary and will prove very beneficial to the prolonged lift and satisfactory operation of the pumping unit.

Interval Part Maintenance

Before each installation and after each uninstallation

Every 2 to 3 months if pump stands idle for longer period of time

All parts Inspect all piping connections for evidence of leakage, loosening or

other damage and repair if necessary.

Pump bowl assembly Inspect the integrity of the pump mounting fasteners which may loosen

due to vibration, and tighten if necessary. Motor Periodic testing, see Chapter 6.7, Page 52. Every 2 - 3 months Power cable, motor Electrical tests of the motor, see Chapter 6.8, Page 53. Pump bowl assembly Pump test run, see Chapter 6.6, Page 51.

Table 7 Maintenance schedule

Page 50 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

6.3 Working substances and auxiliary agents

Motor lubricants

The specific type of oil used in the motor is given in Cha

ter 12.2 "Data sheet". Do not use other oils.

The motor does not require periodic changing of oil. However, larger intervals.

Pump bowl assembly lubricants

NOTE Not all components or sub-

The pump bowl assembly does not contain lubri-

cant The b

earings of the pump bowl assembly are self-

ated by the liquid being pumped.

lubri

it may be necessary to f

assemblies necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c assemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

of a pumping unit are

omponen

ill up oil in

ts or sub-

6.4 Motor maintenance

Motor maintenance can consist of anything from disassembly and inspection to complete rewinding and overhaul. In normal service, motor maintenance should be required infrequently.

To determine when motor maintenance is needed,

sting should be faithfully performed as

dic te

perio described in Chapter 6.7 "Periodic testing ", Page

52. If periodic testing is performed satisfactorily,

the need for motor maintenance can usually be anticipated and maintenance scheduled accordingly.

When periodic testing indicates a motor problem,

mp and inspect the motor while still

remove the p vertical in the top of the well to check its electrical condition (see Chapter 6.8 "Electrical tests", Page

53). Also rotate the shaft manually to check for

possible binding. Spare motors should be maintained in field stock to permit rapid re-installation when a pump is pulled.

No attempt should be made to repair a motor in the field. If a mo Flowserve service representative for further in-

tor pro

blem is suspected, contact a

structions. When repair of a motor is required, install a spare motor in its place and arrange to have the pumping unit returned to the factory.

6.5 Pump maintenance

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c assemblies supplied by Flowserve

The pumping unit can be operated without mainte-

ce mea

nan eration or pumping, caused by sand or a corrosive pumping medium, make premature removal necessary.

Fluctuating and/or rapidly increasing current consumptio pump bowl assembly or motor.

Strong oscillation of the pressure and at the same time of the ammeter water inflow.

in this delivery, see Chapter 12.1 "Scope of delivery".

sures, insofar as no irregularities in op-

n poi

nts to mechanical problems in the

omponen

n be caused by irregular

ts or sub-

6.6 Pump test run

NOTE Not all components or sub-

assemblies of a pumping unit are necessarily supplied by Flowserve or part of this delivery.

These user instructions apply only to the c assemblies supplied by Flowserve in this delivery, see Chapter 12.1 "Scope of delivery".

If the pump bowl assembly should stand idle for a

r peri

longe every 2 to 3 months, in order to recognize malfunctions.

CAUTION The pumping unit must be com-

od of time, perform a 10-minute test run

pletely dium for this test run.

submersed in

omponen

ts or sub-

pumping me-

Page 51 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

6.7 Periodic testing of motor and pump

Motivation

As the pump wears, the internal sealing clearances increa flow (or leakage) from the impeller discharge back to its suction side.

At a fixed differential head, the total flow through each impelle new pump, but more of the flow is recirculated flow that the net flow out of the pump discharge is reduced.

To produce the same net flow output as a new pump, a wo ential head so that the impellers can operate at a higher flow rate to make up for the higher recirulation flow. This reduced performance in a worn pump is the basis for the periodic testing procedure outlined below.

Scope

Periodic testing or mounting of critical pump bowl assembly an as head, flow, line voltage, driver current, starting time, etc., is recommended to establish a reliable performance record for use in evaluating and projecting the pumping unit's condition and in establishing the maintenance requirements for its particular application. Periodic testing is and important part of a well-planned maintenance program.

The scope and frequency of periodic testing is primarily a m severity of pump operating conditions.

A "Periodic Test Record" is provided with each submersibl tests.

Operating conditions during test

Periodic test measurements should be taken under one of the following

• Pumping unit operating

The test flow used should be the same in

• Pumping uni

• Shut-off head redu

which results in increased recalculation

se,

r in a worn pu

pump must operate at a lower differ-

d motor pe

atter of

customer decision based on the

mp is the same as in a

rformance parameters such

e pump to record the results of periodic

conditions:

at a predetermined

test flow.

each test an

d should be greater than 75 % of

the design flow.

t operating at zero flow (dis-

charge valve closed).

ced by 5 % - 10 %.

CAUTION To prevent possible overheating, do

not r

the pump more than

2 minutes against closed valve.

Evaluation

Periodic test data can be used in the following ways to plan

preventative maintenance:

• Method 1 Plot total differential head measurements at

zero flow an

d, if practica

ble, at a fixed test

flow. Extend (extrapolate) the curve to a future time

when the diff

erential

head will be reduced to an unacceptable value. Plan to pull the pump before this future time.

• Method 2 Sometimes, customer flow requirements will

not permit throttling pump flow. If total differential head and flow can be

measured during n

ormal operation, this data can be used to plan preventative maintenance. To do so, plot the measured head and capacity point on the factory pump performance curve and record the test head as a percentage of the performance curve head at the test capacity. Plot this head versus time, extrapolate and use as in method 1.

• Method 3 An alternate method would be to plot capacity

a percentage of performance

(flow rate) a

s curve capacity at test head. Plot this capacity data versus time, extrapolate and use as head data used in method 1. Note that in any case, absolute accuracy of test equipment is not too important, but repeatability is important to permit comparison of worn pump performance with pump performance when new.

Adaptation of maintenance intervals

If direct or projected periodic testing readings show

redu

d shut-off head, change maintenance inter-

vals as follows.

• Shut-off head redu

ced by < 5 %

No preventative maintenance is indicated.

• Shut-off head

ced by 5 % - 10 %

redu

Consider and project maintenance to take place at a time most

venient to the user

con providing the fall off in shut-off head would not exceed 15 % by such time.

Page 52 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

• Shut-off head reduced by 10 % - 15 % Undertake maintenance before the next check

period.

• Shut-off head reduced by > 15 % The pump requires immediate attention and

should not be run further.

6.8 Electrical tests of the motor

DANGER Do not conduct this test in an area

that has been designated a hazardous location.

6.8.1 Insulation test

Before initial starting, as well as after longer storage or idle time, the insulation resistance of the drive must be measured.

The limits for minimum insulation resistance and critical insulation resistance for measurements at 20 °C winding temperature are as follows:

• Critical insulation value after

longer operational time..........................10 M

Ω

CAUTION A relatively low insulation resis-

tance does not definitely show that the pumping unit will break down due to insulation problems.

If however after measurements ove a longer period of time, an extreme drop in the insulation resistance occurs within a short time, these must then be inspected.

If the insulation resistance falls below minimum value, the cause or the malfunctioning part (power cable, line connection or windings) must be determined and the insulation weakness removed.

6.8.2 Continuity testing

DANGER During and after the measurement,

the connector ends of the motor line and/or the connection terminals partly carry dangerous voltage and may not be touched.

Before the measurement, ensure

that there is no line voltage.

To measure the insulation, disconnect all leads of the power cable of the motor.

All leads must carefully be cleaned of all dirt. Heed the operating instructions of the insulation measuring device.

Insulation measurement is always performed with a measuring-circuit voltage of 1000 V. The measured value must be read after a minute of measurement duration.

DANGER The motor windings or power cable,

charged up to the measuring-circuit voltage, must be discharged afte measurement by means of the insulation measuring device.

1. For continuity testing of the motor stator windings, use low resistance Ohm-Meter (4-pole Kelvin Bridge)

2. Perform continuity test with motor. The terminal resistance must first be measured in the three possible combinations (1-2, 1-3, 2-3). These three values must not vary by more than ± 2% from their average. The terminals must be grounded before the low resistance Ohm-Meter leads are connected. The temperature of the winding in °C must also be measured and recorded.

Page 53 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

6.9 Spare parts

6.9.1 Recommended spares and consumable items

Flowserve generally provides spare parts listings as part of the origin

Flowserve recommends that the customer holds the following s

General spares:

• One full spare pum

stalled, and available to replace any unit, or one full spare pump installed in system with valve.

Spares for the pump bowl assembly:

• One full set o

• One pump sh

• Two full sets

Spares for the motor:

• Cas

• Case shipping plugs.

• Shaft shipping cap n

• Driver sh

• Coupling lock pin with retaining ring, if re-

• Motor oil (F

6.9.2 Ordering spare parts

Ordering identical duplicate spare parts

When ordering identical duplicate replacement parts fo

• pump serial n

e vent plug with gasket.

quire

d (depends on pump type).

see Chapter 12.2 "Data sheet").

r this pumping unit, be certain to state

al order specifications.

ares at the installation site.

p, assembled, but not in-

bowl assembly bearings

aft key.

of case gaskets.

uts and lock washers.

aft key.

lowserve part no. and quantity

umber,

Ordering spare parts for pumps with modified operating co

If the operating conditions have changed since pump wa operating conditions. This is especially important when selecting new impellers.

CAUTION Should a

Ordering oversized or undersized parts

If oversized or undersized parts are required add:

• Req possibl

• Finishing by rough")

NOTE If the customer finishes parts the

Replacement of parts alternated during operation

Flowserve accepts no responsibility for incorrect

ement of original parts which have been al-

replac tered in the field.

6.9.3 Storage of spare par ts

nditions

s purchased, add full particulars of new

change in operating conditions be co nearest Flowserve representative o factory to determine if such a change is feasible with the existing pumping unit.

uired dimensions (with sketch of part, if

e).

Flowserve or by customer ("leave

customer as sibility.

Determine whether such a change is feasible.

nsidered, consult you

sumes th

e sole respon-

Storage of spare metal parts

Shelf life:

• size,

• type,

• servi

• part name, and

• part referen

as indicated on the applicable sectional drawing in Chap

ce (or application)

ce number

ter 8 "Parts list and drawings".

• Indefinitely Storage conditions:

• Adequately

Page 54 of 68

prote

physical damage.

cted from moisture and

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Storage of rubber parts, e. g. spare O-rings

Shelf life:

• Maximum three years Storage conditions:

• Stored in ori

• Adequately p

inal heat sealed packaging

rotected from air, light, ozone, radiation, excessive temperature > 49 °C (> 120°F), contamination, and physical damage.

6.10 Tools for repair and maintenance

Refer to Chapter 4.2 "Equipment and personnel required", Page 19.

Page 55 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

7 FAULTS, CAUSES AND REMEDIES

DANGER Before repairing the pumping unit,

read Chapter 1.6 "Safety", Page 6.

Before starting any maintenance o repair work or removing any parts o the pumping unit:

1. Switch off the motor, see Chapte

5.5 "Stopping and shutdown", Page 49.

2. Completely separate the pumping unit from the power supply.

Page 56 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

FAULT SYMPTOM

Motor protection triggered

Pump does not start

⇓

Flow inadequate

⇓

Pumping unit runs, but does not pump

⇓

Shut-off head current (amps) is higher than originally

⇓

Shut-off head is diminished but shut-off curre

⇓

Shut-off head is diminished and shut-off current (a

⇓

Duty capacity and head are low but running current (amps) and shut-off valves are normal

⇓

Pump starts bus trips circuit breaker

⇓

Pump does not start

⇓

PROBABLE CAUSES POSSIBLE REMEDIES

⇓

recorded but shut-off head is not diminished

nt (amps) is unchanged

mps) is much higher

A. SYSTEM TROUBLES

Pump or motor sluggish Check smooth running of pump and

motor.

z Heat to great because total system head does

Reduce head.

not correspond to pump characteristics.

z Unit not suspended in pumping medium due to

inadequate installation depth.

Check well level and/or suspend unit deeper.

B. MECHANICAL TROUBLES

Pump blocked due to impurities in the pump. Disassemble pump section and clean.

z Reduction of area in the pressure pipe be-

Completely open isolator valves.

cause isolator valves are not completely open.

z Reduction of area in the pressure pipe be-

Clean pressure pipe.

cause pressure pipe is clogged.

z Reduction of area in the pressure pipe be-

Clean pipework.

cause of foreign body in the pipe.

z Reduction of area in the pressure pipe be-

Remove unit and regenerate well.

cause well filter stopped up. z Pressure pipe leak due to defective pipework. Check pipework. z Impellers worn out because of high sand con-

tent in the pumping medium.

Remove pump and repair. Check material selection. Analyze water.

z Impellers worn out because of corrosive pump-

ing medium

Remove pump and repair. Check material selection.

Analyze water. z Impellers worn out because of cavitation. Check operating conditions. z Pressure pipe not free because main slide

Check blockage and control units.

valve is closed.

z Motor runs but pump does not turn because

Remove unit and repair.

coupling between pump and motor is defective.

z Suction sieve stopped up because of foreign

Remove unit and clean suction sieve..

body in well z Fracture in riser pipe Replace respective riser pipe z Valve open on by-pass line etc. Close respective valve

Page 57 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

FAULT SYMPTOM

Motor protection triggered

Pump does not start

⇓

Flow inadequate

⇓

z Blockage in discharge or intake Disassemble and clean discharge and

z Valve in system is not fully open Fully open valve

C. ELECTRICAL TROUBLES

z Insulation failure Measure insulation resistance. z Insulation failure Measure insulation resistance.

z Pumping unit is stuck Try momentarily reversing rotation by

Pumping unit runs, but does not pump

⇓

Shut-off head current (amps) is higher than originally recorded but shut-off head is not diminished

⇓

Shut-off head is diminished but shut-off current (amps) is unchanged

⇓

Shut-off head is diminished and shut-off current (amps) is much higher

⇓

Duty capacity and head are low but running current (amps) and shut-off valves are normal

⇓

Pump starts bus trips circuit breaker

⇓

Pump does not start

⇓

PROBABLE CAUSES POSSIBLE REMEDIES

⇓

intake.

Motor circuit breaker adjusted too

Current consumption of motor too high due to

Phase failure. Check fuses.

Voltage failure due to blown fuse(s). Replace fuse(s).

Defective power cable. Replace power cable. z

Incorrect rotating direction. Change rotating direction.

Rotating speed too low because of under volt-

Rotating speed too low because motor runs

Rotating speed too low due to bearing dam-

z z

Drop in line voltage If amperage remains within 110 % of

under voltage o

age or wrong frequency.

with one phase.

age.

r wrong frequency.

low. Readjust motor circuit breaker

according to rating plate or Chapter

12.2 "Data sheet". Check system voltage and frequency.

Check if the information on the type plate corresponds with the system voltage and frequency.

Examine power cables for damage.

Check system voltage and frequency.

Check fuses.

Remove pumping unit and repair.

the rated value: No remedy necessary. If amerage does not remain within

110

% of the rate value: Check line

voltage

Check voltage.

interchanging any two leads

Page 58 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

8 PARTS LIST AND DRAWINGS

Page 59 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

9 CERTIFICATION

Certificates determined from the Contract requirements are provided with these user instructions where applicable. Examples are certificates for CE marking, etc.

ates sent sepa-

If required, copies of other certifi rately to the purchaser should be obtained from the purchaser for retention with these user instructions.

Page 60 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

10 OTHER RELEVANT DOCUMENTA-

TION AND MANUALS

10.1 Change notes

If any changes, agreed with Flowserve Pump Division, are made to the product after its supply, a record of the details should be maintained with these user instructions.

10.2 Abbreviations

ATEX Equipment for Potentially Explosive At-

mospheres NPSH Net positive suction head OD Outer diameter rpm revolutions per minute VDE German Association for electrical, elect-

ronic and inf

band der Elektrotechnik, Elektronik und Informationstechnik e.V.")

ormation technologies ("Ver-

Page 61 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

11 GLOBAL CONTACT POINTS, EU CE

MARKER AND SERVICE CONTACTS

Page 62 of 68

12 APPENDIX

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

Page 63 of 68

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

12.1 Scope of delivery

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

12.2 Data sheet

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

12.3 Tightening torques

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

12.4 Safety data sheet for motor oil

Byron Jackson Double Mechanical Seal Submersible Pumping Unit • 1042.293/9 • June 04

USA and Canada

Flowserve Corporation Headquarters 5215 North O'Conner Blvd. Suite 2300 Irving, Texas 75039, USA

Tel +1 972 443 6500 Toll free 800 728 PUMP (7867) Fax +1 972 443 6800

Europe, Middle East & Africa

Flowserve Limited (Pump Division) Harley House, 94 Hare Lane Claygate, Esher, Surrey KT10 0RB United Kingdom

Tel +44 (0)1372 463 700 Fax +44 (0)1372 460 190

Visit our web site at: www.flowserve.com

Latin America & Caribbean

Flowserve Corporation (Pump Division) 6840 Wynnwood Lane Houston, Texas 77008, USA

Tel +1 713 803 4434 Fax +1 713 803 4497

Asia Pacific

Flowserve Pte Ltd (Pump Division) 200 Pandan Loop, 06-03/04 Pantech 21, Singapore 128388

Tel +65 775 3003 Fax +65 779 4607

Your Flowserve company contact:

Flowserve Hamburg GmbH

Friedrich-Ebert-Damm 105 D-22047 Hamburg

Post Address: PO Box 70 13 20 D-22013 Hamburg Germany

Telephone: +49 (0)40 69 689 379 Repair & Service Fax: +49 (0)40 69 689 480 Sales & Admin Fax: +49 (0)40 69 689 242 Email: hamburg@flowserve.com

Your local Flowserve representative:

You will find your local Flowserve-Agent " Sales Support Locator System" under: www.flowserve.com

Flowserve Byron Jackson Type M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 INTRODUCTION AND SAFETY

1.6.3 Personnel qualification, training and protective clothing

1.6.4 Authorized and prohibited use

2 TRANSPORT AND STORAGE

2.2.3 Transport of the motor

2.2.2 Equipment and personnel required

2.2.4 Transport of the pump bowl assembly

3.1.1 General Description

3.1.3 Motor serial number

3.4.3 Development of the well

3.4.5 Effect of pumping sand

3.4.6 Effect of air or gas

3.5.1 General electrical requirements

3.5.3 Short circuit protection

4.4.2 Sequence of installation

4.4.3 Prepare installation site

4.4.4 Arrange components fo r installation

Install pump bowl assembly

5.3.1 First-time start-up of the pump

5.3.2 Normal start-up of the pump

5.4.1 Performance and operating limits

Interval Part Maintenance

Table 7 Maintenance schedule

6.9.1 Recommended spares and consumable items

6.9.2 Ordering spare parts

6.9.3 Storage of spare par ts

7 FAULTS, CAUSES AND REMEDIES

8 PARTS LIST AND DRAWINGS