Xylem 8100 User Manual

INSTRUCTION MANUAL

AC2515

REVISION C

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

8100 Series Centrifugal Pumps

TABLE OF CONTENTS

INTRODUCTION...................................................3

PUMP IDENTIFICATION ..............................3

SAFETY INSTRUCTION...............................4

INSTALLATION ....................................................5

RECEIVING THE PUMP ...............................5

LIFTING THE PUMP .....................................5

STORAGE .....................................................7

LOCATION ....................................................7

FOUNDATION...............................................7

BASE PLATE SETTING (BEFORE PIPING) 8

GROUTING PROCEDURE ...........................9

ALIGNMENT PROCEDURE .........................9

ANSI/OSHA COUPLER GUARD

REMOVAL/INSTALLATION ..................9

DOWELING .................................................14

SUCTION AND DISCHARGE PIPING........15

STUFFING BOX LUBRICATION.................17

OPERATION .......................................................20

PRE-START CHECKS ................................20

PRIMING .....................................................20

STARTING ..................................................21

OPTIONAL CHECKLIST .............................21

SHUTDOWN ...............................................21

FREEZE PROTECTION..............................21

FIELD TESTS..............................................22

MAINTENANCE..................................................23

GENERAL MAINTENANCE AND PERIODIC

INSPECTION.......................................23

MAINTENANCE OF FLOOD DAMAGED

PUMPS ................................................23

LUBRICATION ............................................23

SEAL INFORMATION .................................25

MAINTENANCE TIME TABLE ...........................27

TROUBLE SHOOTING.......................................28

TROUBLE SHOOTING (cont.)...........................29

SERVICE.............................................................31

DISASSEMBLY AND REASSEMBLY

PROCEDURES ...................................31

CHANGING ROTATION .............................31

A. DISMANTLING (PUMP WITH PACKING)

.............................................................33

ASSEMBLY (PUMP WITH PACKING)........34

OPTIONAL METHOD FOR INSTALLING

PACKING (After Pump Disassembly)..37

B. DISMANTLING (PUMP WITH

MECHANICAL SEALS ON SHAFT)....38

ASSEMBLY (PUMP WITH MECHANICAL

SEALS ON SHAFT).............................40

C. DISMANTLING (PUMP WITH

MECHANICAL SEALS ON SHAFT

SLEEVES) ...........................................43

ASSEMBLY (PUMP WITH MECHANICAL

SEALS ON SHAFT SLEEVES) ...........45

ADJUSTABLE WEAR RINGS .....................48

OIL LUBRICATED BEARINGS ...................48

VERTICAL UNITS (MODELS 200, 250, 300)

............................................................ 49

INSTRUCTIONS FOR ORDERING PARTS52

APPENDIX “A” ENGINEERING DATA............. 53

APPENDIX “B” ..................................................57

EXPLOSION VIEW: PACKING................... 57

EXPLOSION VIEW: MECHANICAL SEALS

ON SHAFT .......................................... 58

EXPLOSION VIEW: MECHANICAL SEALS

ON SHAFT SLEEVES......................... 59

REPLACEMENT PARTS LIST ...................60

APPENDIX “C” FIELD TEST REPORT ............ 61

USEFUL FORMULAS................................. 62

NOTE

The information contained in this book is intended to assist operating personnel by providing information on the characteristics of the purchased equipment.

It does not relieve the user of their responsibility of using accepted engineering practices in the installation, operation, and maintenance of this equipment.

Any further questions, contact AC Fire Pump, (847) 966-3700.

INTRODUCTION

We welcome you as a user of AC Fire Pump. Your pump is a product of careful engineering and skilled workmanship. We believe you have the best pump possible for the service intended. With care and preventative maintenance, our AC Fire Pump will deliver efficient, trouble-free service.

This manual is furnished to acquaint you with some of the practical ways to install, operate, and maintain this pump. Read it completely before doing any work on your unit and keep it handy for future reference.

To maintain this unit at maximum efficiency, follow the recommended installation and servicing procedures outlined in this manual. To guide in the installation of the pump for maximum operating time and minimum downtime, you may contact the AC Fire Pump Network of Sales and Service Representative.

Experienced, factory-trained service personnel offer prompt, efficient service at reasonable rates. These service personnel can find and correct costly errors such as poor grouting, misalignment, pipe stresses transmitted to the pump casing, or improperly sized piping. A service person may be requested through your nearest AC Fire Pump Sales Representatives.

Replacement and spare parts, including special attention to your individual problems, may also be obtained through the AC Fire Pump Representative.

For warranty coverages, refer to your sales contract.

PUMP IDENTIFICATION

There are two identification plates on each pump. The pump rating plate gives identification and rating information. Figure 1 shows an example of a typical Rating Plate.

rating plate to identify the pump in his operation. (e.g. CWP-11 stands for Chilled Water Pump No.

11)

Size Type

8X8X17 8100

Serial Number

1-21937-1-1

GPM Head (ft.) RPM

1500 200 1780

Model Number Imp. Dia. (in.)

150 14.80

Max. Field Hydrotest Pressure

262 PSI

Identification No. Year

CWP-11 2000

MORTON GROVE, IL USA AC0687

FIGURE 1 – RATING PLATE

The frame plate, shown below, gives information concerning the bearings and their lubrication. The inboard and outboard bearing numbers refer to the bearing manufacturer’s numbers.

Frame Inb. Brg.

F-20-E4 6039

Lubrication Out. Brg.

GREASE 5308

Part No.

AC0685

FIGURE 2 – FRAME PLATE

Permanent records for this pump are referenced by the Serial Number and it must, therefore, be used to order all spare and replacement parts. The last digit indicates the specific pump on orders for more than one pump. For example, if an order called for six pumps, all pumps would have the same first three sets of digits and the last digit will change to identify each of the six. (e.g. 1-21937-1-

, 1-21937-1-2, etc.)

The identification number is a number which the end user of the pump requests to be put on the

SAFETY INSTRUCTION

The warning and caution decals located on the pump are there for the safety of anyone involved with the installation, operation, and maintenance of the pump. PLEASE READ THE DECALS CAREFULLY.

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual and on the pump safety instruction decals to draw attention to safety related instructions. When used the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.

WARNING:

Do not operate pump at or near zero flow (closed discharge shutoff valve). Explosion could result due to large temperature rise in the fluid being pumped. Failure to follow these instructions could result in property damage, severe personal injury, or death.

WARNING:

If pump is to be used on process fluids above 120°F, pump surface temperatures could be warm enough to cause burns. We recommended pump surfaces be insulated or appropriately guarded. Failure to follow these instructions could result in severe personal injury.

INSTALLATION

RECEIVING THE PUMP

Check the pump for damage immediately upon arrival. (An absolute must!) Prompt reporting of any damage to the carrier’s agent, with notations made on the freight bill, will expedite satisfactory adjustment by the carrier.

Pumps and drivers are normally shipped from the factory mounted on a baseplate. Couplings may either be completely assembled or have the coupling hubs mounted on the shafts and the connecting members removed. When the connecting members are removed, they will be packaged in a separate container and shipped with the pump or attached to the baseplate.

LIFTING THE PUMP

The following instructions are for the safe lifting of the Series 8100 pump.

The pump unit should be unloaded and handled by lifting equally at four or more points on the baseplate. The lugs on the upper half casing are designed for lifting the upper half casing only.

Horizontal

1. Bare Pump (Model 100)

WARNING: Falling Objects Hazard

Eyebolts or lifting lugs, if provided, are for lifting only the components to which they are attached. Failure to follow these instructions could result in serious personal injury or death, or property damage.

Using a nylon sling, chain, or wire rope, hitch around both bearing supports (See Figure 3).

2. Pump, Base, and Driver (Model 150)

NYLON SLING, CHAIN OR WIRE ROPE

CHOKER HITCH AROUND BEARING FRAME

FIGURE 3 – MODEL 100

Pump, base, and driver assemblies where the base length exceeds 100 inches may not be safe to lift as a complete assembly. Damage to the baseplate may occur. If the driver has been mounted on the baseplate at the factory, it is safe to lift the entire assembly. If driver has not been mounted at the factory and the overall baseplate lengths exceeds 100 inches, do not lift the entire assembly consisting of pump, base, and driver. Instead lift the pump and baseplate to its final location without the driver. Then mount the driver.

Bases supplied with lifting holes:

Large bases are supplied with lifting holes in the sides or the ends of the base (See Figure 4).

Care must be taken to size equipment for unbalanced loads which may exist if the motor is not mounted on the base at the time of lifting. Motor may or may not be mounted at the factory.

45º MAX

FIGURE 4 – MODEL 150

Using ANSI/OSHA Standard “S” hooks, place the “S” hooks in the holes provided in the four corners of the base. Be sure the points of the hooks do not touch the bottom of the pump base. Attach nylon slings, chains, or wire rope to the “S” hooks. Size the equipment for the load, and so the lift angle will be less than 45° from the vertical.

Bases supplied without lifting holes:

Place one sling around the outboard bearing housing. Place the remaining sling around the back end of the motor as close to the mounting feet as possible. Make sure the sling does not damage the housing cover or conduit box.

Join the free ends of the slings together and place over the lifting hook. Use extreme care when positioning sling under the motor so it cannot slip off (See Figure 5).

or wire rope using latch hook or standard shackle and end loop.

NYLON SLING, CHAIN, OR WIRE ROPE

30º

MAX

45º

MAX

FIGURE 5 – MODEL 150

Vertical

1. Half Pedestal (Model 200)

WARNING: Falling Objects Hazard

Place nylon sling, chain or wire rope around both flanges. Use a latch hook or standard shackle and end loops.

FIGURE 6 – MODEL 200

Be sure to use shoulder eyebolts that are manufactured per ANSI B18.15 and sized to fit the holes provided.

Be sure lifting equipment is of sufficient length to keep the lift angle less than 30° from the vertical (See Figure 7).

Be sure the lifting equipment is of sufficient length to keep the lift angle less than 30° from the vertical (See Figure 6).

2. Full Pedestal (Model 300)

Install eyebolts in the three holes provided at the top of the support, being sure to tighten securely. Attach nylon sling, chain

NYLON SLING,

30º

MAX

CHAIN, OR WIRE ROPE

FIGURE 7 – MODEL 300

STORAGE

The following storage procedures apply to the Series 8100 pump only. Other accessories such as motors, steam turbines, gears, etc., must be handled per the respective manufacturer’s recommendations.

Temporary

Temporary storage is considered one month or less. If the pump is not installed and operated soon after arrival, store it in a clean, dry place that has slow, moderate changes in ambient temperature. Rotate the shaft periodically to coat the bearings with lubricant and to retard oxidation, corrosion, and to reduce the possibility of false brinelling of the bearings. Shaft extensions and other exposed machine surfaces should be coated with an easily removable rust preventative such as Ashland Oil Tectyl No. 502C.

For oil lubricated bearings, fill the frame completely with oil. Before putting equipment into operation, drain the oil and refill to proper level.

Cortec Corp. VCI-329 (for both grease and oil lubricated bearings). Seal all vents and apply a water proof tape around the oil seals in the bearing frame. Remember for pumps with oil lubricated bearings to drain the oil from the frame and refill to the proper level before running the pump.

LOCATION

The pump should be installed as near to the suction supply as possible, with the shortest and most direct suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction line) should not exceed the limits for which the pump was sold.

When installing the pump, consider its location in relation to the system to assure that sufficient Net Positive Suction Head (NPSHA) is available at the pump inlet connection. Available NPSH (NPSHA) must always equal or exceed the required NPSH (NPSHR) of the pump.

The pump must be primed before starting. Whenever possible, the pump should be located below the fluid level to assure priming. This condition provides a positive suction head on the pump. It is also possible to prime the pump by pressurizing the suction vessel.

The pump should be installed with sufficient accessibility for inspection and maintenance. A clear space with ample head room should be allowed for the use of an overhead crane or hoist to lift the unit.

NOTE: Allow a sufficient amount of space to dismantle pump without disturbing the pump suction and discharge piping.

Select a dry place above the floor level wherever possible. Take care to prevent pump from freezing during cold weather when not in operation. Should the possibility of freezing exist during a shut-down period, the pump should be completely drained, and all passages and pockets where liquid might collect should be blown out with compressed air.

Make sure there is a suitable power source available for the pump driver. If motor driven, the electrical characteristics of the power source should be identical to those shown on motor data plate.

Long Term

Storage longer than one month is considered long term storage. Follow the same procedure for temporary storage with the following addition. Add one half ounce of a corrosion inhibiting concentrated oil such as

FOUNDATION

The pump is built to provide years of service if installed properly and attached to a suitable foundation. A base of concrete weighing 2 ½ to 5 times the weight of the pump is recommended.

The foundation should be poured without interruption to within 1/2 to 1 ½ inches of the finished height. The top surface of the foundation should be well scored and grooved before the concrete sets; this provides a bonding surface for the grout.

FIGURE 9A – SETTING BASE PLATE AND GROUTING YEAR 2000 STYLE BASE FOR

BOTH MOTOR AND ENGINE DRIVEN UNITS

BASEPLATE

Foundation bolts should be set in concrete as shown in Figure 8. An optional 4-inch long tube around the bolts at the top of the concrete will allow some flexibility in bolt alignment to match the holes in the base plate. Allow enough bolt length for grout, shims, lower base plate flange, nuts and washers. The foundation should be allowed to cure for several days before the base plate is shimmed and grouted.

FOUNDATION

PIPE SLEEVE

BOLT

(OPTIONAL)

WASHER

BUILT-UP CONCRETE FOUNDATION

FIGURE 8 – FOUNDATION

SHIMS

GROUT

FORM

BOLT SLEEVE

ANCHOR BOLT

CONCRETE

FIGURE 9B – GROUTING PRE-YEAR 2000

STYLE BASE FOR MOTOR DRIVEN UNITS

a. Use blocks and shims under base for

support at anchor bolts and midway between bolts, to position base approximately 1" above the concrete foundation, with studs extending through holes in the base plate.

b. By adding or removing shims under the

base, level and plumb the pump shaft and flanges. The base plate does not have to be level.

BASE PLATE SETTING (BEFORE PIPING) NOTE: This procedure assumes that a concrete

foundation has been prepared with anchor or hold down bolts extending up ready to receive unit. It must be understood that pump and motor have been mounted and rough aligned at the factory. If motor is to be field mounted, consult factory for recommendations. AC Fire Pump CANNOT assume responsibility for final alignment.

NOTE: TO KEEP SHIMS IN

ALLOW 1” FOR SHIMS. PLACE ON BOTH SIDES OF ANCHOR BOLTS.

LEVELING OF PUMP BASE ON CONCRETE FOUNDATION.

PLACE ALLOW GROUT TO FLOW AROUND HOLD DOWN LUGS.

GROUT

GROUT ONLY TO TOP OF BASE RAIL.

PUMP BASE RAIL

CONCRETE FOUNDATION

c. Draw anchor nuts tight against base, and

observe pump and motor shafts or coupling hubs for alignment. (Temporarily remove coupling guard for checking alignment.)

d. If alignment needs improvement, add

shims or wedges at appropriate positions under base, so that retightening of anchor nuts will shift shafts into closer alignment. Repeat this procedure until a reasonable alignment is reached.

NOTE: Reasonable alignment is defined as that which is mutually agree upon by pump contractor and the accepting facility (final operator). Final alignment procedures are covered under “Alignment Procedures.”

e. Check to make sure the piping can be

aligned to the pump flanges without placing pipe strain on either flange.

f. Pour grout in the base plate completely

(See “Grouting Procedure”) and allow grout to dry thoroughly before attaching

piping to pump. (24 hours is sufficient time with approved grouting procedure.)

GROUTING PROCEDURE

Grout compensates for uneven foundation, distributes weight of unit, and prevents shifting. Use an approved, non-shrinking grout, after setting and leveling unit (See Figure 9).

a. Build strong form around the foundation to

contain grout.

b. Soak top of concrete foundation

thoroughly, then remove surface water.

c. Base plate should be completely filled with

grout.

d. After the grout has thoroughly hardened,

check the foundation bolts and tighten if necessary.

e. Check the alignment after the foundation

bolts are tightened.

f. Approximately 14 days after the grout has

been poured or when the grout has thoroughly dried, apply an oil base paint to the exposed edges of the grout to prevent air and moisture from coming in contact with the grout.

dried thoroughly according to instructions. Final alignment should be made by shimming driver only. Alignment should be made at operating temperatures.

WARNING: Unexpected Start-up Hazard

Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury or death and property damage.

ANSI/OSHA COUPLER GUARD REMOVAL/INSTALLATION

WARNING: Unexpected Start-up Hazard

Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury or death and property damage.

NOTE: Do not spread the inner and outer guards more than necessary for guard removal or installation. Over spreading the guards may alter their fit and appearance.

Removal

a. Remove the two capscrews that hold the

outer (motor side) coupler guard to the support bracket(s).

ALIGNMENT PROCEDURE NOTE: A flexible coupling will only compensate for

small amounts of misalignment. Permissible misalignment will vary with the make of coupling. Consult coupling manufacturer’s data when in doubt.

Allowances are to be made for thermal expansion during cold alignment, so that the coupling will be aligned at operating temperature. In all cases, a coupling must be in alignment for continuous operation. Even though the coupling may be lubricated, misalignment causes excessive wear, vibration, and bearing loads that result in premature bearing failure and ultimate seizing of the pump. Misalignment can be angular, parallel, or a combination of these, and in the horizontal and vertical planes. Final alignment should be made by moving and shimming the motor on the base plate, until the coupling hubs are within the recommended tolerances measured in total runout. All measurements should be taken with the pump and motor foot bolts tightened. The shaft of sleeve bearing motors should be in the center of its mechanical float.

NOTE: Proper alignment is essential for correct pump operation. This should be performed after base plate has been properly set and grout has

b. Spread the outer guard and pull it off the

inner guard.

c. Remove the capscrew that holds the inner

guard to the support bracket.

d. Spread the inner guard and pull it over the

coupler.

Installation

a. Check coupler alignment before

proceeding. Correct if necessary.

b. Spread the inner guard and place it over

the coupler.

c. With the inner guard straddling the

support bracket, install a capscrew through the hole (or slot) in the support bracket and guard located closest to the pump. Do not tighten the capscrew.

d. Spread the outer guard and place it over

the inner guard.

e. Install the outer guard capscrews by

following the step stated below which pertains to your particular pump:

i. For pumps with a motor saddle support

bracket: Ensure the outer guard is

straddling the support arm, and install but do not tighten the two remaining capscrews.

ii. For pumps without a motor saddle

support bracket: Insert the spacer washer between the holes located closest to the motor in the outer guard, and install, but do not tighten, the two remaining capscrews.

ANSI/OSHA Coupling Guard Exploded View For Typical 8100 Series Fire Pump Installation

OUTER GUARD

LOCATE SUPPORT ARM BETWEEN OUTER GUARD ENDS. ALIGN THE ARM WITH HOLES IN THE OUTER GUARD AND HOLES IN THE SADDLE BRACKET.

f. Position the outer guard so it is centered

around the shaft, and so there is less than a 1/4" of the motor shaft exposed. On guards that utilize a slotted support bracket, the inner guard will have to be positioned so there is only a 1/4" of the pump shaft exposed.

g. Holding the guard in this position, tighten

the three capscrews.

INNER GUARD

ATTACH SUPPORT BRACKET TO BEARING HOUSING

SUPPORT BRACKET

NUT

LOCKWASHER

MOTOR SADDLE BRACKET ATTACH TO MOTOR SADDLE

CAPSCREW

FLAT WASHER

SPACER WASHER

THIS OPTION USED IN PLACE OF SPACER WHERE OVERALL LENGTH OF GUARD EXCEEDS 12 INCHESOR GUARD WITH IS OVER 10 INCHES ACROSSTHE FLATS.

Method 1 – Straight Edge Alignment for Standard Sleeve Type Coupler with Black Rubber Insert

(See Figure 10A)

Proceed with this method only if satisfied that face and outside diameters of the coupling halves are square and concentric with the coupling borers. If this condition does not exist or elastomeric couplings do not make this method convenient, use Method 2.

1. Check angular misalignment using a micrometer or caliper. Measure from the outside of one flange to the outside of the opposite flange at four points 90° apart. DO NOT ROTATE COUPLER.

BRACKET SUPPORT ATTACHED INSIDE HERE IN LINE WITH BOLT

BRACKET SUPPORT

Misalignment up to 1/64" per inch of coupler radius is permissible.

2. At four points 90° apart (DO NOT ROTATE COUPLER), measure the parallel coupler misalignment by laying a straight edge across one coupler half and measuring the gap between the straight edge and opposite coupler half. Up to a 1/64" gap is permissible.

STRAIGHT EDGE

FEELER GAGE

ANGULAR ALIGNMENT PARALLEL ALIGNMENT

INCORRECT ALIGNMENT

i. For single element couplings, a

satisfactory parallel misalignment is .004"T.I.R., while a satisfactory angular misalignment is .004"T.I.R. per inch of radius R (See Figure 10B).

PARALLEL ALIGNMENT

DIAL INDICATOR

STRAIGHT EDGE

FEELER GAGE

CORRECT ALIGNMENT

FIGURE 10A – CHECKING ALIGNMENT

(METHOD 1)

Method 2 – For Orange Hytrel Insert, 3500 RPM Operation, or All Other Coupler Types Except as Noted Below

(See Figure 10B)

a. Make sure each hub is secured to its

respective shaft and that all connecting and/or spacing elements are removed at this time.

b. The gap between the coupling hubs is set

by the manufacturer before the units are shipped. However, this dimension should be checked. (Refer to the coupling manufacturer’s specifications supplied with the unit.)

c. Scribe index lines on coupling halves as

shown in Figure 10B.

d. Mount dial indicator on one hub as shown

for parallel alignment. Set dial to zero.

e. Turn both coupling halves so that index

lines remain matched. Observe dial reading to see whether driver needs adjustment (See paragraph i below).

f. Mount dial indicator on one hub as shown

for angular alignment. Set dial to zero.

g. Turn both coupling halves so that index

lines remain matched. Observe dial reading to see whether driver needs adjustment (See paragraph i below).

h. Assemble coupling. Tighten all bolts and

set screw(s). It may be necessary to repeat steps c through f for a final check.

INDEX LINE

RESILIENT SEPARATOR

ANGULAR ALIGNMENT

DIAL INDICATOR

FIGURE 10B – CHECKING ALIGNMENT

(METHOD 2)

Grid Couplings NOTE: The following procedure is intended

for mounting and alignment of Rexnord Industries, LLC. and Clarke Fire Protection Products, Inc., Tapered Grid Couplings.

Adequate lubrication is essential for satisfactory operation. Grease supplied by the coupling manufacturer is highly recommended. Other greases to be used should be approved by the coupling manufacturer.

Alignment is shown using a spacer bar and straight edge. Rexnord Industries, LLC. and Clarke Fire Protection Products, Inc. state this practice has been proven for many industrial applications. Superior alignment can be achieved through the use of dial indicators as shown above.

1. Clean all metal parts using non-flammable solvent.

2. Lightly coat seals with coupling vendor supplied grease and place on shafts before mounting shaft hubs.

3. Install keys and mount hubs with flange faces flush with shaft ends or as otherwise specified.

4. Reposition hubs on shafts as required to achieve the required hub gap shown in Figure 10H or otherwise specified. The length of engagement on each shaft

should be roughly equal to the shaft diameter.

5. Tighten setscrews.

6. Bring the pump and motor halves of the coupler into approximate height alignment, by placing equal amounts of shims under all the motor feet.

7. Tighten the motor bolts.

8. Use a spacer bar equal in thickness to the gap specified in Figure 10C. Insert bar, as shown below, to same depth at 90° intervals and measure clearance between bar and hub face with feeler gauges. The difference in minimum and maximum measurements must not exceed the angular installation limits shown in Figure 10H.

misalignment, strike the side of the motor foot with a mallet.

11. Tighten the motor bolts and check again. If a correction is made, re-check alignment

directions. Repeat this process until

in all the desired result is obtained.

12. Pack gap and grooves with coupling vendor supplied grease before inserting grid. When grids are furnished in two or more segments, install them so that all cut ends extend in the same direction as shown below. This will ensure correct grid contact with non-rotating pin in cover halves.

13. Spread the grid slightly to pass over the coupling teeth and seat with a soft mallet.

FIGURE 10C – USING SPACER BAR

9. Align so that a straight edge rests (as shown in Figure 10D) on both hubs and also at 90° intervals without rotating the coupling. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Figure 10H.

FIGURE 10D – USING STRAIGHT EDGE

10. If adjustment is needed, loosen the motor bolts and add (or remove) an equal amount of shims under each motor foot to align the height. To correct side

FIGURE 10E – SEATING THE GRID

14. Pack the spaces between and around the grid with as much as coupling vendor supplied grease as possible and wipe off the excess until flush with the top of the grid.

15. Position seals on hubs to line-up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side.

gaskets stay in position during fastener tightening.

FIGURE 10G – COVER INSTALLATION,

VERTICAL POSITION

17. Ensure the lube plugs are installed in the cover.

WARNING: Coupling Failure

FIGURE 10F – COVER INSTALLATION

16. If the shafts are not horizontal, or coupling is to be used vertically, assemble cover halves with the lug and match mark UP or

Do not operate coupling without proper lubrication

Failure to follow these instructions could result in serious personal injury or death and property damage.

on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tightening to torque specified in Figure 10H. Ensure

Tightening Torque

Installation Limits

End Floa t

Par allel

Offset

Size

1040T 0.006 0.003 0.125 0.211 100 120 3600 0.12 1050T 0.008 0.004 0.125 0.212 200 250 3600 0.15 1060T 0.008 0.005 0.125 0.258 200 440 3600 0.19 1070T 0.008 0.005 0.125 0.259 200 440 1800 0.25 1080T 0.008 0.006 0.125 0.288 200 825 1800 0.38

(P)

Max Inch Max Inch Inch Inch

Angular

(x-y)

Hub Gap +/- 10%

Physical

Limit (Min)

2xF

Values

Cover Fastener

Tightening Torque

Values

In. Se r ie s

Fasteners

(lb*in)

Flange

Type

31 & 35

In. Se r ie s

Fas tener s

(lb*in) lb

Ma ximu m

Allow able

RPM Lube Wt.

FIGURE 10H – MISALIGNMENT & FASTENER TORQUE VALUES

Final Alignment

Final alignment cannot be accomplished until the pump has been operated initially for a sufficient length of time to attain operating temperature. When normal operating temperature has been attained, secure the pump to re-check alignment and compensate for temperature accordingly. See Alignment Section.

WARNING: Rotating Components Hazard

Do not operate pump without all guards in place. Failure to follow these instructions could result in serious personal injury or death and property damage.

WARNING: Coupling Failure

Do not operate pump with coupling out of alignment. Ensure final coupling alignment is within the values stated above or according to the coupling manufacturer’s instructions. Coupling, pump, or driver failure may occur.

OPTIONAL Alignment Procedure

If desired, the pump and motor feet can be doweled to the base after final alignment is complete. This should not be done until the unit has been run for a sufficient length of time and alignment is within the tolerance. See Doweling Section.

CAUTION: Extreme Temperature and/or Flying Debris Hazard

Eye protection and gloves required. Failure to follow these instructions could result in property damage and/or moderate personal injury.

NOTE: Pump may have been doweled to base at factory.

DOWELING

Pump units may, if desired, be dowelled on diagonally opposite feet. This should not be done until the unit has been run for a sufficient length of time and alignment is within the above alignment tolerance.

Failure to follow these instructions could result in serious personal injury or death and property damage.

DIAL INDICATOR

SEPARATORS TO

TAKE UP BEARING

PARALLEL ALIGNMENT ANGULAR ALIGNMENT

FIGURE 11 – CHECKING ALIGNMENT (METHOD 2)

REFERENCE

MAR

SLACK

SUCTION AND DISCHARGE PIPING

The introduction of a pump into a piping system which is not well designed or adjusted may cause strain on the pump, leading to misalignment or even impeller rubbing. Since slight strain may go unnoticed, final alignment should be done with the system full.

Pipe flanges should not impose any strain on the pump. This can be checked by a dial indicator. Any strain must be corrected by adjustments in the piping system.

Make sure that all piping joints are air-tight.

Where flanged joints are used, assure that inside diameters match properly.

Remove burrs and sharp edges when making up joints.

Do not “spring” piping when making any connections.

Provide for pipe expansion when hot fluids are to be pumped.

When installing the pump piping, be sure to observe the following precautions:

Piping should always be run to the pump.

Do not move pump to pipe. This could make final alignment impossible.

Both the suction and discharge piping should be independently anchored near the pump and properly aligned so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe hangers or other supports at necessary intervals to provide support. When expansion joints are used in the piping system they must be installed beyond the piping supports closest to the pump. Tie bolts and spacer sleeves should be used with expansion joints to prevent pipe strain. Do not install expansion joints next to the pump or in any way that would cause a strain on the pump resulting from system pressure changes. When using rubber expansion joints, follow the recommendations of the Technical Handbook on

Rubber Expansion Joints and Flexible Pipe Connectors. It is usually advisable to increase the

size of both suction and discharge pipes at the pump connections to decrease the loss of head from friction.

Install piping as straight as possible, avoiding unnecessary bends. Where necessary, use 45° or long radius 90° fittings to decrease friction losses.

Suction Piping

When installing the suction piping, observe the following precautions (See Figure 13).

The sizing and installation of the suction piping is extremely important. It must be selected and installed so that pressure losses are minimized and sufficient liquid will flow into the pump when started and operated. Many NPSH (Net Positive Suction Head) problems can be directly attributed to improper suction piping systems.

Suction piping should be short in length, as direct as possible, and never smaller in diameter than the pump suction opening. A minimum of ten (10) pipe diameters between any elbow or tee and the pump should be allowed. If a long suction pipe is required, it should be one or two sizes larger than the suction opening, depending on its length.

CAUTION:

An elbow should not be used directly before the suction of a double suction pump if its plane is parallel to the pump shaft. This can cause an excessive axial load or NPSH problems in the pump due to an uneven flow distribution (See Figure 12). If there is no other choice, the elbow should have straightening vanes to help evenly distribute the flow.

WATER VELOCITY INCREASES

HERE, CAUSING A GREATER

FLOW TO ONE SIDE OF THE

IMPELLER

CASING

PUMP CASING

SUCTION ELBOW

FIGURE 12 – UNBALANCED LOADING OF A DOUBLE SUCTION IMPELLER

DUE TO UNEVEN FLOW AROUND AN ELBOW ADJACENT TO THE PUMP

Eccentric reducers should be limited to one pipe size reduction each to avoid excessive turbulence and noise. They should be of the conical type. Contour reducers are not recommended.

When operating on a suction lift, the suction pipe should slope upward to the pump nozzle. A horizontal suction line must have a gradual rise to the pump. Any high point in the pipe can become filled with air and prevent proper operation of the pump. When reducing the piping to the suction opening diameter, use an eccentric reducer with the eccentric side down to avoid air pockets.

NOTE: When operating on suction lift never use a concentric reducer in a horizontal suction line, as it tends to form an air pocket in the top of the reducer and the pipe.

Figure 13 shows some correct and incorrect suction piping arrangements.

PUMP SUCTION FLANGE

2. When foot valves are used, or where there are other possibilities of “water hammer,” close the discharge valve slowly before shutting down the pump.

3. Where two or more pumps are connected to the same suction line, install gate valves so that any pump can be isolated from the line. Gate valves should be installed on the suction side of all pumps with a positive pressure for maintenance purposes. Install gate valves with stems horizontal to avoid air pockets. Globe valves should not be used, particularly where NPSH is critical.

4. The pump must never be throttled by the use of a valve on the suction side of the pump. Suction valves should be used only to isolate the pump for maintenance purposes, and should always be installed in positions to avoid air pockets.

IMPELLER

When installing valves in the suction piping, observe the following precautions:

1. If the pump is operating under static suction lift conditions, a foot valve may be installed in the suction line to avoid the necessity of priming each time the pump is started. This valve should be of the flapper type, rather than the multiple spring type, sized to avoid excessive friction in the suction line. (Under all other conditions, a check valve, if used, should be installed in the discharge line. See Discharge Piping)

SUCTION PIPE INSTALLED WITH A GRADUAL RISE TO PUMP

LEVEL

CENTER LINE OF PIPE

AIR POCKET

GRADUAL RISE TO PUMP

NO AIR POCKETS

CORRECT

AIR POCKET

INCORRECT

AIR POCKET

INCORRECT

NO AIR POCKETS

CORRECT

GRADUAL RISE TO PUMP

CHECK VALVE

GATE VALVE

INCREASER

Discharge Piping

If the discharge piping is short, the pipe diameter can be the same as the discharge opening. If the piping is long, the pipe diameter should be one or two sizes larger than the discharge opening. On long horizontal runs, it is desirable to maintain an even a grade as possible. Avoid high spots, such as loops, which will collect air and throttle the system or lead to erratic pumping.

A slow closing check valve and an isolating gate valve should be installed in the discharge line. The check valve (triple duty valve), placed between pump and gate valve, protects the pump from excessive back pressure, and prevents liquid from running back through the pump in case of power failure. The gate valve is used in priming and starting, and when shutting the pump down.

Pressure Gauges

Properly sized pressure gauges should be installed in both the suction and discharge nozzles in the gauge taps provided. The gauges will enable the operator to easily observe the operation of the pump, and also determine if the pump is operating in conformance with the performance curve. If cavitation, vapor binding, or other unstable operation should occur, widely fluctuating discharge pressure will be noted.

ECCENTRIC REDUCER

CORRECT

DISTANCE PLUS ECCENTRIC REDUCER STRAIGNTENS FLOW

CORRECT

PATH OF WATER

INCORRECT

FIGURE 13 – SUCTION PIPING

ARRANGMENTS

STUFFING BOX LUBRICATION

Contaminants in the pumped liquid must not enter the stuffing box. These contaminants may cause severe abrasion or corrosion of the shaft, or shaft sleeve, and rapid packing or mechanical seal deterioration; they can even plug the stuffing box flushing and lubrication system. The stuffing box must be supplied at all times with a source of clean, clear liquid to flush and lubricate the packing or seal. It is important to establish the optimum flushing pressure that will keep contaminants from the stuffing box cavity. If this pressure is too low, fluid being pumped may enter the stuffing box. If the pressure is too high, excessive packing or seal wear may result; and extreme heat may develop in the shaft causing higher bearing temperatures. The most desirable condition, therefore, is to use a seal water pressure 15-20 psig above the maximum stuffing box pressure.

If the pump system pressure conditions vary during the day, packing adjustment becomes

difficult. Consideration should be given to using a mechanical seal. (See Mechanical Seals.)

Packing

Standard pumps are normally packed before shipment. If the pump is installed within 60 days after shipment, the packing will be in good condition with a sufficient supply of lubrication. If the pump is stored for a longer period, it may be necessary to repack the stuffing box. In all cases, however, inspect the packing before the pump is started.

NOTE: Packing adjustment is covered in the Maintenance section of this manual.

On some applications, it is possible to use internal liquid lubrication (pumped liquid) to lubricate packing. Only when all of the following conditions prevail, can this be done:

1. Liquid is clean, free from sediment and chemical precipitation and is compatible with seal materials.

2. Temperature is above 32°F and below 160°F.

3. Suction pressure is below 75 psig.

4. Lubrication (pumped liquid) has lubricating qualities.

5. Liquid is non-toxic and non-volatile.

When the liquid being pumped contains solids or is otherwise not compatible with packing materials, an outside supply of seal liquid should be furnished. In general, external-injection liquid (from an outside source) is required when any of the above conditions cannot be met.

The standard stuffing box consists of rings of packing (see assembly section for number of rings), a seal cage (optional), and a gland. A shaft sleeve which extends through the box and under the gland is normally provided to protect the shaft.

A tapped hole is supplied in the stuffing box directly over the seal cage to introduce a clean, clear sealing medium. The stuffing box must, at all times, be supplied with sealing liquid at a high enough pressure to keep the box free from foreign matter, which would quickly destroy the packing and score the shaft sleeve.

Only a sufficient volume of sealing liquid to create a definite direction of flow from the stuffing box inward to the pump casing is required, but the pressure is important. Apply seal water at a rate of approximately .25 GPM at a pressure approximately 15 to 20 psig above the suction pressure. (Approximately one (1) drop per second.)

One recommended method to minimize error in regulating flushing water is a “Controlled Pressure System” (Figure 14). It is important to set the pressure reducing valve adjusted to a value slightly exceeding the maximum stuffing box operating pressure (assuming it is reasonably constant). A flow indicating device will detect a failing of the bottom packing rings allowing leakage in the pump.

External sealing liquid should be adjusted to the point where the packing runs only slightly warm, with a very slow drip from the stuffing box. Excess pressure from an external source can be very destructive to packing. More pressure is required, however, for abrasive slurries than for clear liquids. Examination of the leakage will indicate whether to increase or decrease external pressure. If slurry is present in the leakage, increase the pressure until only clear liquid drips from the box. If the drippage is corrosive or harmful to personnel, it should be collected and piped away.

A common error is to open the external piping valve wide and then control the drippage by tightening the packing gland. A combination of both adjustments is essential to arrive at the optimum condition. The life of packing and sleeve depends on careful control more than any other factor.

FLOWMETER

PRESSURE GUAGE

STUFFING BOX

PRESSURE REDUCING VALAVE

FIGURE 14 – CONTROLLED PRESSURE

SYSTEM

Mechanical Seals

Mechanical seals are preferred over packing on some applications because of better sealing qualities and longer serviceability. When a seal is properly installed, it will last longer than packing on similar applications. A mechanical shaft seal is supplied in place of a packed stuffing box when specifically requested. The change from packing to an alternate arrangement may be made in the field by competent service personnel. Conversion parts may be order from your AC Fire Pump Sales Representative.

Just as with packing, the mechanical seal chamber must be supplied, at all times, with a source of clean, clear liquid to flush and lubricate the seal. The most important consideration is to establish the optimum flushing pressure that will keep contaminants from the seal cavity. If this pressure is too low, fluid being pumped may enter the stuffing box. If the pressure is too high, excessive seal wear may result.

When contaminants are present in the system fluid, an external source of clean seal water must be supplied. Supply approximately .25 GPM at a pressure approximately 15 to 20 psig above the suction pressure.

Figure 14 shows the recommended flush system for mechanical seal. Water enters the seal chamber, lubricates the seal face, and exits into the pump itself. Positive flow in the seal water line indicates adequate seal water pressure.

Cartridge Seals

Follow the appropriate lubrication directions for mechanical seals given in this section. Most cartridge seals provide flushing connections on their glands. Use the cartridge seal gland flushing taps (if provided) for your seal water connections instead of the stuffing box tap. The quench taps on the glands (if present) are normally only used in chemical applications. Consult seal manufacturer’s literature for more detailed information.

Cyclone Sediment Separators

If the fluid being pumped contains sediment and there is no external, clean water source available to flush the mechanical seals, a cyclone sediment separator can be used to remove most of the sediment from the liquid being pumped so it can be used to flush the seals. The separator is placed in the seal water piping line and removes the sediment to an external drain (normally back to the pump suction line).

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