Page 1
Installation, Operation and
Maintenance Instructions
Model 7200CB, API Type BB5 Double-Casing
Multi-Stage API 610 11th Edition
Page 2
Page 3
Table of Contents
Introduction and Safety .......................................................................................................... 4
Introduction ............................................................................................................................. 4
Safety ...................................................................................................................................... 4
Safety terminology and symbols ........................................................................................... 5
Environmental safety ............................................................................................................ 5
User safety ........................................................................................................................... 6
Ex-approved products .......................................................................................................... 8
Monitoring equipment ........................................................................................................... 8
Product warranty ..................................................................................................................... 9
Transportation and Storage ................................................................................................. 10
Inspect the delivery ............................................................................................................... 10
Inspect the package ........................................................................................................... 10
Inspect the unit ................................................................................................................... 10
Transportation guidelines ...................................................................................................... 10
Pump handling and lifting ................................................................................................... 10
Storage guidelines ................................................................................................................ 12
Long-term storage .............................................................................................................. 12
Table of Contents
Product Description .............................................................................................................. 13
General description ............................................................................................................... 13
Nameplate information .......................................................................................................... 14
Installation ............................................................................................................................. 17
Preinstallation ....................................................................................................................... 17
Pump location guidelines .................................................................................................... 17
Foundation requirements ................................................................................................... 17
Baseplate-mounting procedures ........................................................................................... 18
Prepare the baseplate for mounting ................................................................................... 18
Prepare the foundation for mounting .................................................................................. 19
Install and level the baseplate ............................................................................................ 19
Install the pump, driver, and coupling .................................................................................... 20
Pump-to-driver alignment ...................................................................................................... 21
Alignment checks ............................................................................................................... 21
Permitted indicator values for alignment checks ................................................................ 22
Alignment measurement guidelines ................................................................................... 22
Attach the dial indicators for alignment ............................................................................... 22
Perform angular alignment for a vertical correction ............................................................ 23
Perform angular alignment for a horizontal correction ........................................................ 23
Perform parallel alignment for a vertical correction ............................................................. 24
Perform parallel alignment for a horizontal correction ........................................................ 25
Perform complete alignment for a vertical correction .......................................................... 26
Perform complete alignment for a horizontal correction ..................................................... 26
Grout the baseplate .............................................................................................................. 26
Piping checklists ................................................................................................................... 28
General piping checklist ..................................................................................................... 28
Suction-piping checklist ...................................................................................................... 29
Discharge piping checklist .................................................................................................. 30
Bypass-piping considerations ............................................................................................. 31
Auxiliary-piping checklist .................................................................................................... 31
Final piping checklist .......................................................................................................... 31
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 1
Maintenance Manual
Page 4
Table of Contents
Commissioning, Startup, Operation, and Shutdown ......................................................... 32
Preparation for startup .......................................................................................................... 32
Remove the coupling guard .................................................................................................. 33
Check the rotation - Frame Mounted ..................................................................................... 33
Couple the pump and driver .................................................................................................. 33
Coupling guard assembly ................................................................................................... 34
Bearing lubrication ................................................................................................................ 38
Oil volumes ......................................................................................................................... 38
Lubricating-oil requirements ............................................................................................... 38
Acceptable oil for lubricating bearings ................................................................................ 39
Lubricate the bearings with oil ............................................................................................ 39
Lubricate the bearings with pure or purge-oil mist (optional) .............................................. 40
Lubricate the bearings after a shutdown period .................................................................. 42
Shaft sealing with a mechanical seal .................................................................................... 42
Connection of sealing liquid for mechanical seals ................................................................. 43
Prime the pump with the suction supply above the pump ..................................................... 43
Start the pump ...................................................................................................................... 44
Pump operation precautions ................................................................................................. 45
Shut down the pump ............................................................................................................. 46
Make the final alignment of the pump and driver ................................................................... 46
Doweling the pump casing .................................................................................................... 46
Dowel for motor installation ................................................................................................ 46
Dowel for cold and hot service ............................................................................................ 47
Additional dowel for hot service .......................................................................................... 47
Maintenance ........................................................................................................................... 49
Maintenance schedule .......................................................................................................... 49
Bearing maintenance ............................................................................................................ 50
Mechanical-seal maintenance .............................................................................................. 50
Disassembly ......................................................................................................................... 51
Disassembly precautions ................................................................................................... 51
Tools required .................................................................................................................... 51
Prepare for disassembly ..................................................................................................... 51
Bundle Removal Using Disassembly Cradle ...................................................................... 53
Bundle Removal Using Slings Only .................................................................................... 59
Prepare for Bundle Disassembly ........................................................................................ 62
Disassemble the radial end (ball bearing pumps) ............................................................... 63
Disassemble the thrust end (ball bearing pumps) ............................................................... 64
Disassemble the Radial End (Sleeve/Hydrodynamic Bearing Pumps) ............................... 65
Disassemble the Thrust End (Sleeve/Hydrodynamic Bearing Pumps) ............................... 68
Disassemble the Bundle ..................................................................................................... 73
Preassembly inspections ...................................................................................................... 81
Replacement guidelines ..................................................................................................... 81
Shaft replacement guidelines ............................................................................................. 84
Bearings inspection ............................................................................................................ 85
Replace the wear bushings ................................................................................................ 86
Reassembly .......................................................................................................................... 89
Assemble the Bundle .......................................................................................................... 89
Confirm the seal chamber runout ....................................................................................... 96
Assemble the radial end (ball bearing pumps) .................................................................... 97
Assemble the thrust end (ball bearing pumps) ................................................................... 99
Assemble the Radial End (Sleeve/Hydrodynamic Bearing Pumps) .................................. 101
Assemble the Thrust End (Sleeve/Hydrodynamic Bearing Pumps) .................................. 103
Prepare for Bundle Reassembly ....................................................................................... 109
Bundle Assembly Using Disassembly Cradle ................................................................... 110
Bundle Assembly Using Slings Only ................................................................................. 115
Final Assembly Steps ....................................................................................................... 117
2 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Table of Contents
Post-assembly checks ...................................................................................................... 119
Assembly references ........................................................................................................ 120
Troubleshooting .................................................................................................................. 122
Operation troubleshooting ................................................................................................... 122
Alignment troubleshooting .................................................................................................. 123
Parts Listings and Cross-Sectionals ................................................................................. 124
Parts list .............................................................................................................................. 124
Cross-sectional diagrams ................................................................................................... 127
Local ITT Contacts .............................................................................................................. 129
Regional offices .................................................................................................................. 129
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 3
Maintenance Manual
Page 6
Introduction and Safety
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations, or
events that are not considered in this manual or in the sales documents, please contact the
nearest ITT representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could
cause death, serious personal injury, or damage to the equipment. This includes any modification to
the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never
apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly
stated in this manual.
• If the pump/motor is damaged or leaking, do not operate as it may cause an electric shock, fire,
explosion, liberation of toxic fumes, physical harm, or environmental damage. Correct/repair the
problem prior to putting back in service.
• Do not change the service application without the approval of an authorized ITT representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical
injury, damage, or delays.
4 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 7
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: result in death or serious injury
Introduction and Safety
A hazardous situation which, if not avoided, will
Hazard categories
WARNING: result in death or serious injury
CAUTION: result in minor or moderate injury
NOTICE:
A hazardous situation which, if not avoided, could
A hazardous situation which, if not avoided, could
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
The Ex symbol
The Ex symbol indicates safety regulations for Ex-approved products when used in
atmospheres that are potentially explosive or flammable.
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 5
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Introduction and Safety
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation.
Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Observe these safety precautions before you work with the product or are in connection with
the product:
6 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is pressurized.
• Never operate a pump without a properly installed coupling guard.
Introduction and Safety
Make sure that the pump is isolated from the system and that pressure is relieved before
you disassemble the pump, remove plugs, or disconnect piping.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these
rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated
against diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 7
Maintenance Manual
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Page 10
Introduction and Safety
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel are
isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that are provided by an authorized ITT representative.
Description of ATEX
The ATEX directives are a specification enforced in Europe for electrical and non-electrical
equipment installed in Europe. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these
guidelines to equipment installed in any potentially explosive atmosphere.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not change
the conditions of the service without the approval of an ITT representative. When you install or
maintain explosion proof products, always comply with the directive and applicable standards
(for example, IEC/EN 60079–14).
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
8 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved
products.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Introduction and Safety
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However,
should the need arise for a warranty claim, then contact your ITT representative.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 9
Maintenance Manual
Page 12
Transportation and Storage
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation guidelines
Pump handling and lifting
Precautions for moving the pump
Use care when moving pumps. Consult with a lifting and rigging specialist before lifting or
moving the pump to avoid possible damage to the pump or injury to personnel.
WARNING:
Make sure that the unit cannot roll or fall over and injure people or damage property.
NOTICE:
Use a forklift truck with sufficient capacity to move the pallet with the pump unit on top.
Precautions for lifting the pump
WARNING:
Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steeltoed shoes at all times.
NOTICE:
• Make sure that the lifting equipment supports the entire assembly and is only used by
authorized personnel.
• Do not attach sling ropes to shaft ends.
Lifting the pump
Hoist a bare pump using suitable slings under the bearing housing saddle on each end.
Figure 1: Example of the proper lifting method for a bare pump
10 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Transportation and Storage
Figure 2: Example of the proper lifting method for a bare pump
Baseplate-mounted units have lifting points for use with proper lifting devices.
Figure 3: Example of the proper lifting method for baseplate-mounted units without a driver
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 11
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Transportation and Storage
Figure 4: Example of the proper lifting method for baseplate-mounted units with a driver
Storage guidelines
Long-term storage
If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least every three months.
Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit
and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your local
ITT sales representative.
12 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Product Description
General description
Product description
The Model 7200CB is a horizontal centrifugal pump that meets the requirements of API 610
11th Editions (ISO 13709 2nd Edition) and has these characteristics:
• High-pressure
• High-temperature
• Multi-stage
• Between the bearings
Product Description
Casing
Impeller
Seal chamber
Power end
The casing is centerline mounted with top-suction and top-discharge nozzles. The compression
gaskets at the three metal-to-metal sealing faces are fully confined.
The flanges are ASME Class 900 raised-face serrated with a 125-250 RMS finish. Other
flanges are also available:
• ASME Class 900 ring joint
• ASME Class 1500 raised-face serrated
• ASME Class 1500 ring joint
• ASME Class 2500 raised-face serrated
• ASME Class 2500 ring joint
The impeller is fully closed and key driven.
The seal chamber meets API 682 3rd Edition dimensions for improved performance of
mechanical seals. Customer-selected cartridge mechanical seals are standard.
The power end has these characteristics:
• Carbon steel bearing housings are standard.
• The oil level is viewed through a sight glass.
• Constant-level oilers and labyrinth seals are standard.
• No machining is required in order to convert the standard ring oil lube to either purge or
pure mist. Pure mist applications require minor bearing housing modifications.
• Pressure lubrication is required with hydrodynamic thrust bearings.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 13
Maintenance Manual
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Product Description
Bearings
Shaft
Baseplate
Bearing type Characteristics
Inboard (radial)
Outboard (thrust)
• Consists of a single-row deep-groove ball bearing (standard)
• Carries only radial load
• Optional sleeve bearings
• Consists of a pair of single-row angular contact ball bearings
mounted back-to-back (standard)
• Shouldered and locked to the shaft
• Retained in the bearing frame to enable the bearing to carry both
radial and thrust loads
• Optional hydrodynamic thrust bearing for use with sleeve type journal
bearings
The heavy duty shaft has these characteristics:
• Designed for cartridge mechanical seals
• Minimal shaft deflection at the seal faces (0.002 in. [0.051 mm]) when run in the worstcase condition (typically minimum flow)
• Lateral modes at least +/- 15% of excitation frequency unless modes are critically damped
per API 610.
The fabricated steel baseplate supports the pump, driver, and accessories in accordance with
API-610 latest Edition (ISO 13709) requirements.
Direction of rotation
The shaft rotates counterclockwise when viewed from the coupling.
Nameplate information
Important information for ordering
Every pump has a nameplate that provides information about the pump. The nameplate is
located on the pump casing.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item
numbers.
Nameplate types
Nameplate Description
Bearing frame Provides information about the lubrication system used.
ATEX If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the
IECEx If applicable, your pump unit might have the following IECEx nameplate affixed to the
baseplate, or the discharge head. The nameplate provides information about the
ATEX specifications of this pump.
pump and/or baseplate. The nameplate provides information about the IECEx
specifications of this pump.
14 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Nameplate on the pump casing using English units
Product Description
Nameplate field Explanation
MODEL Pump model
SIZE Size of the pump
FLOW Rated pump flow, in gallons per minute
HEAD Rated pump head, in feet
RPM Rated pump speed, in revolutions per minute
HYDRO PRESS Hydrostatic pressure at 100°F, in pounds per square inch
MAX. DES. WORKING Maximum working pressure at temperature °F, in pounds per square inch
PRESS
S/N Serial number of the pump
CONT./ITEM NO. Customer contract or item number
IMP. DIA. Rated impeller diameter
MAX. DIA. Maximum impeller diameter
STD. DIM. Standard ANSI dimensional code
MAT'L Material of construction
Nameplate on the pump casing using metric units
Nameplate field Explanation
MODEL Pump model
SIZE Size of the pump
FLOW Rated pump flow, in gallons per minute
HEAD Rated pump head, in feet
RPM Rated pump speed, in revolutions per minute
HYDRO PRESS Hydrostatic pressure at 38°C, in pounds per square inch
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 15
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Product Description
Nameplate field Explanation
MAX. DES. WORKING Maximum working pressure at temperature °C, in pounds per square inch
PRESS
S/N Serial number of the pump
CONT./ITEM NO. Customer contract or item number
IMP. DIA. Rated impeller diameter
MAX. DIA. Maximum impeller diameter
STD. DIM. Standard ANSI dimensional code
MAT'L Material of construction
Nameplate on the bearing frame
Table 1: Explanation of the nameplate on the bearing frame
Nameplate field Explanation
BRG. O. B. Outboard bearing designation
BRG. I. B. Inboard bearing designation
S/N Serial number of the pump
LUBE Lubricant, oil or grease
ATEX nameplate
Nameplate field Explanation
II Group 2
2 Category 2
G/D Pump can be used when gas and dust are present
T4 Temperature class
NOTICE:
Make sure that the code classifications on the pump are compatible with the specific
environment in which you plan to install the equipment. If they are not compatible, do not
operate the equipment and contact your ITT representative before you proceed.
16 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Installation
Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and
any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.
• Electrical Connections must be made by certified electricians in compliance with all international,
national, state, and local rules.
NOTICE:
Supervision by an authorized ITT representative is recommended to ensure proper installation.
Failure to do so may result in equipment damage or decreased performance.
Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can
result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified
lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for
the entire load being lifted.
Installation
Guideline Explanation/comment
Keep the pump as close to the liquid source as This minimizes the friction loss and keeps the
practically possible. suction piping as short as possible.
Make sure that the space around the pump is This facilitates ventilation, inspection, maintenance,
sufficient. and service.
If you require lifting equipment such as a hoist or This makes it easier to properly use the lifting
tackle, make sure that there is enough space above equipment and safely remove and relocate the
the pump. components to a safe location.
Protect the unit from weather and water damage This is applicable if nothing else is specified.
due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in closed Acceptable devices:
systems unless the system is constructed with
properly-sized safety devices and control devices.
Take into consideration the occurrence of unwanted
noise and vibration.
If the pump location is overhead, undertake special Consider a consultation with a noise specialist.
precautions to reduce possible noise transmission.
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid
support for the unit.
• The location and size of the foundation bolt holes must match those shown on the
assembly drawing provided with the pump data package.
• The foundation must weigh between two and three times the weight of the pump.
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices,
consult the engineer or architect in charge before
you operate the pump.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 17
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Installation
Sleeve-type bolts
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
1. Baseplate
2. Shims or wedges
3. Foundation
4. Sleeve
5. Dam
6. Bolt
J-type bolts
1. Baseplate
2. Shims or wedges
3. Foundation
4. Dam
5. Bolt
Baseplate-mounting procedures
Prepare the baseplate for mounting
This procedure assumes you have a basic knowledge of baseplate and foundation design and
installation methods. Follow industry-standard procedures, such as API RP 686/ PIP REIE 686,
or this procedure before you grout the baseplate.
1. Make sure that all baseplate surfaces that will contact grout are free from contamination
such as rust, oil, and grime.
2. Thoroughly clean all baseplate surfaces that will come in contact with grout.
Make sure to use a cleaner that will not leave residue.
18 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Page 21
NOTICE:
You may need to sandblast the surfaces of a baseplate that come in contact with grout, and
then coat those surfaces with a primer that is grout-compatible. Make sure to remove all
equipment before sandblasting.
3. Make sure that all machined surfaces are free from burrs, rust, paint, or any other type of
contamination.
If necessary, use a honing stone to remove burrs.
Prepare the foundation for mounting
1. Chip the top of the foundation to a minimum of 1.0 in. (25.0 mm) in order to remove porous
or low-strength concrete.
If you use a pneumatic hammer, make sure that it does not contaminate the surface with oil
or other moisture.
NOTICE:
Do not chip the foundation using heavy tools such as jackhammers. This can damage the
structural integrity of the foundation.
2. Remove water or debris from the foundation bolt holes or sleeves.
3. If the baseplate uses sleeve-type bolts, then fill the sleeves with a non-binding, moldable
material. Seal the sleeves in order to prevent the grout from entering.
4. Coat the exposed portion of the anchor bolts with a non-bonding compound such as paste
wax in order to prevent the grout from adhering to the anchor bolts.
Do not use oils or liquid wax.
5. If recommended by the grout manufacturer, coat the foundation surface with a compatible
primer.
Installation
Install and level the baseplate
NOTICE:Illustrations are for reference only and may not depict the particular pump model.
WARNING:
Never operate any pumping system with a blocked suction and discharge. Operation, even for a brief
period under these conditions, can cause confined pumped fluid to overheat, which results in a violent
explosion. You must take all necessary measures to avoid this condition. If pump becomes plugged shut
down and unplug prior to restarting pump.
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can
cause personal injury and damage to property, and may void the warranty.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 19
Maintenance Manual
Page 22
Installation
Figure 5: Jackscrew locations, side view
1. Lower the baseplate carefully onto the foundation bolts.
The baseplate will rest on top of the foundation on the jackscrews provided on the
baseplate.
2. Adjust the leveling jackscrews, located adjacent to the foundation bolt holes, until the
baseplate rests 1 to 2 in. (25 to 50 mm) above the foundation in order to allow for adequate
grouting.
This provides even support for the baseplate after grouting.
3. Level the baseplate to within 0.002 in./ft. (0.167 mm/m) of the length or width of the
baseplate by adjusting the jackscrews.
• The maximum total variation from one end or side of the baseplate to the other is
0.015 in. (0.38 mm).
• Use the equipment mounting surfaces in order to establish the level.
4. Use a non-bonding (anti-seize) compound such as paste wax to coat the portions of the
jackscrews that will contact the grout.
This facilitates removal of the screws after grouting.
NOTICE:
Do not use oils or liquid wax.
5. Thread the nuts onto the foundation bolts and hand-tighten.
Install the pump, driver, and coupling
1. Mount and fasten the pump on the baseplate. Use applicable bolts.
2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.
3. Install the coupling.
See the installation instructions from the coupling manufacturer.
20 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 23
Pump-to-driver alignment
Precautions
WARNING:
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or
unintended contact of rotating parts. Follow the coupling installation and operation procedures from
the coupling manufacturer.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
NOTICE:
Proper alignment is the responsibility of the installer and the user of the unit. Check the
alignment of frame-mounted units before you operate the unit. Failure to do so can result in
equipment damage or decreased performance.
Alignment methods
Three common alignment methods are used:
• Dial indicator
• Reverse dial indicator
• Laser
Follow the instructions from the equipment manufacturer when you use the reverse dial
indicator or laser methods. Detailed instructions for using the dial indicator method are
contained in this chapter.
Installation
Alignment checks
When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of alignment checks
Type of check When it is used
Initial alignment (cold alignment) Prior to operation when the pump and the driver are at ambient
check temperature.
Final alignment (hot alignment) After operation when the pump and the driver are at operating
check temperature.
Initial alignment (cold alignment) checks
When Why
Before you grout the baseplate This ensures that alignment can be accomplished.
After you grout the baseplate This ensures that no changes have occurred during the grouting
After you connect the piping This ensures that pipe strains have not altered the alignment.
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the driver
Periodically This follows the plant operating procedures.
process.
If changes have occurred, you must alter the piping to remove pipe
strains on the pump flanges.
are at operating temperature.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 21
Maintenance Manual
Page 24
Installation
Permitted indicator values for alignment checks
NOTICE:
The specified permitted reading values are valid only at operating temperature. For cold
settings, other values are permitted. You must use the correct tolerances. Failure to do so can
result in misalignment and reduced pump reliability.
IMPORTANT
• For electric motors, the motor shaft initial (cold) parallel vertical alignment setting should
be 0.002 to 0.004 in. (0.05 to 0.10 mm) lower than the pump shaft.
• For other drivers such as turbines and engines, follow the driver manufacturer's
recommendations.
When dial indicators are used to check the final alignment, the pump and drive unit are
correctly aligned when these conditions are true:
• The total indicator runout is a maximum of 0.002 in. (0.05 mm) at operating temperature.
• The tolerance of the indicator is 0.0005 in./in. (0.0127 mm/mm) of indicator separation at
operating temperature.
Alignment measurement guidelines
Guideline Explanation
Rotate the pump coupling half and the driver This prevents incorrect measurement.
coupling half together so that the indicator rods
have contact with the same points on the driver
coupling half.
Move or shim only the driver in order to make This prevents strain on the piping installations.
adjustments.
Make sure that the hold-down bolts for the driver This keeps the driver stationary since movement
feet are tight when you take indicator measure- causes incorrect measurement.
ments.
Make sure that the hold-down bolts for the driver This makes it possible to move the driver when you
feet are loose before you make alignment correc- make alignment corrections.
tions.
Check the alignment again after any mechanical This corrects any misalignments that an adjustment
adjustments. may have caused.
Attach the dial indicators for alignment
You must have two dial indicators in order to complete this procedure.
1. Attach two dial indicators on the pump coupling half (X):
a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter
of the driver coupling half (Y).
This indicator is used to measure parallel misalignment.
b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner
end of the driver coupling half.
This indicator is used to measure angular misalignment.
22 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 25
2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with
the driver coupling half (Y) but do not bottom out.
3. Adjust the indicators if necessary.
Perform angular alignment for a vertical correction
1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the
driver coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The coupling halves are farther apart at the
bottom than at the top. Perform one of these
steps:
• Add shims in order to raise the feet of the
driver at the shaft end.
• Remove shims in order to lower the feet of the
driver at the other end.
Positive The coupling halves are closer at the bottom than
at the top. Perform one of these steps:
• Remove shims in order to lower the feet of the
driver at the shaft end.
• Add shims in order to raise the feet of the
driver at the other end.
Installation
1. Shims
Figure 6: Example of incorrect vertical alignment (side view)
4. Repeat the previous steps until the permitted reading value is achieved.
Perform angular alignment for a horizontal correction
1. Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y),
90° from the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start
position (3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The coupling halves are farther apart on the right side than
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 23
Maintenance Manual
the left. Perform one of these steps:
• Slide the shaft end of the driver to the left.
• Slide the opposite end to the right.
Page 26
Installation
When the reading value is... Then...
Positive The coupling halves are closer together on the right side
than the left. Perform one of these steps:
• Slide the shaft end of the driver to the right.
• Slide the opposite end to the left.
Figure 7: Example of incorrect horizontal alignment (top view)
4. Repeat the previous steps until the permitted reading value is achieved.
Perform parallel alignment for a vertical correction
Refer to the alignment table in "Permitted indicator values for alignment checks" (see Table of
Contents for location of table) for the proper cold alignment value based on the motor
temperature rise and the pump operating temperature.
Before you start this procedure, make sure that the dial indicators are correctly set up.
A unit is in parallel alignment when the parallel indicator (P) does not vary by more than
0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator (P) to zero at the top-center position (12 o’clock) of the
driver coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The pump coupling half (X) is lower than the
Positive The pump coupling half (X) is higher than the
driver coupling half (Y). Remove shims of a
thickness equal to half of the indicator reading
value under each driver foot.
driver coupling half (Y). Add shims of a thickness
equal to half of the indicator reading value to each
driver foot.
NOTICE:
24 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 27
1. Shims
Figure 8: Example of incorrect vertical alignment (side view)
4. Repeat the previous steps until the permitted reading value is achieved.
Installation
Perform parallel alignment for a horizontal correction
A unit is in parallel alignment when the parallel indicator (P) does not vary by more than
0.002 in. (0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator (P) to zero on the left side of the driver coupling half (Y),
90° from the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start
position (3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The driver coupling half (Y) is to the left of the
Positive The driver coupling half (Y) is to the right of the
4. Slide the driver carefully in the appropriate direction.
pump coupling half (X).
pump coupling half (X).
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 25
Maintenance Manual
Page 28
Installation
NOTICE:Make sure to slide the driver evenly. Failure to do so can negatively affect
horizontal angular correction.
Figure 9: Example of incorrect horizontal alignment (top view)
5. Repeat the previous steps until the permitted reading value is achieved.
Perform complete alignment for a vertical correction
A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P)
do not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the top-center position (12 o’clock) of
the driver coupling half (Y).
2. Rotate the indicators to the bottom-center position (6 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment
until you obtain the permitted reading values.
Perform complete alignment for a horizontal correction
A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P)
do not vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the left side of the driver coupling half
(Y), 90° from the top-center position (9 o’clock).
2. Rotate the indicators through the top-center position to the right side, 180° from the start
position (3 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment
until you obtain the permitted reading values.
Grout the baseplate
Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the
instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is recommended.
26 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 29
Installation
NOTICE:It is assumed that the installer who grouts the baseplate has knowledge of acceptable
methods. More detailed procedures are described in various publications, including API
Standard 610, 8th Edition, Appendix L; API RP 686, Chapter 5; and other industry standards.
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout through the grout hole into the baseplate up to the level of the dam.
When you pour the grout, remove air bubbles from it by using one of these methods:
• Puddle with a vibrator.
• Pump the grout into place.
5. Allow the grout to set.
1. Baseplate
2. Shims or wedges
3. Grout
4. Foundation
5. Sleeve
6. Dam
7. Bolt
6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48
hours.
1. Baseplate
2. Grout
3. Foundation
4. Dam
5. Bolt
7. Remove the leveling jackscrews after the grout hardens in order to remove any stress
points.
8. Tighten the foundation bolts.
9. Recheck the alignment.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 27
Maintenance Manual
Page 30
Installation
Piping checklists
General piping checklist
Precautions
CAUTION:
• Never draw piping into place by using force at the flanged connections of the pump. This can
impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe
strain adversely affects the operation of the pump, which results in physical injury and damage to
the equipment.
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the
suction side. This action can result in decreased performance, unexpected heat generation, and
equipment damage.
CAUTION:
Flange loads from the piping system, including those from the thermal expansion of the piping, must not
exceed the limits of the pump. Casing deformation can result in contact with rotating parts, which can
result in excess heat generation, sparks, and premature failure.
Piping guidelines
Guidelines for piping are given in the Hydraulic Institute Standards available from the Hydraulic
Institute at 9 Sylvan Way, Parsippany, NJ 07054-3802. You must review this document before
you install the pump.
Checklist
Check Explanation/comment Checked
Check that all piping is supported This helps to prevent:
independently of, and lined up
naturally with, the pump flange.
See Alignment criteria for pump • Wear on the pump bearings, seal, and shafting
flanges.
Keep the piping as short as pos- This helps to minimize friction losses.
sible.
Check that only necessary fittings This helps to minimize friction losses.
are used.
Do not connect the piping to the —
pump until:
• The grout for the baseplate or
sub-base becomes hard.
• The hold-down bolts for the
pump are tightened.
Make sure that all the piping joints This prevents air from entering the piping system or
and fittings are airtight. leaks that occur during operation.
If the pump handles corrosive
fluids, make sure that the piping
allows you to flush out the liquid
before you remove the pump.
If the pump handles liquids at
elevated temperatures, make
sure that the expansion loops and
joints are properly installed.
Make sure that all piping compo- —
nents, valves and fittings, and
pump branches are clean prior to
assembly.
Make sure that the isolation and Locate the check valve between the isolation valve and
check valves are installed in the the pump. This will permit inspection of the check valve.
discharge line. The isolation valve is required for regulation of flow, and
• Strain on the pump
• Misalignment between the pump and the drive unit
for inspection and maintenance of the pump. The check
valve prevents pump or seal damage due to reverse
flow through the pump when the driver is turned off.
28 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 31
Check Explanation/comment Checked
Use cushioning devices. This protects the pump from surges and water hammer
Alignment criteria for pump flanges
Type Criteria
Axial The flange gasket thickness is ±0.03 in. (0.8 mm).
Parallel Align the flange to be within 0.001 in./in. to 0.03 in./
Concentric You can easily install the flange bolts by hand.
Fastening
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing fasteners.
Suction-piping checklist
Performance curve reference
Installation
if quick-closing valves are installed in the system.
in. (0.025 mm/mm to 0.8 mm/mm) of the flange
diameter.
CAUTION:
Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction
side. This action can result in decreased performance, unexpected heat generation, and equipment
damage.
Net positive suction head available (NPSHA) must always exceed NPSH required (NPSHR) as
shown on the published performance curve of the pump.
Suction-piping checks
Check Explanation/comment Checked
Check that the distance between This minimizes the risk of cavitathe inlet flange of the pump and tion in the suction inlet of the
the closest elbow is at least five pump due to turbulence.
pipe diameters.
Check that elbows in general do —
not have sharp bends.
Check that the suction piping is The suction piping must never
one or two sizes larger than the have a smaller diameter than the
suction inlet of the pump. suction inlet of the pump.
Install an eccentric reducer between the pump inlet and the
suction piping.
Check that the eccentric reducer —
at the suction flange of the pump
has the following properties:
• Sloping side down
• Horizontal side at the top
When suction strainers or suction Suction strainers help to prevent
bells are used, check that they are clogging.
at least three times the area of the
suction piping.
If more than one pump operates This recommendation helps you to
from the same liquid source, achieve a higher pump perforcheck that separate suction-piping mance.
lines are used for each pump.
Mesh holes with a minimum diameter of 1/16 in. (1.6 mm) are
recommended.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 29
Maintenance Manual
Page 32
Installation
Check Explanation/comment Checked
If necessary, make sure that the —
suction piping includes a drain
valve and that it is correctly installed.
Liquid source below the pump
Check Explanation/comment Checked
Make sure that the suction piping This helps to prevent the occuris free from air pockets. rence of air and cavitation in the
Check that the suction piping —
slopes upwards from the liquid
source to the pump inlet.
Check that all joints are air-tight. —
If the pump is not self-priming, Use a foot valve with a diameter
check that a device for priming the that is at least equivalent to the
pump is installed. diameter of the suction piping.
Liquid source above the pump
Check Explanation/comment Checked
Check that an isolation valve is This permits you to close the line
installed in the suction piping at a during pump inspection and maindistance of at least two times the tenance.
pipe diameter from the suction
inlet.
Make sure that the suction piping This helps to prevent the occuris free from air pockets. rence of air and cavitation in the
Check that the piping is level or —
slopes downward from the liquid
source.
Make sure that no part of the —
suction piping extends below the
suction flange of the pump.
Make sure that the suction piping This prevents air from entering the
is adequately submerged below pump through a suction vortex.
the surface of the liquid source.
pump inlet.
Do not use the isolation valve to
throttle the pump. Throttling can
cause these problems:
• Loss of priming
• Excessive temperatures
• Damage to the pump
• Voiding the warranty
pump inlet.
Discharge piping checklist
Checklist
Check Explanation/comment Checked
Check that an isolation valve is in- The isolation valve is required for:
stalled in the discharge line.
Check that a check valve is installed in The location between the isolation valve and the
the discharge line, between the isola- pump allows inspection of the check valve.
tion valve and the pump discharge
outlet.
If increasers are used, check that they —
are installed between the pump and
the check valve.
If quick-closing valves are installed in This protects the pump from surges and water
the system, check that cushioning de- hammer.
vices are used.
30 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
• Priming
• Regulation of flow
• Inspection and maintenance of the pump
The check valve prevents damage to the pump and
seal due to the back flow through the pump, when
the drive unit is shut off. It is also used to restrain
the liquid flow.
Maintenance Manual
Page 33
Bypass-piping considerations
When to use a bypass line
Provide a bypass line for systems that require operation at reduced flows for prolonged
periods. Connect a bypass line from the discharge side (before any valves) to the source of
suction.
When to install a minimum-flow orifice
You can size and install a minimum-flow orifice in a bypass line in order to prevent bypassing
excessive flows. Consult your ITT representative for assistance in sizing a minimum-flow
orifice.
When a minimum-flow orifice is unavailable
Consider an automatic recirculation control valve or solenoid-operated valve if a constant
bypass (minimum-flow orifice) is not possible.
Auxiliary-piping checklist
Precautions
WARNING:
• Cooling systems such as those for bearing lubrication and mechanical-seal systems must be
operating properly to prevent excess heat generation, sparks, and premature failure.
• Sealing systems that are not self-purging or self-venting, such as plan 23, require manual venting
prior to operation. Failure to do so will result in excess heat generation and seal failure.
Installation
NOTICE:
The mechanical seal must have an appropriate seal-flush system. Otherwise, excess heat
generation and seal failure can occur.
When to install
You may need to install auxiliary piping for bearing cooling, seal-chamber cover cooling,
mechanical seal flush, or other special features supplied with the pump. Consult the pump data
sheet for specific auxiliary piping recommendations.
Checklist
Check Explanation/comment Checked
Check that the minimum flow for –
each component is 1 gpm (4 lpm).
If the bearing and seal chamber
cover cooling are provided, then
the auxiliary piping must flow at 2
gpm (8 lpm).
Check that the cooling water pres- –
sure does not exceed 100 psig
(7.0 kg/cm2).
Final piping checklist
Check Explanation/comment Checked
Check that the shaft rotates Rotate the shaft by hand. Make
smoothly. sure there is no rubbing that can
Re-check the alignment to make If pipe strain exists, then correct
sure that pipe strain has not the piping.
caused any misalignment.
lead to excess heat generation or
sparks.
Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and 31
Maintenance Manual
Page 34
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Preparation for startup
DANGER:
Avoid death or serious injury. Explosion and/or seizure of pump can cause fire and/or burns. Never
operate pump past the pressure and temperature limits shown on the nameplate on the pump.
WARNING:
• Failure to follow these precautions before you start the unit will lead to serious personal injury and
equipment failure.
• Do not operate the pump below the minimum rated flows or with the suction or discharge valves
closed. These conditions can create an explosive hazard due to vaporization of pumped fluid and
can quickly lead to pump failure and physical injury.
• Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Operating the pump above
maximum rated flow shown on the pump curve leading to an increase in horsepower and vibration
along with an increase in NPSHr resulting in mechanical seal and/or shaft failure and/or loss of
prime.
• Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Speed of pump must reach
2000 rpm for 2 pole motors and 1000 rpm for 4 pole motors within 10 seconds or an increase in
vibration and rotor deflection and decrease in rotor stability leading to mechanical seal and/or shaft
failure and/or pump seizure can occur.
• Never operate the pump without the coupling guard correctly installed.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
• Operating the pump in reverse rotation can result in the contact of metal parts, heat generation, and
breach of containment.
• Avoid death or serious injury. Explosion and/or seizure of pump can cause fire and/or burns. Assure
balance line is installed and either piped to the pump suction or back to the suction vessel to avoid
vaporization of pumped fluid.
DANGER:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Assure all openings are sealed
off prior to filling pump.
Precautions
NOTICE:
• Verify the driver settings before you start any pump.
• Make sure that the temperature change does not exceed 20°F (11°C) per minute.
• The maximum allowable temperature change for an abnormal transient event such as
thermal shock is 250°F (121°C).
You must follow these precautions before you start the pump:
• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in order
to prevent premature failure at initial startup.
• Bring variable-speed drivers to the rated speed as quickly as possible.
• If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump prior
to operation. Circulate a small amount of fluid through the pump until the casing
temperature is within 100°F (38°C) of the fluid temperature. Accomplish this by flowing
32 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
Maintenance Manual
Page 35
fluid from pump inlet to discharge drain (optionally, the casing vent can be included in
warm-up circuit but not required). Soak for (2) hours at process fluid temperature.
At initial startup, do not adjust the variable-speed drivers or check for speed governor or overspeed trip settings while the variable-speed driver is coupled to the pump. If the settings have
not been verified, then uncouple the unit and refer to instructions supplied by the driver
manufacturer.
Remove the coupling guard
1. Remove the nut, bolt, and washers from the slotted hole in the center of the coupling guard.
2. Slide the driver half of the coupling guard toward the pump.
3. Remove the nut, bolt, and washers from the driver half of the coupling guard.
4. Remove the driver-side end plate.
5. Remove the driver half of the coupling guard:
a) Slightly spread the bottom apart.
b) Lift upwards.
6. Remove the remaining nut, bolt, and washers from the pump half of the coupling guard.
It is not necessary to remove the end plate from the pump side of the bearing housing. You
can access the bearing-housing tap bolts without removing this end plate if maintenance of
internal pump parts is necessary.
7. Remove the pump half of the coupling guard:
a) Slightly spread the bottom apart.
b) Lift upwards.
Commissioning, Startup, Operation, and Shutdown
Check the rotation - Frame Mounted
WARNING:
• Operating the pump in reverse rotation can result in the contact of metal parts, heat generation, and
breach of containment.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
1. Lock out power to the driver.
2. Make sure that the coupling hubs are fastened securely to the shafts.
3. Make sure that the coupling spacer is removed.
The pump ships with the coupling spacer removed.
4. Unlock power to the driver.
5. Make sure that everyone is clear, and then jog the driver long enough to determine that the
direction of rotation corresponds to the arrow on the bearing housing or close-coupled
frame.
6. Lock out power to the driver.
Couple the pump and driver
WARNING:
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
•
1. Check the gap between the coupling hubs against the dimensions shown on the elevation
drawing or as stamped on the coupling hub. For any necessary adjustment, move the
driver not the pump.
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Motors with sleeve bearings may be manufactured with 1/4 or 1/2 in. (6.35 or 12.7 mm) end
movement (float) in the motor rotor. For limited end-float arrangement, the gap between the
coupling halves must be set in a different manner. If specific directions are not indicated in
the motor instructions, then follow this procedure:
NOTICE:
If the driver was mounted at the factory, the setting for the coupling is already determined.
a) Slide the rotor towards the outboard end of the motor as far as it will go and mark the
shaft at the motor frame.
b) Slide the rotor towards the inboard end of the motor as far as it will go and mark the
shaft again.
The distance between the marks should be either 1/2 or 1/4 in. (6.35 or 12.7 mm) if the
motor is arranged for limited end-float travel.
c) Scribe a third mark on the shaft halfway between the scribe marks made in the previous
steps.
d) Clamp the rotor in place.
1. Sleeve bearing
2. Thrust collar
3. Coupling
2. Use the instructions from the coupling manufacturer to lubricate and install the coupling.
3. Check the angular and parallel alignment of the coupling halves. See Pump-to-driver
alignment in the Installation chapter.
Coupling guard assembly
Precautions
WARNING:
• Avoid death or serious injury. Assure mechanical seal guard is properly installed using supplied
fastening hardware.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
• The coupling used in an Ex-classified environment must be properly certified and must be
constructed from a non-sparking material.
Install the coupling guard
1. Is the end plate (pump end) already installed?
• If yes: Make any necessary coupling adjustments and then proceed to step 2.
• If no: Complete these steps:
34 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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a) Remove the spacer portion of the coupling.
Refer to the instructions from the coupling manufacturer for assistance.
b) If the coupling hub diameter is larger than the diameter of the opening in the end plate,
then remove the coupling hub.
c) Remove the thrust bearing end-cover screws.
d) Align the end plate to the thrust bearing end cover so that the holes in the end plate
align with the holes in the end cover.
e) Replace the three thrust bearing end cover screws and torque to the values shown in
the Maximum torque values for fasteners table.
f) Replace the coupling hub (if removed) and the spacer portion of the coupling.
Refer to the instructions from the coupling manufacturer for assistance.
Complete any coupling adjustments before you proceed with the coupling guard assembly.
2. Slightly spread the opening of the coupling guard half and place it over the pump end plate.
The annular groove in the guard is located around the end plate.
Position the opening (flange) so that it does not interfere with the piping but still allows for
access when you install the bolts.
1. Annular groove
2. Deflector fan guard
3. Coupling guard half
3. Place one washer over the bolt and insert the bolt through the round hole at the front end of
the guard half.
4. Place a second washer over the exposed end of the bolt.
5. Thread a nut onto the exposed end of the bolt and tighten firmly.
This figure shows the proper sequence of components:
1. Nut
2. Washer
3. Bolt
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Commissioning, Startup, Operation, and Shutdown
1. Nut
2. Washer
3. Bolt
This figure shows an assembled unit:
1. Driver
2. Coupling guard half
6. Slightly spread the opening of the remaining coupling guard half and place it over the
installed coupling guard half so that the annular groove in the remaining coupling guard half
faces the driver.
1. Annular groove
2. Coupling guard half
3. Driver
36 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Commissioning, Startup, Operation, and Shutdown
7. Place the end plate over the driver shaft and locate the end plate in the annular groove at
the rear of the coupling guard half.
1. Annular groove
2. End plate
8. Repeat steps 3 through 5 for the rear end of the coupling guard half, except that you hand
tighten the nut.
9. Slide the rear coupling guard half towards the motor so that it completely covers the shafts
and coupling.
1. Driver
2. Slide to fit
10. Repeat steps 3 through 5 for the center slots in the coupling guard.
11. Firmly tighten all nuts on the guard assembly.
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Commissioning, Startup, Operation, and Shutdown
Bearing lubrication
Precautions
WARNING:
Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation,
sparks, and premature failure.
NOTICE:
Avoid equipment damage. Refer to driver/coupling/gear manufactures IOM for instructions and
recommendations for lubrication.
Pumps are shipped without oil
You must lubricate oil-lubricated bearings at the job site.
Ring oil lubrication
Ring oil-lubricated bearings are standard. Bearing housings are supplied with constant-level
oilers and sight glasses. Make sure that oil rings are properly seated in the grooves in the shaft.
Pure or purge oil-mist lubrication
Pure or purge oil mist are optional features. Follow the oil-mist generator manufacturer's
instructions. The inlet and outlet connections are located on the top and bottom of the bearing
housing, respectively.
Oil volumes
Oil volume requirements for ball/ball
This table shows the required amount of oil for oil-lubricated bearings.
All frames in this table use a Watchdog Oiler, which has a capacity of 4 oz. (118 ml).
Bearing housing oil volume
ounces milliliters
80 2365
Oil volume requirements for sleeve/hydrodynamic type bearings
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump and
the cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
Avoid equipment damage. Assure there is adequate pressurized oil flow as the pump coasts
down.
The sleeve/hydrodynamic type bearing is a pressurized lubrication system where oil is flowed
into the bearing. This system does not have an oil sump. The system requires a flow rate of 0.5
gpm (0.12 m3/hr) for the sleeve bearing and 1.0 gpm (0.23m3/hr) for Kingsbury #5 and 2.0 gpm
(0.45 m3/hr) for Kingsbury #6 for the hydrodynamic thrust bearing at 15 psi (100 kPA).
Lubricating-oil requirements
Oil quality requirements
Use a high-quality turbine oil with rust and oxidation inhibitors with rated viscosity shown below
at 100°F (38°C).
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Oil requirements based on temperature
For the majority of operating conditions, bearing temperatures run between 120°F (49°C) and 180°F
(82°C), and you can use an oil of ISO viscosity grade 68 at 100°F (38°C). If temperatures exceed 180°F
(82°C), refer to the table for temperature requirements.
Temperature Oil requirement
Bearing temperatures exceed 180°F (82°C) Use ISO viscosity grade 100. Bearing temperatures
Pumped-fluid temperatures are extreme Refer to the factory or a lubrication expert.
Acceptable oil for lubricating bearings
Acceptable lubricants
Table 2:
Brand Lubricant type
Ball/Ball Sleeve/Hydrodynamic
Exxon Teresstic EP 68 Teresstic EP 32
Mobil DTE Heavy Medium DTE 732
Sunoco Sunvis 968 Sunvis 932
Royal Purple SYNFILM ISO VG 68 SYNFILM ISO VG 32
Lubricate the bearings with oil
Commissioning, Startup, Operation, and Shutdown
are generally about 20°F (11°C) higher than bearing-housing outer surface temperatures.
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump and
the cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
Ring oil-lubricated pumps are supplied with an oiler that maintains a constant oil level in the
bearing housing.
1. Fill the oil reservoir in the bearing frame:
a) Fill the bearing chamber through the main body of the Watchdog until it reaches the
optimum fluid level visible in the bullseye sight.
b) Fill the watchdog reservoir using a funnel.
c) Verify o-ring is on the Watchdog oiler spout.
d) Place your thumb over the reservoir spout. Invert and insert the spout into the internal
threaded boss on the main body.
e) Tighten reservoir. Do not over-tighten.
f) Verify that proper oil level is maintained per the following diagram.
NOTICE:
Do not fill the oil reservoir of the bearing frame through the plug at the top.
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Commissioning, Startup, Operation, and Shutdown
2. Check that the oil level is correct. The correct oil level is centered in the bullseye sight
glass, when the pump is not in operation. During operation, bullseye sight gives a false oil
level reading. Shown is general schematic. Oil level is below outer race of bearing.
1. Plug
2. Reservoir
3. Main body
Lubricate the bearings with pure or purge-oil mist (optional)
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump and
the cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
Before lubricating with purge-oil mist, make sure that the bearing frame is properly lubricated.
See Lubricate the bearings with oil.
The oil requirements for ring-oil-lubricated bearings also apply to oil-mist-lubricated bearings.
NOTICE:
Oil mist is recommended for use on ball bearing arrangements only. See Convert to oil-mist
lubrication.
1. Prepare the oil-mist generator according to the manufacturer's instructions.
2. Connect the oil-mist supply lines to the oil-ring inspection plug connections.
40 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Commissioning, Startup, Operation, and Shutdown
Note that only one of the two connection ports in the radial bearing housing (134) is used
(immediately above the single row radial bearing). You must connect to both connections
on the thrust bearing housing, because there are two rows of bearings.
Oil-mist connections
A. Radial and thrust
B. Thrust only
C. Radial and thrust drain
Convert to oil-mist lubrication
NOTICE:
Make sure that pipe threads are clean and apply thread sealant to plugs and fittings.
You can convert from ring-oil lubrication to oil-mist lubrication in pumps with ball bearing
construction. The radial and thrust end bearing housings (134) have pre-drilled connections for
oil misting:
• 1/4 in. NPT connection on the inboard side of the housing
• 1/2 in. NPT connection on the outboard side
Purge-oil mist lubrication provides intermittent oil mist in the bearing housing. This system uses
the oil sump in the housing, and requires the oil ring and the constant-level oiler.
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Commissioning, Startup, Operation, and Shutdown
Pure-oil mist lubrication provides constant oil mist in the bearing housing. This system does not
use the oil sump, oil ring, or constant-level oiler. The drain connections in the bearing housing
are used as part of the oil recirculation system.
1. On the radial housing, replace the 1/4 in. NPT plug with an oil-mist fitting provided by the
oil-mist system manufacturer.
The 1/2 in. NPT connections remains plugged because it is not required in the oil-mist
system.
2. On the thrust housing, replace the 1/4 in. NPT plug with an oil-mist fitting. Replace the 1/2
in. NPT plug with a 1/2 in. to 1/4 in. bushing and insert an oil-mist fitting provided by the oilmist system manufacturer.
Oil-mist connections
A. Radial and thrust (1/4 in.)
B. Thrust only (1/2 in.)
C. Radial and thrust drain
NOTICE:
In both housings, the inboard channel beneath the 1/4 in. NPT connection must be 1/4 in. plugepoxied to prevent rapid oil drainage. Drill a 1/8 in. hole for required but restricted drainage.
Lubricate the bearings after a shutdown period
1. Flush out the bearings and bearing frame with a light oil to remove contaminants.
During flushing, make sure to rotate the shaft slowly by hand.
2. Flush the bearing housing with the proper lubricating oil to ensure oil quality after cleaning.
3. Refer to "Reassembly" section for proper bearing greasing procedure.
Shaft sealing with a mechanical seal
Precautions
WARNING:
The mechanical seal used in an Ex-classified environment must be properly certified. Prior to startup,
make sure that all areas that could leak pumped fluid to the work environment are closed.
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NOTICE:
• The mechanical seal must have an appropriate seal-flush system. Otherwise, excess heat
generation and seal failure can occur.
• Cooling systems such as those for bearing lubrication and mechanical-seal systems must
be operating properly to prevent excess heat generation, sparks, and premature failure.
• Sealing systems that are not self-purging or self-venting, such as plan 23, require manual
venting prior to operation. Failure to do so will result in excess heat generation and seal
failure.
Shipping
Pumps may be shipped with or without a mechanical seal installed.
Cartridge-type mechanical seals
Cartridge-type mechanical seals are commonly used. Cartridge seals are preset by the seal
manufacturer and require no field settings. Cartridge seals installed by the user require
disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the
seal has been installed in the pump by ITT, these clips have already been disengaged.
Other mechanical seal types
For other types of mechanical seals, refer to the instructions provided by the seal manufacturer
for installation and setting.
Commissioning, Startup, Operation, and Shutdown
Connection of sealing liquid for mechanical seals
Seal lubrication is required
Seal faces must have liquid film between them for proper lubrication. Locate the taps using the
illustrations shipped with the seal.
Seal flushing methods
You can use these methods in order to flush or cool the seal:
Method Description
Product flush Run the piping so that the pump pushes the pumped fluid from the casing and
External flush Run the piping so that the pump injects a clean, cool, compatible liquid directly into
Other You can use other methods that employ multiple gland or seal chamber
injects it into the seal gland. If necessary, an external heat exchanger cools the
pumped fluid before it enters the seal gland.
the seal gland. The pressure of the flushing liquid must be 5 to 15 psi (0.35 to 1.01
kg/cm2) greater than the seal chamber pressure. The injection rate must be 0.5 to
2 gpm (2 to 8 lpm).
connections. Refer to the mechanical seal reference drawing and piping diagrams.
Prime the pump with the suction supply above the pump
1. Slowly open the suction isolation valve.
2. Open the air vents on the suction and discharge piping, the casing, the seal chamber, and
the seal piping, if provided, until all air is vented and only the pumped fluid flows out.
3. Close the air vents.
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Commissioning, Startup, Operation, and Shutdown
1. Discharge isolation valve
2. Check valve
3. Suction isolation valve
Start the pump
WARNING:Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop
the driver immediately, reprime, and attempt to restart the pump.
CAUTION:
• Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the
• Observe the pump for vibration levels, bearing temperature, and excessive noise. If normal levels
• On pure or purge-oil mist-lubricated units, remove the viewing port plugs to verify that oil mist
• On frame mounted units, ensure that the oil level is correct prior to starting pump. Close coupled
• Ensure all flush and cooling systems are operating correctly prior to starting pump.
Before you start the pump, you must perform these tasks:
• Open the suction valve.
• Open any recirculation or cooling lines.
1. Fully close or partially open the discharge valve, depending on system conditions.
2. Start the driver.
3. Slowly open the discharge valve until the pump reaches the desired flow.
4. Immediately check the pressure gauge to ensure that the pump quickly reaches the correct
5. If the pump fails to reach the correct pressure, perform these steps:
6. Monitor the pump while it is operating:
driver, reprime, and attempt to restart the pump.
are exceeded, shut down the pump and resolve the issue.
flowing properly. Replace the plugs.
pumps do not have oil lubricated bearings.
discharge pressure.
a) Stop the driver.
b) Prime the pump again.
c) Restart the driver.
a) Check the pump for bearing temperature, excessive vibration, and noise.
44 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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b) If the pump exceeds normal levels, then shut down the pump immediately and correct
the problem.
A pump can exceed normal levels for several reasons. See Troubleshooting for
information about possible solutions to this problem.
7. Repeat steps 5 and 6 until the pump runs properly.
Pump operation precautions
General considerations
CAUTION:
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the
suction side since this can result in decreased performance, unexpected heat generation, and
equipment damage.
• Do not operate pump past the maximum flow. For maximum flow refer to the pump performance
curve.
• Do not overload the driver. Driver overload can result in unexpected heat generation and equipment
damage. The driver can overload in these circumstances:
• The specific gravity of the pumped fluid is greater than expected.
• The pumped fluid exceeds the rated flow rate.
• Do not operate pump below hydraulic or thermal minimum flow. For hydraulic minimum flows refer
to technical manual and pump performance curve. To calculate thermal minimum flow, refer to HI
Centrifugal Pumps for Design and Application ANSI/HI 1.3-2000.
• Make sure to operate the pump at or near the rated conditions. Failure to do so can result in pump
damage from cavitation or recirculation.
Commissioning, Startup, Operation, and Shutdown
Operation at reduced capacity
WARNING:
Never operate any pumping system with a blocked suction and discharge. Operation, even for a brief
period under these conditions, can cause confined pumped fluid to overheat, which results in a violent
explosion. You must take all necessary measures to avoid this condition. If pump becomes plugged shut
down and unplug prior to restarting pump.
CAUTION:
• Avoid excessive vibration levels. Excessive vibration levels can damage the bearings, stuffing box
or seal chamber, and the mechanical seal, which can result in decreased performance.
• Avoid increased radial load. Failure to do so can cause stress on the shaft and bearings.
• Avoid heat build-up. Failure to do so can cause rotating parts to score or seize.
• Avoid cavitation. Failure to do so can cause damage to the internal surfaces of the pump.
Operation under freezing conditions
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump and
the cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
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Commissioning, Startup, Operation, and Shutdown
Shut down the pump
WARNING:
The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe proper
decontamination procedures in order to eliminate the possible exposure to any hazardous or toxic fluids.
Wear the proper personal protective equipment. Potential hazards include, but are not limited to, high
temperature, flammable, acidic, caustic, explosive, and other risks. You must handle and dispose of
pumped fluid in compliance with the applicable environmental regulations.
1. Slowly close the discharge valve.
2. Shut down and lock the driver to prevent accidental rotation.
Make the final alignment of the pump and driver
WARNING:
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or
unintended contact of rotating parts. Follow the coupling installation and operation procedures from
the coupling manufacturer.
You must check the final alignment after the pump and driver are at operating temperature. For
initial alignment instructions, see the Installation chapter.
1. Run the unit under actual operating conditions for enough time to bring the pump, driver,
and associated system to operating temperature.
2. Shut down the pump and the driver.
3. Remove the coupling guard.
4. Check the alignment while the unit is still hot.
See Pump-to-driver alignment in the Installation chapter.
5. Reinstall the coupling guard.
6. Restart the pump and driver.
Doweling the pump casing
You must dowel the pump casing to the baseplate pedestals in order to maintain the proper
pump position. There are two methods for doweling the pump casing, depending on whether
the pump is used in a cold application or a hot application. Hot doweling is required above
250°F (121°C). All pumps are equipped for hot doweling.
When the driver is mounted at the factory, the pump is doweled for both cold and hot
applications; the driver is not doweled in order to allow for final field alignment. When the driver
is mounted in the field, the pump is not doweled. Therefore, these doweling procedures,
typically done at the factory, must be done in the field.
NOTICE:
You should dowel only after completing the final alignment.
Dowel for motor installation
1. Center the pump on its pedestal so that the hold-down bolts are centered in the tapped
holes of the pump pedestal.
2. Place the motor on the baseplate with the proper shaft separation (DBSE = distance
between shaft ends).
3. Tighten the pump hold-down bolts.
46 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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4. After you have determined the correct motor location on the motor pedestals, mark the
location of the motor on the pedestals with a hole punch through the hold-down bolt holes
in the motor feet.
5. Remove the motor, then drill and tap the punched holes on the motor pedestal.
NOTICE:
Scribe the motor shims in order to return them to the correct location on the motor pedestal.
6. Set the motor back onto the baseplate with the shims in the correct location. Tighten the
hold-down bolts.
7. Loosen the pump and motor hold-down bolts. Confirm that the pump and motor are not
bolt-bound in order to make sure that the final drilled holes will be correctly located.
NOTICE:
Do not dowel the pump prior to this procedure because you will not be able to move the
pump on its pedestals.
Dowel for cold and hot service
Required tools:
• Two number 7 taper pins
• One number 7 taper pin reamer
• 21/64 in. or "Q" size drill
• Hardwood block or soft-faced hammer
Commissioning, Startup, Operation, and Shutdown
NOTICE:
This procedure must be done only after the pump is properly aligned with the driver on the
baseplate.
1. Drill two holes through the pump foot and pump pedestal. Position each hole between the
hold-down bolt and the end of the pump foot at the coupling end on both sides.
2. Ream the holes with a number 7 taper pin reamer to the proper fit with the taper dowel pins.
Insert the pins deep enough so that only the threaded portions are exposed when the pins
are fully seated.
3. Seat the taper pins firmly in the holes with a hardwood block or soft-faced hammer.
If you should ever need to remove the dowel pins, tighten the hex nuts provided on the pins. If
the pins are not seated deeply enough, put a spacer under the hex nuts in order to lift the pins
free when the hex nuts are tightened.
NOTICE:
Always remove the dowel pins before removing the casing. Failure to do so can result in casing
damage.
Additional dowel for hot service
WARNING:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Assure pump casing has been
properly hot doweled to prevent misalignment of rotor assembly leading to mechanical seal, bearing,
coupling and/or shaft failure.
Required tools:
• Supplied hardware stated below
• Impact wrench
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Commissioning, Startup, Operation, and Shutdown
NOTICE:
This procedure must be done only after the pump is properly aligned with the driver on the
baseplate.
1. Install pin (394) into casing.
2. Place block (441) on pedestal located on baseplate and align with pin (394) in casing.
3. Secure block with lockwasher (438E) and capscrew (370F) to baseplate.
48 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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Maintenance
Maintenance schedule
Maintenance inspections
A maintenance schedule includes these types of inspections:
• Routine maintenance
• Routine inspections
• Three-month inspections
• Annual inspections
Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if
the environment is classified as potentially explosive.
Routine maintenance
Perform these tasks whenever you perform routine maintenance:
• Lubricate the bearings.
• Inspect the seal.
Routine inspections
Perform these tasks whenever you check the pump during routine inspections:
• Check the level and condition of the oil through the sight glass on the bearing frame.
• Check for unusual noise, vibration, and bearing temperatures.
• Check the pump and piping for leaks.
• Analyze the vibration.
• Inspect the discharge pressure.
• Inspect the temperature.
• Check that there is no leakage from the mechanical seal.
Maintenance
Three-month inspections
Perform these tasks every three months:
• Check that the foundation and the hold-down bolts are tight.
• Check the mechanical seal if the pump has been left idle, and replace as required.
• Change the oil every three months (2000 operating hours) at minimum.
• Change the oil more often if there are adverse atmospheric or other conditions that
• Check the shaft alignment, and realign as required.
Annual inspections
Perform these inspections one time each year:
• Check the pump capacity.
• Check the pump pressure.
• Check the pump power.
If the pump performance does not satisfy your process requirements, and the process
requirements have not changed, then perform these steps:
1. Disassemble the pump.
2. Inspect it.
3. Replace worn parts.
might contaminate or break down the oil.
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Maintenance
Bearing maintenance
Bearing lubrication schedule
Type of lubrication First lubrication Lubrication intervals
Ring oil Add oil before you install and start After the first 200 hours, change
Purge oil
Pure oil Follow the recommendations from Follow the recommendations from
Forced oil
Mechanical-seal maintenance
WARNING:
The mechanical seal used in an Ex-classified environment must be properly certified. Prior to startup,
make sure that all areas that could leak pumped fluid to the work environment are closed.
CAUTION:
Never operate the pump without liquid supplied to mechanical seal. If you run a mechanical seal dry,
even for a few seconds, this can cause seal damage. Physical injury can occur if a mechanical seal fails.
the pump. Change the oil after the oil every 2000 operating hours
200 hours for new bearings. or every three months.
the manufacturer. the manufacturer.
NOTICE:
• Sealing systems that are not self-purging or self-venting, such as plan 23, require manual
venting prior to operation. Failure to do so will result in excess heat generation and seal
failure.
• Cooling systems, such as those for bearing lubrication and mechanical-seal systems, must
be operating properly to prevent excess heat generation, sparks, and premature failure.
• The mechanical seal must have an appropriate seal flush system or excess heat
generation and seal failure can occur.
Cartridge-type mechanical seals
Cartridge-type mechanical seals are commonly used. Cartridge seals are preset by the seal
manufacturer and require no field settings. Cartridge seals installed by the user require
disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the
seal has been installed in the pump by ITT, these clips have already been disengaged.
Other mechanical seal types
For other types of mechanical seals, refer to the instructions provided by the seal manufacturer
for installation and setting.
Reference drawing
The manufacturer supplies a reference drawing with the data package. Keep this drawing for
future use when you perform maintenance and seal adjustments. The seal drawing specifies
the required flush fluid and attachment points.
Before you start the pump
Check the seal and all flush piping.
Mechanical seal life
The life of a mechanical seal depends on the cleanliness of the pumped fluid. Due to the
diversity of operating conditions, it is not possible to give definite indications as to the life of a
mechanical seal.
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Disassembly
Disassembly precautions
WARNING:
• This manual clearly identifies accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never
apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly
stated in this manual.
• Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical
injury.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear
steel-toed shoes at all times.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe
proper decontamination procedures in order to eliminate the possible exposure to any hazardous or
toxic fluids. Wear the proper personal protective equipment. Potential hazards include, but are not
limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. You must handle
and dispose of pumped fluid in compliance with the applicable environmental regulations.
• A small amount of liquid will be present in certain areas like the seal chamber.
NOTICE:
• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves
while handling these parts.
• Make sure that all replacement parts are available before you disassemble the pump for
overhaul.
Maintenance
Tools required
In order to disassemble the pump, you need these tools:
• Brass drift punch
• Cleaning agents and solvents
• Dial indicators
• Drill
• Feeler gauges
• Hex wrenches
• Induction heater
• Lifting sling
• Micrometers (inside and outside)
• Open end wrenches
• Press
• Soft face hammer
• Spanner wrench
• Spanning type puller
• Tap
• Torque wrench with sockets
Prepare for disassembly
CAUTION:
Allow all system and pump components to cool before you handle them to prevent physical injury.
1. Close the isolation valves on the suction and discharge sides of the pump.
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2. Drain the liquid from the piping; flush the pump if necessary.
3. Disconnect all auxiliary piping, tubing, and equipment that will interfere with the removal of
the head and the rotor.
4. Remove the oil drain plugs (408A) from the bottom of the bearing housings (134) and drain
the oil.
Dispose of the oil in accordance with applicable regulations.
5. Remove the oiler bottle (251) and store it in a safe place.
6. Remove the coupling guard (501B) and motor coupling guard endplate (234B).
Refer to Remove the coupling guard in the Commissioning, Startup, Operation, and
Shutdown chapter.
7. Unbolt and remove the coupling spacer (235B).
Follow the instructions provided by the coupling manufacturer for assistance.
8. Remove the coupling guard pump endplate(234A).
9. Unbolt and remove balance line bolts (791L) and nuts (357T). Remove balance line and
gasket (351M).
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10. Loosen and remove head nuts and washers (425 and 533).
Bundle Removal Using Disassembly Cradle
1. Loosen and remove suction cover nuts (425B and 426B).
2. Remove the suction cover locking plates (519).
3. Remove the coupling nut (520).
Maintenance
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Maintenance
4. Install extension adapter (850A) and tighten suction cover nuts (426B).
5. Tighten stub shaft extension tie (850N) to pump shaft (122).
6. Install extension tie (850B) and tighten bolts (851A).
7. Tighten coupling nut (520).
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Maintenance
8. Install caster adapter plate (850D) and tighten suction cover nuts (425B).
9. Install caster mounting plate (850E) and tighten bolts (850B) with washers (853A and
853B).
10. Install jack screw (851C).
11. Install casters (854) and tighten bolts (851D).
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12. Install rail supports (850L) to assembly rail (850H). Using jack screws (851E) and nuts
(852), adjust as necessary to level with ground and baseplate. Tighten nuts (852) and bolts
(851F).
13. Install rail stop (850M) and tighten bolt (851G) and nut (852A).
Assemble cart for head.
14. Install cart bracket (850G) to cart (850F) and tighten bolts (851H) with washers (853C).
15. Install casters (854A) to cart and tighten bolts (851J).
Assemble cart to head.
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16. Install cart to head (184) and tighten bolts (851K) with washers (853D).
17. Install stop plate (850J) and stop lever (850K) and tighten bolts (851L and 851M) and nut
(852B) with washers (853E and 853F).
18. Use the jackscrews (419) in order to loosen the head (184) from the casing (100). Push
bundle out of casing (100) until there is enough room to install the extension (850C). Install
extension (850C) and tighten bolts (851N).
19. Repeat line 18 until bundle is fully through the casing (100).
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Maintenance
20. Install jack stands (850P and 850R) and tighten bolt (851P) and nut (852C). Adjust until
jack stand fits snuggly under bundle.
21. Place suitable slings as shown and place some tension on the bundle.
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22. Loosen and remove bolts (851N) and remove extension (850C) from extension tie (850N).
23. Remove suction cover gaskets (351C and 351S).
24. Loosen and remove bolts (851K) and washers (853D) and remove cart from head (184).
25. Hoist bundle using suitable slings as shown.
Bundle Removal Using Slings Only
1. For non-cartridge designs, proceed to step 3. Loosen and remove suction cover nuts (425B
and 426B).
2. Remove the suction cover locking plates (519).
3. For non-cartridge designs only, disassemble the pump coupling hub per "Prepare for
Bundle Disassembly" section and disassemble the radial end per the appropriate bearing
section.
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4. Use the jackscrews (419) in order to loosen head (184) from the casing (100).
5. Using suitable slings pull bundle out until radial end of shaft / housing is inside casing (100).
60 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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6. Reposition the slings around bundle and remove from the casing (100).
Maintenance
7. Remove suction cover gaskets (351C and 351S).
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Maintenance
Prepare for Bundle Disassembly
1. If disassembly cradle was not used, proceed to step 4. Remove the coupling nut (520).
2. For disassembly cradle only, loosen and remove bolts (851A) and remove extension tie
(850B).
3. For disassembly cradle only, remove stub shaft extension tie (850N).
4. For disassembly cradle only, loosen and remove suction cover nuts (426B) and remove
extension adapter (850A).
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Maintenance
5. For bundle remove with slings only, remove the coupling nut (520).
6. Remove the coupling hub (233) and coupling key (400) from the pump.
7. Reposition the setting tabs in order to maintain the position of the mechanical seal. Loosen
all set screws on sleeve collar. Refer to the seal installation drawing provided by the
manufacture. Position both seals at this time.
Disassemble the radial end (ball bearing pumps)
1. Unbolt and remove the cover bolts (371C) and the outboard end cover (119A). Unbolt and
remove the inboard cover bolts (371C).
The outboard labyrinth seal (332A) and the bearing housing gasket (360A) will come off
with the outboard cover (119A).
2. Remove the oil ring (114).
3. Remove the dowel pins (469J) between the bearing housing flange and the suction cover
flange. Tighten the nut on the dowel pin to back it out of the hole.
The connection point of the bearing housing (134) to the suction cover (182) is referred to
as the saddle.
4. Unbolt the bearing housing (134) from the saddle by removing the nuts (357P).
5. Pull the bearing housing (134) off the bearings.
6. Loosen the setscrew (388L) on the oil ring sleeve (324) and remove the sleeve.
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Maintenance
7. Use a bearing puller in order to remove the radial bearing (168) from the shaft.
8. Remove the inboard bearing cover (119A). The inboard labyrinth seal (333A) and the
bearing housing gasket (360A) will come off with inboard cover (119A).
9. Remove the gland nuts (355) and the mechanical seal (250).
Refer to the instructions provided by the mechanical seal manufacturer.
Disassemble the thrust end (ball bearing pumps)
1. Unbolt and remove the cover bolts (371C) and the outboard thrust bearing end cover
(109A). Unbolt and remove the inboard cover bolts (371C).
The bearing housing gaskets (360A) will remain on the end covers (109A).
2. Remove the oil ring (114).
3. Remove the dowel pins (469J) between the bearing housing flange and the head flange.
Tighten the nut on the dowel pin to back it out of the hole.
The connection point of the bearing housing (134) to the head (184) is referred to as the
saddle.
4. Unbolt the bearing housing (134) from the saddle by removing the nuts (357P).
5. Pull the bearing housing (134) off the bearings.
6. Remove the locknut (136) and the lockwasher (382).
7. Remove the oil ring sleeve (443B), which is held in place by the thrust locknut (136).
8. Use a bearing puller in order to remove the thrust bearing (112) from the shaft (122).
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Maintenance
The inner race on this inner duplex bearing remains on the shaft when the bearing is pulled.
Remove this inner race by applying heat. Do this away from the pump site.
WARNING:
The pump may handle hazardous and/or toxic liquids. Trapped or undrained liquid can cause explosions
when heat is applied. Never apply heat at the pump site for this reason. Heat can also distort machined
surfaces.
9. Remove bearing spacer (217)
10. Remove the inboard bearing cover (119). The inboard labyrinth seal (333A), and the
bearing housing gasket (360A) will come off with the inboard cover (119A).
11. Remove the gland nuts (355) and the mechanical seal (250).
Refer to the instructions provided by the mechanical seal manufacturer.
Disassemble the Radial End (Sleeve/Hydrodynamic Bearing Pumps)
1. Unbolt upper half of the bearing housing (134) from the saddle by removing the nuts (357P)
and studs (375). The connection point of the bearing housing (134) to the suction cover
(182) is referred to as the saddle.
2. Remove the two dowel pins between the upper and lower halves of the bearing housing
(134). Tighten the nut on the dowel pin to back it out of the hole.
3. Unbolt upper half of the bearing housing (134) and remove.
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4. Remove upper half of sleeve bearing (117). Notice that the sleeve bearing is pinned to the
upper half of the bearing housing.
5. Remove the outboard labyrinth seal (332A).
6. Using a sling lift up on the shaft and rotate out lower half of sleeve bearing (117).
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Maintenance
7. Remove the dowel pins (469J) between the bearing housing flange and saddle flange.
Tighten the nut on the dowel pin to back it out of the hole.
8. Unbolt lower half of the bearing housing (134) from the saddle by removing the nuts (357P).
9. Remove lower half of the bearing housing (134).
10. Remove the inboard labyrinth seal (333A).
11. Remove gland nuts (355) and the mechanical seal (250).
Refer to the instructions provided by the mechanical seal manufacturer.
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Maintenance
Disassemble the Thrust End (Sleeve/Hydrodynamic Bearing Pumps)
1. Unbolt and remove oil pump / endplate bolts (370L) and remove oil pump (219), if supplied,
or endplate (119C) if no oil pump is installed. Coupling sleeve might come off with oil pump.
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Maintenance
2. Unbolt and remove adapter bolts (370V) and remove oil pump adapter (318A). The oil
pump adapter gasket (360D) will come off with the oil pump adapter (318A).
3. For pumps with oil pump only, remove coupling sleeve if it didn’t come off in step #1.
Loosen set screw on coupling hub and remove coupling hub and coupling key (178Y).
4. Unbolt upper half of the bearing housing (134A) from the saddle by removing the nuts
(357P) and studs (375). The connection point of the bearing housing (134A) to the head
(184) is referred to as the saddle.
5. Remove the two dowel pins between the upper and lower halves of the bearing housing
(134A). Tighten the nut on the dowel pin to back it out of the hole.
6. Unbolt upper half of the bearing housing (134A) and remove. Use jackscrews on the
horizontal parting flange as necessary in order to separate the two halves.
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Maintenance
7. Remove shims (390C & 390M).
8. Remove filler plate (441A). The o-ring (412M) and roll pin (394) will come off with filler plate
(441A).
9. Remove tilt pad bearings and holders (280). The holders are split and will have to be
rotated to remove all of the tilt pad bearings.
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Maintenance
10. Loosen the setscrew (222B) on the thrust collar nut (283) and unthread thrust collar nut.
Threads on thrust collar nut are left handed.
11. Remove thrust collar (280) and thrust collar key (282).
12. Remove bearing spacer (217).
13. Remove upper half of sleeve bearing (117). Notice that the sleeve bearing is pinned to the
upper half of the bearing housing.
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Maintenance
14. Using a sling lift up on the shaft and rotate out lower half of sleeve bearing (117).
15. Remove the dowel pins (469J) between the bearing housing flange and saddle flange.
Tighten the nut on the dowel pin to back it out of the hole.
16. Unbolt lower half of the bearing housing (134A) from the saddle by removing the nuts
(357P).
17. Remove lower half of the bearing housing (134A).
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18. Remove the inboard labyrinth seal (333A).
19. Remove gland nuts (355) and the mechanical seal (250).
Refer to the instructions provided by the mechanical seal manufacturer.
Disassemble the Bundle
Maintenance
1. Install eyebolts (not supplied) in the pre-drilled threaded holes in the top outside perimeter
of the head (184).
WARNING:
Use the eyebolts to lift only the head. They will not support the weight of the entire bundle.
2. Remove head (184) from the discharge cover (150B). The head gasket (351) and belleville
washer (354A) will come off with the head (184). If not remove both these items.
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Maintenance
3. Unbolt and remove locating ring retainer bolts (371B) and remove locating ring retainer
(253).
4. Remove sleeve locating ring (361F).
5. Remove balance drum sleeve (128) from shaft (122).
6. Remove sleeve key (178).
CAUTION:
Avoid injury. Assure the suction cover is securely fastened to a stable surface to avoid the bundle from
becoming unstable while assembling/disassembling in the vertical orientation.
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
7. Heat the last stage impeller (101M) hub to 300°F-400°F (150°C-200°C). Using the puller
holes on the impeller hub remove from shaft (122).
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Maintenance
8. Remove impeller locating ring (361H) and impeller key (178).
CAUTION:
Burn hazard. The discharge cover will get hot. Wear insulated gloves when handling the discharge cover.
9. Heat the intermediate cover (150) outer diameter to 300°F-400°F (150°C-200°C). For a 3
stage, double suction first stage pump this will be the inboard suction cover (182A). Install
eyebolts (not supplied) into the lifting holes and use pry slots to remove discharge cover
(150B).
NOTICE:
Allow the shaft and intermediate cover to cool to ambient temperature before proceeding
with disassembly.
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Maintenance
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
10. Heat the next impeller (101A-101L) hub to 300°F-400°F (150°C-200°C). Using a hook in
the impeller vanes (vertical disassembly only) remove from shaft (122).
11. Remove impeller locating ring (361H) and impeller key (178).
CAUTION:
Burn hazard. The intermediate cover will get hot. Wear insulated gloves when handling the intermediate
cover.
12. Heat the next intermediate cover (150) outer diameter to 300°F-400°F (150°C-200°C).
Note the last intermediate cover that is removed, the suction cover (182) for single suction
pumps or the inboard suction cover (182A) for double suction pumps will be the part that is
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Maintenance
heated. Install eyebolts (not supplied) into the lifting holes and use the pry slots to remove
intermediate cover (150).
NOTICE:
Allow the shaft and intermediate cover to cool to ambient temperature before proceeding
with disassembly.
13. Repeat steps 10 through 12 until all impellers, except 1st stage, and intermediate covers
are removed.
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Maintenance
14. For double suction pumps only, remove inboard suction cover (182A) from suction cover
(182). The inboard suction cover gaskets (351K & 351W) will come off with the inboard
suction cover (182A).
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15. Remove remaining shaft assembly from suction cover (182).
Maintenance
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
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Maintenance
16. Heat the 1st stage impeller (101) hub to 300°F-400°F (150°C-200°C) and remove from
shaft (122). For double suction pumps, the first stage impeller (101) is removed from the
opposite end.
17. Remove impeller key (178).
CAUTION:
Burn hazard. The interstage sleeve will get hot. Wear insulated gloves when handling the sleeve.
18. For double suction pumps only, heat the interstage sleeve (204) to 300°F-400°F (150°C200°C) and remove from shaft (122).
19. For double suction pumps only, remove interstage sleeve key (178).
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Preassembly inspections
Replacement guidelines
Casing check and replacement
WARNING:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and assure gasket sealing
surfaces are not damaged and repair or replace as necessary.
Inspect the casing, suction covers and head for cracks and excessive wear or pitting.
Thoroughly clean gasket surfaces and alignment fits to remove rust and debris.
Repair or replace these parts if you notice any of these conditions:
• Localized wear or grooving that is greater than 1/8 in. (3.2 mm) deep
• Pitting that is greater than 1/8 in. (3.2 mm) deep
• Irregularities in the casing-gasket seat surface
• Wear ring clearances that exceed the values in the Minimum running clearances table
NOTICE:
When clearances between the rings become excessive (increase by 50%), hydraulic
performance decreases substantially.
Maintenance
Casing, suction covers and head areas to inspect
The arrows point to the areas to inspect for wear:
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Maintenance
Impeller, intermediate and discharge cover replacement
This table shows the criteria for replacment:
Impeller, intermediate and discharge cover When to replace
parts
Impeller / Diffuser vanes
Vane edges When you see cracks, pitting, or corrosion damage
Keyway and bores When you see damage
Wear ring surfaces When the clearance to the casing wear ring has
• When grooved deeper than 1/16 in. (1.6 mm),
or
• When worn evenly more than 1/32 in. (0.8 mm)
increased by 50% over the values in the Minimum
running clearances table
Impeller checks
• Check and clean the impeller bore diameter.
• Check the impeller balance. Rebalance the impeller if it exceeds the ISO G1.0 (4W/N)
criteria.
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Impeller areas to inspect
Maintenance
NOTICE:
You must have extremely accurate tooling equipment to balance impellers to the ISO G1.0
criteria. Do not attempt to balance impellers to this criteria unless this type of tooling and
equipment is available.
A. Shroud
B. Wear ring
C. Vane
Labyrinth seal replacement
Replace the labyrinth-seal O-ring if it has cuts and cracks.
Oil ring replacement
Oil rings must be as round as possible in order to function properly. Replace oil rings if they are
worn, distorted, or damaged beyond reasonable repair.
Cartridge mechanical seal replacement
Cartridge-type mechanical seals should be serviced by the seal manufacturer. Refer to the
instructions from the mechanical seal manufacturer for assistance.
Coupling guard replacement
Repair or replace the coupling guard if you notice corrosion or other defects.
Gaskets, O-rings, and seats replacement
WARNING:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Replace any damaged or worn
gaskets/o-rings.
• Replace all gaskets and O-rings at each overhaul and disassembly.
• Inspect the seats. They must be smooth and free of physical defects.
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Maintenance
In order to repair worn seats, skin cut them in a lathe while you maintain dimensional
relationships with other surfaces.
• Replace parts if the seats are defective.
Additional parts
Inspect and either repair or replace all other parts, if inspection indicates continued use would
be harmful to satisfactory and safe pump operation.
Inspection must include these items:
• Bearing end covers (109A and 119A)
• Labyrinth seals (332A and 333A)
• Bearing locknut (136)
• Impeller key (178) and coupling key (400)
• Bearing lockwasher (382)
• All nuts, bolts, and screws
Shaft replacement guidelines
Shaft measurement check
Check the bearing fits of the shaft. If any are outside the tolerances shown in the Bearing fits
and tolerances table, then replace the shaft.
Shaft straightness check
Check the shaft straightness. Use "V" blocks or balance rollers to support the shaft on the
bearing fit areas. Replace the shaft if runout exceeds the values in the Shaft and rotor runout
requirements table.
NOTICE:Do not use shaft centers for the runout check as they may have been damaged during
the removal of the bearings or impeller.
Shaft surface check
Check the shaft surface for damage. Replace the shaft if it is damaged beyond reasonable
repair.
Rotor
Allowable runouts of the fully assembled rotor are listed in the Shaft and rotor runout
requirements table.
Table 3: Shaft and rotor runout requirements
Characteristic Requirement
Flexibility factor, L4/D
84 Model 7200CB, API Type BB5 Barrel Multistage / ISO 13709 2nd Edition / API 610 11th Edition Installation, Operation, and
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>1.9x109mm
(3.0x106in.)
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Characteristic Requirement
Allowable shaft runout, TIR 40 µm
Component fit to shaft Interference
Allowable rotor radial runout, TIR* 60 um
*Total indicated runout of impeller hubs and sleeves
Bearings inspection
Condition of bearings
Do not reuse bearings. The condition of the bearings provides useful information on operating
conditions in the bearing frame.
Checklist
Perform these checks when you inspect the bearings:
• Inspect the bearings for contamination and damage.
• Note any lubricant condition and residue.
• Inspect the ball bearings to see if they are loose, rough, or noisy when you rotate them.
• Investigate any bearing damage to determine the cause. If the cause is not normal wear,
correct the issue before you return the pump to service.
Maintenance
(0.0015 in.)
(0.0025 in.)
Replacement bearings
Replacement bearings must be the same as, or equivalent to, those listed in this table.
NOTICE:
Thrust bearings must have machined bronze cages (retainers).
Table 4: Model 7200CB ball bearing fits
Bearing numbers are based on SKF/MRC designations.
Radial bearing Thrust bearing Bearing housing Shaft turn in (mm)
6216 7313/BECBM 5.5118 (140.00) Thrust Radial
6313 7313/BECBM 5.5118 (140.00) 2.5597 (65.02)
6314 7314/BECBM 5.9055 (150.00) 2.7565 (70.02)
Bearing housings
Perform these checks when you inspect the bearing housings:
bore in (mm)
5.5128 (140.03) 2.5597 (65.02) 3.1502 (80.02)
2.5592 (65.00) 3.1497 (80.00)
5.5128 (140.03) 2.5592 (65.00)
5.9065 (150.03) 2.7560 (70.00)
• Check that the bearing housings are very clean, with no burrs.
• Remove all loose and foreign material.
• Check the bearing housing bores against the values in the Ball bearing fits table.
• Repair or replace housings as necessary.
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Replace the wear bushings
The throat bushing (125), interstage bushing (double suction pumps only) (146) and balance
drum (129) are held in place by a press fit and three set screws (222D and 222Z).
1. Remove the bushing:
a) Remove the set screws.
b) Press the throat bushing (125) into the seal chamber of the suction cover (182) and
head (184) bore. Use jackscrew (not provided) to remove drum (129) from head (184).
Press the interstage bushing (double suction pumps only) into cross over area of
inboard suction cover (182A).
2. Install new bushing:
a) Thoroughly clean the bushing and drum fit in the suction cover (182), inboard suction
cover (182A) and head (184). Apply an anti-seize compound to the bore.
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b) Chill the new throat bushing (125), interstage bushing (146) and drum (129) using dry
WARNING:
Dry ice and other chilling substances can cause physical injury. Contact the supplier for information and
advice for proper handling precautions and procedures.
c) Locate, drill and tap three new set screw holes equally spaced between the original
d) Install set screw (222D and 222Z) and upset threads.
Replace the wear rings
The casing wear rings (164, 164A, 164B, 144) and impeller wear rings (202, 202A, 202B, 203)
are held in place by a press fit and three setscrews (222E, 320).
1. Remove the wear rings:
a) Remove the setscrews.
b) Remove the wear rings from the suction cover (182), the inboard suction cover (182A),
Maintenance
ice or other suitable chilling substance, and install the bushing into the fit of the suction
cover (182) and head (184). The drum into the fit of the head (184). The interstage
bushing into the fit of the inboard suction cover (182A).
Be prepared to tap the bushing in place with a hardwood block or soft-faced hammer.
holes in each new bushing and bushing seat area.
the intermediate cover (150), the discharge cover (150B) and the impeller (101-101M).
Use suitable pry or puller tools to force the rings from the fits.
You can also machine the rings for removal.
CAUTION:
Excessive machining can damage ring fits and render parts unusable.
2. Install new wear rings:
a) Thoroughly clean the wear-ring seats, and make sure that they are smooth and free of
scratches. For casing rings only, apply an anti-seize compound to the bore.
b) Heat the new impeller wear rings to 180°F–200°F (132°C–143°C) using a uniform
method for heating, such as an oven, and place them on the impeller (101-101M) wearring seats.
WARNING:
Wear insulated gloves when you handle rings. Rings will be hot and can cause physical injury.
• 1. Wear ring - 202B (double suction), 203 (single suction and series)
• 2. Impeller - 101 through 101M
• 3. Wear ring - 202, 202A (1ststage)
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c) Chill the new casing wear ring (164, 164A, 164B, 144) using dry ice or other suitable
chilling substance, and install the ring into the fit of the suction cover (182), inboard
suction cover (182A), intermediate cover (150) and discharge cover (150B).
Be prepared to tap the ring in place with a hardwood block or soft-faced hammer.
WARNING:
Dry ice and other chilling substances can cause physical injury. Contact the supplier for information and
advice for proper handling precautions and procedures.
d) Locate, drill, and tap three new setscrew holes equally spaced between the original
holes in each new ring and ring seat area.
e) Install the setscrews (222E) and upset threads.
3. Check the casing wear rings runout and distortion by measuring the bore at each setscrew
location with inside micrometers or vernier calipers.
Machine any distortion in excess of 0.003 in. (0.08 mm) before you trim the new impeller
wear rings.
4. Confirm the bore of the casing wear rings.
5. Turn the impeller wear rings to size after you mount it on the impeller.
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NOTICE:
The impeller and wear-ring clearance setting procedures must be followed. Improperly
setting the clearance or not following any of the proper procedures can result in sparks,
unexpected heat generation, and equipment damage.
All replacement impeller wear rings are supplied 0.020 in. to 0.030 in. (0.508 mm to 0.762
mm) oversize. See the table Minimum running clearances for final running clearances.
Machine the impeller rings accordingly.
When the impeller assembly is supplied as a spare part (impeller with wear rings), the wear
rings are machined to the required dimension.
Minimum running clearances
Impeller wear rings
Balance drum sleeve (128) and interstage sleeve (204) clearance is 0.010 in (0.25 mm). Impeller wear
rims clearance is 0.010 in (0.25 mm) if Goulds standard or per below table if API 610. Note tolerance on
clearance is +/-0.002 in (0.05 mm)
Diameter of rotating member at clearance Minimum diametrical clearance
in. mm in. mm
3.500 to 3.999 90.00 to 99.99 0.014 0.36
4.000 to 4.499 100.00 to 114.99 0.015 0.38
4.500 to 4.999 115.00 to 124.99 0.016 0.41
5.000 to 5.999 125.00 to 149.99 0.017 0.43
6.000 to 6.999 150.00 to 174.99 0.018 0.46
7.000 to 7.999 175.00 to 199.99 0.019 0.48
8.000 to 8.999 200.00 to 224.99 0.020 0.51
9.000 to 9.999 225.00 to 249.99 0.021 0.53
10.000 to 10.999 250.00 to 274.99 0.022 0.56
11.000 to 11.999 275.00 to 299.99 0.023 0.58
12.000 to 12.999 300.00 to 324.99 0.024 0.61
Maintenance
Reassembly
Assemble the Bundle
1. Install the impeller wear rings (202, 202A, 202B and 203).
See Replace the wear rings in the Preassembly inspections section.
2. Install the casing wear rings (164, 164A, 164B and 144).
See Replace the wear rings in the Preassembly inspections section.
3. Install throat bushing (125), interstage bushing (146) (double suction pumps only) and
balance drum (129).
See Replace the wear bushings in the Preassembly inspections section.
NOTICE:
The wear ring clearance setting procedures must be followed. Improperly setting the
clearance or not following any of the proper procedures can result in sparks, unexpected
heat generation and equipment damage.
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4. Install 1st stage impeller key (178).
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
5. Assemble the 1st stage impeller (101) onto the shaft (122) from the thrust end. The impeller
is an interference fit. Use an electric induction heater to heat the impeller to 300°F-400°F
(150°C-200°C). For double suction pumps, the first stage impeller (101) is assembled from
the coupling end.
Apply an anti-seize compound to the outer diameter of the impeller rings.
6. For double suction pumps only, install interstage sleeve key (178).
CAUTION:
Burn hazard. The interstage sleeve will get hot. Wear insulated gloves when handling the sleeve.
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7. For double suction pumps only, assemble the interstage sleeve (204) onto the shaft (122).
The sleeve is an interference fit. Use an electric induction heater to heat the sleeve to
300°F-400°F (150°C-200°C).
Apply an anti-seize compound to the outer diameter of the interstage sleeve.
CAUTION:
Avoid injury. Assure the suction cover is securely fastened to a stable surface to avoid the bundle from
becoming unstable while assembling/disassembling in the vertical orientation.
8. Assemble shaft assembly into suction cover (182).
WARNING:
Dry ice and other chilling substances can cause physical injury. Contact the supplier for information and
advise for proper handling precautions and procedures.
9. For double suction pumps only, install the inboard suction cover gaskets (351K & 351W).
Apply high vacuum grease to gasket. Install alignment dowel pin (185) into inboard suction
cover (182A). Dowel pin is a press fit. Chill pin using dry ice or other suitable chilling
substance. Be prepared to tap the pin in place with a soft faced hammer. Apply an anti-
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Maintenance
seize compound to the register fit. Assemble the inboard suction cover (182A) onto the
suction cover (182).
WARNING:
Dry ice and other chilling substances can cause physical injury. Contact the supplier for information and
advise for proper handling precautions and procedures.
CAUTION:
Burn hazard. The intermediate cover will get hot. Wear insulated gloves when handling the intermediate
cover.
10. Install alignment dowel pin (185) into intermediate cover (150). Dowel pin is a press fit.
Chill pin using dry ice or other suitable chilling substance. Be prepared to tap the pin in
place with a soft faced hammer. Assemble intermediate cover (150) to the suction cover
(182) for single suction pumps or to the inboard suction cover (182A) for double suction
pumps. Subsequent assemblies will be to the previous intermediate cover (150). Step is not
required for 3 stage double suction pumps. The intermediate cover is an interference fit.
Heat the outer diameter of the previous cover to 300°F-400°F (150°C-200°C). Install
eyebolts (not supplied) into the lifting holes to assemble the intermediate cover (150).
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11. Check total travel of rotating assembly. This will remain constant within 0.039 in (1 mm). If
large variation occurs disassemble and diagnose. Something is not seated properly.
12. Install impeller locating ring (361H) and impeller key (178). Apply high vacuum grease to
both locating ring and key or super glue them in place so they don’t fall out when
assembling the impeller.
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
NOTICE:
Allow the shaft and intermediate cover to cool to ambient temperature before proceeding
with disassembly.
13. Assemble impeller (101A-101L) onto the shaft (122) from the thrust end. The impeller is an
interference fit. Use an electric induction heater to heat the impeller to 300°F-400°F
(150°C-200°C). Apply an anti-seize compound to the outer diameter of the impeller rings.
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Maintenance
14. Repeat steps 10 through 13 until all impellers, except last stage, and intermediate covers
are disassembled.
WARNING:
Dry ice and other chilling substances can cause physical injury. Contact the supplier for information and
advise for proper handling precautions and procedures.
CAUTION:
Burn hazard. The discharge cover will get hot. Wear insulated gloves when handling the discharge cover.
15. Install alignment dowel pin (185) into discharge cover (150B). Dowel pin is a press fit. Chill
pin using dry ice or other suitable chilling substance. Be prepared to tap the pin in place
with a soft faced hammer. Assemble discharge cover (150B) to the intermediate cover
(150). For 3 stage double suction pump it will be assembled to the inboard suction cover
(182A). The discharge cover is an interference fit. Heat the outer diameter of the previous
cover to 300°F-400°F (150°C-200°C). Install eyebolts (not supplied) into the lifting holes to
assemble the discharge cover (150B).
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16. Install impeller locating ring (361H) and impeller key (178). Apply high vacuum grease to
both locating ring and key or super glue them in place so they don’t fall out when
assembling the impeller.
CAUTION:
Burn hazard. The impeller will get hot. Wear insulated gloves when handling the impeller.
17. Assemble the last stage impeller (101M) onto the shaft (122) from the thrust end. The
impeller is an interference fit. Use an electric induction heater to heat the impeller to 300°F400°F (150°C-200°C). Use puller holes on the impeller hub to assemble onto shaft.
Apply an anti-seize compound to the outer diameter of the impeller rings.
18. Check total travel of rotating assembly. This will remain constant within 0.039 in (1 mm). If
large variation occurs disassemble and diagnose. Something is not seated properly.
19. Install sleeve key (178). Apply high vacuum grease to key or super glue it in place so it
doesn’t fall out when assembling the sleeve.
20. Assemble the balance drum sleeve (128) onto the shaft (122) from the thrust end.
Apply an anti-seize compound to the outer diameter of the balance drum sleeve.
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Maintenance
21. Install sleeve locating ring (361F).
22. Install locating ring retainer (253). Tighten locating ring retainer bolts (371B).
23. Install belleville washer (354A) and the head gasket (351) onto head (184). Apply a liberal
amount of high vacuum grease to washer and gasket so it doesn’t fall out when assembling
the head.
24. Insert eyebolts (not supplied) in the pre-drilled threaded holes in the top outside perimeter
of the head (184).
WARNING:
Use the eyebolts to lift only the head. They will not support the weight of the entire bundle.
25. Assemble head (184) onto the discharge cover (150B). Apply an anti-seize compound to
the register fit where indicated by the arrow.
Confirm the seal chamber runout
The bearing housings (134 and 134A) are doweled to the head (184) and suction cover (182)
during the original build. However, in order to assure the correct running position of the shaft,
use this procedure in order to confirm the seal chamber runout before you install the cartridge
mechanical seals:
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Maintenance
1. Install the bearings (for ball bearings use a flapper wheel to make inside diameter of old
bearing a slight clearance fit) on the shaft and bolt the bearing housings (134 and 134A) to
the suction cover (182) and head (184).
2. Mount the dial indicator on the shaft (122). Rotate the shaft (122) so that the indicator rides
along the seal chamber bore for 360°.
3. If the total indicator reading exceeds 0.005 in. (0.127 mm), determine the cause and make
corrections.
It may be necessary to readjust the housing.
a) Remove the dowel pins and use the adjusting screws to bring the runout to within 0.002
in. (0.0508 mm).
b) Redowel the housings in a different location.
4. Check the seal-chamber face runout.
a) With a dial indicator mounted on the shaft, rotate the shaft so that the indicator rides
along the seal-chamber face for 360°.
b) If the total indicator reading exceeds the allowable runout as this table shows,
determine the cause and make corrections.
Seal chamber bore in inches (millimeters) Maximum allowable total indicator reading in
5.118 (130) 0.0025 (0.0635)
5.512 (140) 0.0030 (0.0762)
6.299 (160) 0.0030 (0.0762)
6.693 (170) 0.0035 (0.0889)
7.087 (180) 0.0035 (0.0889)
inches (millimeters)
5. Remove the dowel pins and unbolt the bearing housings. Discard the old ball bearings.
Assemble the radial end (ball bearing pumps)
1. Install the mechanical seal (250) on the shaft. Apply an o-ring lubricant to the inside
diameter of the seal sleeve o-ring. Torque gland nuts (355) to the values found in the
"Maximum Torque Values for Fasteners" table.
2. Install the inboard labyrinth seal (333A) into the inboard radial end cover (119A):
a) Clean the end cover with a solvent.
b) Fit the labyrinth seal (333A) into the bore of the cover (119A). Apply an o-ring lubricant
to the outside diameter of the labyrinth seal o-ring.
c) Tap the seal in with a rubber mallet.
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Maintenance
NOTICE:
Make sure that the expulsion port is at the 6 o'clock position and is properly seated.
3. Install the inboard end cover (119A) and the inboard bearing end cover gasket (360A) onto
the shaft. Apply an o-ring lubricant to the inside diameter of the labyrinth seal o-ring. Apply
high vacuum grease to gasket.
4. Install the radial bearing (168) onto the shaft (122).
The bearing is interference fit.
a) Heat the bearings to 250° F (120° C) with an electronic induction heater.
The induction heater also demagnetizes the bearings.
CAUTION:
Wear insulated gloves when you use a bearing heater. Bearings get hot and can cause physical injury.
NOTICE:
Do not use a torch and do not force.
b) Install the bearing (168) onto the shaft (122).
5. Install the oil-ring sleeve (324) and tighten the setscrew (388L).
6. Install the bearing housing (134) over the bearing. Apply a lubricant that is to be used in
service to the outside diameter of bearing. Finger-tighten the nuts (357P) on the stude
(375). Insert dowel pins (469J) then tighten nuts (357P).
The bearing housing is doweled to the suction cover (182) during the original build to
assure the correct running position of the shaft.
The connection point of the bearing housing (134) to the suction cover (182) is referred to
as the saddle.
NOTICE:
The bearing housing flange must fit metal-to-metal (no gap) to the bearing saddle flange.
7. Tighten the inboard end cover bolts (371C).
8. Install the oil ring (114).
9. Install the outboard labyrinth seal (332A) into the outboard radial-end cover (119A):
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