Xylem A-C User Manual
INSTRUCTION MANUAL
AC8499
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
A-C Fire Pump
Vertical Turbine Fire Pump
A-C Model FP
2
Safety Apparel:
• Insulated work gloves when handling hot bearings or using
bearing heater.
• Heavy work gloves when handling parts with sharp edges,
especially impellers.
• Safety glasses (with side shields) for eye protection, especially in machine shop areas.
• Steel-toed shoes for foot protection when handling parts,
heavy tools, etc.
• Other personal protective equipment to protect against
hazardous/toxic fluid.
Coupling Guards:
• Never operate a pump without a coupling guard properly
installed.
Flanged Connections:
• Never force piping to make a connection with a pump.
• Use only fasteners of the proper size and proper material.
• Ensure there are no missing fasteners.
• Beware of corroded or loose fasteners.
• Do not operate below minimum rated flow, or with suction/
discharge valves closed.
• Do not open vent or drain valves, or remove plugs while
system is pressurized.
Maintenance Safety:
• Always lock out power.
• Ensure pump is isolated from system and pressure is
relieved before disassembling pump, removing plugs, or
disconnecting piping.
• Use proper lifting and supporting equipment to prevent
serious injury.
• Observe all decontamination procedures.
• Know and follow company safety regulations.
Pump Safety Tips
Note: Observe all cautions and warnings highlighted
in the pump Installation, Operation and Maintenance
Instructions.
3
FOREWORD
This manual provides instructions for the Installation, Operation, and Maintenance of the A-C Fire Pumps. This manual
covers a standard product. For special options, supplemental
instructions are available. This manual must be read and
understood before installation and start-up.
This instruction manual covers several different pump models.
Most assembly, disassembly, and inspection procedures are
the same for all the pumps. However, where there are differences, these differences will be noted within the manual. The
design, materials, and workmanship incorporated in the construction of the A-C Fire Pumps makes them capable of giving
long, trouble-free service. The life and satisfactory service of
any mechanical unit, however, is enhanced and extended by
correct application, proper installation, periodic inspection,
condition monitoring and careful maintenance. This instruction
manual was prepared to assist operators in understanding the
construction and the correct methods of installing, operating,
and maintaining these pumps.
The information contained in this book is intended to assist
operating personnel by providing information on the charac-
teristics 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.
A-C Fire Pumps shall not be liable for physical injury,
damage, or delays caused by a failure to observe the
instructions for installation, operation, and maintenance
contained in this manual.
Warranty is valid only when genuine A-C Fire Pumps parts
are used.
Use of the equipment on a service other than stated in the
order will nullify the warranty, unless written approval is
obtained in advance from A-C Fire Pumps.
For information or questions not covered in this manual, contact A-C Fire Pump Systems at (847) 966-3700.
THIS MANUAL EXPLAINS
• Proper Installation
• Start-up Procedures
• Operation Procedures
• Routine Maintenance
• Pump Overhaul
• Trouble Shooting
• Ordering Spare or Repair Parts
4
Warranty
WARRANTY – Company warrants title to the product(s)
and, except as noted with respect to items not of Company’s
manufacturer, also warrants the product(s) on date of shipment to Purchaser, to be of the kind and quality described
herein, and free of defects in workmanship and material.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, INCLUDING BUT NOT LIMITED
TO IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS, AND CONSTITUTES THE ONLY
WARRANTY OF COMPANY WITH RESPECT TO THE
PRODUCT(S).
If within one year from date of initial operation, but not more
than 18 months from date of shipment by Company of any
item of product(s), Purchaser discovers that such item was
not as warranted above and promptly notifies Company in
writing thereof, Company shall remedy such nonconformance
by, at Company’s option, adjustment or repair or replacement
of the item and any affected part of the product(s). Purchaser
shall assume all responsibility and expense for removal, reinstallation, and freight in connection with the foregoing
remedies. The same obligations and conditions shall extend
to replacement parts furnished by Company hereunder.
Company shall have the right of disposal of parts replaced by
it. Purchaser agrees to notify Company, in writing, of any
apparent defects in design, material or workmanship, prior to
performing any corrective action back-chargeable to the
Company. Purchaser shall provide a detailed estimate for
approval by the Company.
ANY SEPARATE LISTED ITEM OF THE PRODUCT(S)
WHICH IS NOT MANUFACTURED BY THE COMPANY
IS NOT WARRANTED BY COMPANY
and shall be
covered only by the express warranty, if any, of the manufacturer thereof.
THIS STATES THE PURCHASER’S EXCLUSIVE
REMEDY AGAINST THE COMPANY AND ITS SUPPLIERS RELATING TO THE PRODUCT(S), WHETHER
IN CONTRACT OR IN TORT OR UNDER ANY OTHER
LEGAL THEORY, AND WHETHER ARISING OUT OF
WARRANTIES, REPRESENTATIONS, INSTRUCTIONS, INSTALLATIONS OR DEFECTS FROM ANY
CAUSE.
Company and its suppliers shall have no obligation as to
any products which has been improperly stored or handled, or which has not been operated or maintained
according to instructions in Company or supplier furnished manuals.
6
SECTION 1 - SAFETY Page
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 - GENERAL INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Receiving & Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Materials & Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 - INSTALLATION
Foundation/Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Bowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the Discharge Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Stuffing Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installing the Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 - OPERATION
Pump Startup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 - PREVENTIVE MAINTENANCE
Packing Adjustment & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Thrust Pot Lubrication & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 - DISASSEMBLY & REASSEMBLY
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection & Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 7 - REPAIR PARTS
Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 8 - APPENDIX I
Installation & Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Index
7
Section 1 - Safety
These pumps have been designed for safe and reliable
operation when property used and maintained in accordance
with instructions contained in this manual. A pump is a pressure containing device with rotating parts that can be hazardous. Operators and maintenance personnel must realize
this and follow safety measures. A-C Fire Pumps shall not be
liable for physical injury, death, damage or delays caused by
a failure to observe the instructions in this manual.
Throughout this manual the words WARNING, CAUTION,
and NOTE are used to indicate procedures or situations
which require special operator attention:
NOTE: Operating procedure, condition, etc. which is essential
to observe.
EXAMPLES:
• NEVER apply heat to remove impeller. It may explode
dueto trapped liquid.
• NEVER use heat to disassemble pump due to risk of
explosion from trapped liquid.
• NEVER operate pump without coupling guard correcly
installed.
• NEVER operate pump beyond the rated conditions to
which the pump was sold.
• NEVER start pump without proper prime (sufficient liquid in
pump casing).
• NEVER run pump below recommended minimum flow or
when dry.
• ALWAYS lock out power to the driver before performing
pump maintenance.
• NEVER operate pump without safety devices installed.
• NEVER operate pump with discharge valve closed.
• NEVER operate pump with suction valve closed.
• DO NOT change conditions of service without approval of
an authorized A-C Fire Pumps representative.
Definitions
General Precautions
WARNING: Operating procedure, practice, etc., which,
if not correctly followed, could result in personal injury
or loss of life.
CAUTION: Operating procedure, practice, etc. which,
if not followed, could result in damage or destruction
of equipment.
WARNING: Personal injuries will result if procedures
outlined in this manual are not followed.
CAUTION: Throttling flow from the suction side may
cause cavitation and pump damage. NOTE: Proper
alignment is essential for long pump life.
WARNING: Pump shall never be operated without
coupling guard installed correctly.
8
The pump should be carefully supported prior to unloading
from the carrier. Handle all components carefully. Inspection
for damage of the shipping crate should be made prior to
unpacking the pump. After unpacking, visually inspect the
pump and check the following:
1. Contents of the pump assembly against the packing list.
2. All components against damage.
3. All shafting for straightness and damage, should the crate
be broken or show careless handling.
Any shortages or damages should be immediately called to
the attention of the local freight agent of the carrier by which
the shipment arrived and proper notation made on the bill.
This will prevent any controversy when claim is made and
facilitate prompt and satisfactory adjustment
Receiving & Checking
Materials & Equipment Required
The material and equipment necessary for installation of the
pump will vary with the size of the pump and the type of
installation.
The following list of standard tools and supplies is offered
only as a guide.
BULK MATERIAL
• Anti-Galling lubricant (such as Dow Corning
"MOLYKOTE")
• Thread Compound
• Lubrication Oil
• Turbine Oil
Grease
RIGGING EQUIPMENT
• Mobile power hoist, traveling crane, or derrick
• Drag line and blocks
• Elevator clamps, if unit is unassembled
• Clevises – for use with eyebolts
• Timbers – size, length, and quantity to support long pump
parts on the floor
• I-Beams or timbers to support pump over installation
HAND TOOLS
• Pipe wrenches
• Feeler gauges
• Set of mechanics tools including: files, wire brush, pliers,
wire cutters and pocket knife
• Clean rags
OPTIONAL TOOLS TO FACILITATE PUMP ASSEMBLY
AND DISASSEMBLY
• Dial indicator to assist in motor and pump alignment
• Collet driver to assist in bowl assembly and disassembly
for pumps with taper lock impellers only
Storage
A-C Fire Pumps carefully preserves and protects its products
for shipment. However, the effective life of the preservatives
applied at the factory can vary from 3 to 18 months depending
on the severity of the environment in which the equipment is
stored. This section provides procedures for preparation prior
to storage and maintenance during storage of A-C Fire
Pumps. These procedures are necessary to protect the preci-
sion parts of the pumps. Specific procedures for storing
motors, gearheads, and engines, should be obtained from the
equipment manufacturer. This section is intended to be of
general assistance to users of A-C Fire Pumps. It shall not
modify, amend and/or otherwise alter the scope of A-C Fire
Pumps warranty responsibilities to the purchaser in any way
whatsoever.
Section 2 - General Information
Introduction
The design, material, and workmanship incorporated in the
construction of A-C Fire Pumps makes them capable of giving
long, trouble free service. The life and satisfactory service of
any mechanical unit, however, is enhanced and extended by
correct application, proper installation, periodic inspection
and careful maintenance. This instruction manual was prepared to assist operators in understanding the construction
and the correct methods of installing, operating, and maintaining these pumps.
Study thoroughly Sections 1 through 6 and carefully follow the
instructions for installing and operating. Sections 5 contains
answers to trouble shooting and maintenance questions.
Keep this instruction manual handy for reference.
CAUTION: The information in this manual is intended
to be used as a guide only. If you are in doubt, consult your A-C Fire Pumps representative for specific information about your pump.
WARNING: Rotating components of the pump
assembly must be covered with a suitable rigid guard
to prevent injury to personnel.
WARNING: A-C Fire Pumps will not be liable for any
damages or delay caused by failure to comply with
the provisions of this instruction manual.
9
STORAGE PREPARATION
A-C Fire Pumps require proper preparation for storage and
regular maintenance during storage. The pump shall be considered in storage when it has been delivered to the job site
and is awaiting installation.
Preferably, the storage area shall be paved, well drained and
free from flooding, and be indoors whenever possible.
Weatherproof coverings used for outdoor storage shall be
flame resistant type sheeting or tarpaulins. They shall be
placed so as to provide good drainage and air circulation and
shall be tied down to protect from wind damage.
Storage area shall be maintained in a clean condition at all
times.
Pumps and/or component parts shall be placed on skids,
pallets, or shoring to permit good air circulation.
Pumps and/or component parts shall be sorted so as to permit ready access for inspection and/or maintenance without
excessive handling.
Pumps and/or component parts stacked during storage shall
be arranged so that the racks, containers, or crates bear full
weight without distortion of pumps or parts. Identification
markings must be readily visible. Any cover removed for internal access shall be replaced immediately.
Pump and bowl assembly shafting shall be rotated counter
clockwise, as a minimum, once a month. Shaft shall not be left
in the same previous position, nor in the extreme raised or
lowered lateral position. Shaft should rotate freely.
NOTE: For further information on these procedures contact your A-C Fire Pumps representative.
RECOMMENDED STORAGE PROCEDURES
Controlled storage facilities should be maintained at an even
temperature 10ºF (6ºC) or more above the dew point with
relative humidity less than 50% and little or no dust. (If these
requirements can not be met the pump is to be considered in
uncontrolled storage.)
For uncontrolled storage periods of 6 months or less, the
pump is to be inspected periodically to insure that all preservatives are intact.
All pipe threads and flanged pipe covers are to be sealed with
tape.
The pump must not be stored closer than six inches (15 cm)
from the ground.
UNCONTROLLED LONG TERM STORAGE
PREPARATIONS
When applicable to the pump, storage periods over six
months require the preceding storage procedure and storage
preparation plus the following:
Inspect the lube oil and seal flush piping and either fill the piping with rust preventative oil, or re-coat the piping periodically
to prevent corrosion.
Place 10 pounds (4.5 kg) of moisture absorbing desiccant or
5 pounds (2.3 kg) of vapor phase inhibitor crystals near the
center of the pump. If the pump is assembled, place an additional one pound (0.5 kg) in the discharge nozzle securely fastened to the discharge elbow.
Install a moisture indicator near the perimeter of the pump.
Cover the pump with 6 mil (0.15 mm) minimum thickness
black polyethylene or equal and seal it with tape. Provide a
small ventilation hole approximately
1
/2 inch (12 mm) diameter.
Provide a roof or shed shelter to protect from direct exposure
to the elements.
General Description
The model FP pump is a vertical turbine fire pump, which is
designed to meet many wide ranges of service.
DRIVERS
When packed stuffing boxes are used with open lineshaft
pumps, hollow shaft motors or right angle gear drives, are
often used with a separate driveshaft through the driver and
connected to the pump by a rigid coupling.
DISCHARGE HEAD
The discharge head is either a cast iron head or a fabricated
‘F’ type head. Ports are provided for connecting the discharge
gauge and stuffing box bypass return. The driver support portion of the discharge head is designed with large hand holes
for easy mechanical seal or stuffing box adjustment.
COLUMN
Threaded or flanged column construction provides positive
shaft and bearing alignment. Bearings are spaced to provide
vibration free operation. This will insure long bearing life and
reduced shaft wear. The lineshaft is supported within the
column by use of bearing retainers in the column assembly.
BOWL ASSEMBLY
The bowls are generally of flanged construction for accurate
alignment and ease of assembly and disassembly. Impellers
are enclosed. For temperatures over 180ºF (82ºC) and in the
larger size bowls, impellers are keyed to the shaft.
THRUST POT
A thrust pot is utilized when the driver is not designed to carry
the pump thrust.
Loading...