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Manual-solids-type-f - v.b.10-11.p65

INSTRUCTION MANUAL
INSTALLATION, OPERATION AND MAINTENANCE

Pump for Solids Type F
IMPELLER DIAMETER INSTALLATION DATE PACKING RINGS QUANTITY:IMPELLER CLEARANCE


1. GENERAL INFORMATION.
1.1 Description.
1.1.1 Casing.
1.1.2 Impeller.
1.1.3 Wear Rings.
1.1.4 Shaft.
1.1.5 Bearing Frame.
1.1.6 Stuffing Box.
1.2 Installation.
1.2.1 Foundation.
1.2.2 Alignments.
1.2.3 Leveling.
1.2.4 Alignments.
Flexible Disk Coupling.
Cardan joint.
Belt Transmission.
1.2.5 Foundation Finishing.
1.2.6 Suction.
1.2.7 Discharge.
1.2.8 Sealing System.
1.2.9 Service Connection.
1.2.11 Final Verification.
1.3 Starting.
1.3.1 Priming.
Positive Suction Pumps.
Negative Suction Pumps. 10 1.3.2 Rotation. 101.3.3 Stuffing Box. 111.3.4 Starting.
1.3.5 Stopping.
1.3.6 Initial and Periodical Checking.
1.3.7 Service Characteristic.
1.3.8 N.P.H.S (Net Positive Suction Head).
1.3.9 Corrosion and Abrasion.
1.4 Maintenance.
1.4.1 Lubrication.
Grease Quantity.
1.4.2 Labyrinth Seal.
1.4.3 Sealing Shaft Syste.
1.4.4 Stuffing Box Packing Replace.
1.4.5 Impeller Clearance.
1.4.6 Failure Causes.
MANUAL PUMP FOR SOLIDS


MANUAL PUMP FOR SOLIDS


1 GENERAL INFORMATION
design allows a quick mounting and dismantling of the impeller even in pumps with many years ofrunning.
You have acquired a valuable equipment. Payattention and be careful with your Hidrostal pump in 1.1.3 Wear Rings ( Part 408 )
order to obtain excellent results.
The wear ring has been designed to be easilyreplaced, allowing to maintain the original efficiency Your pump has been designed and constructed in with a low maintenance cost.
order to render years of constant service, as longas the user stricly follows these instructions must befully understood before starting the pump.
1.1.4 Shaft ( Part 110 )
Carbon steel shaft C-1045 or stainless steel mounted
on grease lubricated bearings. Replaceablestainless steel shaft sleeve to avoid any damage Transcribe the data filled in the pump identification due to the stuffing box packing friction.
plate to this manual and mention it when you referto us for any consultation.
1.1.5 Bearing Frame
Widely sized bearing frame, back pull out designallows the pump to be dismantled without the As you can notice in the instructions we offer a removal of any pipe fastened to the casing. the grease lubricated bearing frame has been designed for a 50,000 hour of operation rate, when warranty stops if the pump is used to pump other the pump runs on its best efficiency point.
1.1.6 Stuffing Box
in our order acknowledgment, likewise by failures Splitted stuffing box type, which allows an easy originated by wrong maintenance, inadequate access to the stuffing box packings for its replacement. The external connection (3) is to emplacement or incorrect installation perform the shaft sealing in the stuffing box.
Normally the equipment is provided by freeasbestos packing.
1.1.1 Casing (Part 400)
Vertical split volute casing with axial suction; radialdischarge and back pull out design, which allows The pump installation should allow the direct a fast bearing frame and impeller service without connectation of the suction and discharge pipe dismantling any pipe fastened to the casing. If with their accessories (valves and fittings) the pump coupling used is a flexible extended type properly supported. The connection should be or cardan type. The motor can also stand fixed to in an independed way to avoid the transmission the base. The casing has been hydrostatically of any strength and tension to the pump. Pipe 1.1.2 Impeller (Part 401)
damage. The pipe flanges before being adjusted Closed type impeller, its hydraulic design provides with the bolts.
a gentle handing of the solids in suspensionavoiding rough changes in direction and Project the pipe so that a minimun of curves, elbows and accesories would be used. Install the The impeller is firmly mounted on the impeller flange pipe the nearest possible to the water supply or fastened to the pump shaft by a central bolt. This the liquid being held. Remember that if the length MANUAL PUMP FOR SOLIDS


of the pipe increases, the loss of capacity of the pump by friction increases as well, thus the cost of When the unit is received with the pump and the the equipment operation.
motor placed on their common base, this unitshould be mounted on its foundation base. The Leave enough space in the installation to allow an couplings should be disconnected, leaving a 3/4" easy access for the inspection job, dismantling and and 1.1/2" space between the top face of the maintenance of the pump and the auxiliary foundation block and the bottom face of the pump equipment. If the pumps are placed in pits, they base, interlocking it with a thin wedge in order to must be protected againts floods.
count with a convenient space.
The flexible couplings should not be used tocompensate the pump and motor shaft misalignment.
It is great importance to mount the pumps on solid The flexible coupling allows only absorbing the foundations, preferently on concrete bases. It is misalignment produced by temperature changes.
normally satisfactory to build a concrate baseusing a 1-3-5 mix ( cement, sand, and gravel )with a thickness according to the basement characteristicThe foundation anchor bolts should be fixed to 1.2.4.1 Flexible Disk Coupling ( Fig. 1.3 ) the concrete as showed in ( Fig. 1.2 ).
In order to align the shafts, the two halves of the The diameter of the pipe placed around the anchor coupling should have the distance recommended by foundation bolt should exceed two or three timesthis last, allowing the anchor foundation bolt to befreely removed to its final position.
1.2.2 Alignment
The pumping units is correctly aligned in the factory,
however the experience has demostrated that flexingand bending could happen during transportation in spite of the tough construction of the bases, in consequence an aligment re-check is needed afterthe complete pump installation.
MANUAL PUMP FOR SOLIDS


its manufacturer. The distance must be: a=a and alignments already performed in other directions, b=b , it can be verified through a gage and a rule.
therefore an accurate final inspection is needed.
The axial distance has to be the same in the wholecoupling circumference; this distance can be If the pumps or motors heat due to the operation measured by introducing a gage between the two conditions, alignment has to be done in these halves of the coupling. (in different parts of the normal thermal conditions, so that contraction and expansion due to temperature changes are The coupling alignment is considered correct compensated. Do not forget that a wrong whenever being measured in four positions with alignment produces vibrations, shafts bending 90º rotation each time, a play no major of 0.05 and excessive bearing wear.
mm. does not appear, in axial or radial direction.
1.2.4.2 Cardan Joint (Fig. 1.4)If the pump uses a cardan joint, the motor andpump shafts have to be parallel. The angelbetween cardan shaft and pump shaft, and theangle between cardan shaft and motor shaft mustbe equal, a difference major of 1º between thisangles is not allowed. It the difference exceeds 1º a decrease of the universal joint life happens.
If for any reason the cardan joint is dismantled,make sure to mount it with the ribbed shaft on its original position.
1.2.5 Foundation Finishing (Fig. 1.5)
When alignment is completed foundation bolts
have to be handadjusted and the base grouted
(mix of one part of cement for two parts of sand),
in order to get a strong pump base support. (See
Fig. 1.2).
The grouting has to be done with a support under
the pump base and over the wet foundation until
the surface support is completely covered.
The metallic base interior cavities must be filled
w i t h c o n c r e t e a v o i d i n g a i r b u b b l e s . O n c e
thefoundation base is ready, the foundation boltsmust be tightened.
1.2.4.3 Belt Transmission Note: The equipment last depends in great
If the pump uses a belt transmission or a chain deal on a correct alignment and grouting.
transmission, V-belts should not be over- We do not assume any warranty if these
tensiond. The tension over the V-belts must be recommendations are not followed.
enough to avoid the slipping between belts andpulleys. Make sure that the belts are similar in 1.2.6Suction (Fig. 1.6)
length, tolerance and dynamically measuredduring its confection. Each belt will take belts The suction pipe must be direct and short, sized comply with these conditions.
according to the pump flow. The suction pipe sizeis greater or equal than the suction pump size.
Note: It is very important to remember that the The flow velocity in the suction pipe must not exceed 2 Mts./sec. Avoid to place any portion of MANUAL PUMP FOR SOLIDS


STRAIGHTAPER (CONCENTRIC) REDUCER OFFSET (ECCENTRIC) REDUCER the suction pipe over the pump suction centerline, If the pump suction is positive it is convenient to because an air pocket could appear in this area install a gate valve in the suction pipe in order to and an erratic pump function could be generated allow an easier inspection job and maintenance.
by this condition.
If the installation contemplates the use of multiple If a reduction is needed to assemble the suction pipe pumps using the same source (reservoir), each to the pump suction, eccentrical reduction is pump should have its own suction pipe.
If this is not possible, the common suction pipe must If the suction is negative a foot value must be be calculated to obtain low flow velocity.
installed in the suction entrance. The foot valve mustbe placed under the fluid lowest level to avoid any air bubbled inlet and at a convenient distance from Discharge pipe must include a gate valve, which reservoir bottom to avoid sludge or sand inlet.
allows the operation and the pump control. If theinstallation has a long discharge pipe or a high If a foot valve installation is not possible due to (pump major than 15 Mts. it is necessary to install a quick size or short space), other system like injectors or closing check valve to avoid the water hammer in vacuum pumps could be used for pump priming. For more specific information, contact Hidrostal For lower highs a standard check valve could be engineering department or your Hidrostal local used. If it is possible, elbows must be avoided and replaced by long radius curves. The MANUAL PUMP FOR SOLIDS


discharge pipe must be sized according to thepump flow rate, avoiding any flow velocity over 3 Mts./sec. The pump discharge size must not be aconditional for pipe discharge sizing. Remember to prevent the connection for pump priming.
Sometimes it is convenient to install an expansionjoint to avoid the transmission of any discharge pipe stress over the pump. (Due to thermal expansion,piping misalignment or due to any other reason).
Service Connection Nº. 1This connection is used to introduce sealing waterto the lantern ring (204). The water introduced to this zone, seals, cools and lubricates the stuffing box zone. This connection should be used if thefluid to be pumped is sewage water or water withsolids in suspension (Fig. 1.8).
1.2.8 Sealing System (Fig. 1.7)
Hidrostal pumps have a special connection toperform a shaft liquid sealing in the stuffing box.
If the pumped fluid is clean and contains no abrasiveparticles, the connection can be performed from thepump discharge.
If the fluid contains abrasive particles another source of clean fluid must be slightly higher than the pumpdischarge pressure. In this case, you should take in account that a portion of this fluid enters the pumpand the balance evacuates through part (101).
1.2.9 Service Connection (Fig. 1.7)
Hidrostal pumps are supplied with the possibility of various service connections. These connections should be applied according to the pump service.
MANUAL PUMP FOR SOLIDS


tendency are pumped. This connection can be done replacing the last packing ring (205) byanother lantern ring (204) Fig. 1.9.
Sometimes the lantern ring position change ise n o u g h , d e p e n d i n g o n t h e p u m p e d f l u i dcharacteristic (204) Fig. 1.10.
The water introduced to this connection goes directly to the shaft sleeve surface (208), nearthe impeller, avoiding the inlet of abrasive materials and lubricating the stuffing box.
1.2.10 Instrumentation
To verify the functioning and the pump running
should be connected.
The pressure gages have to be mounted in aconvenient place for easy checking. A shut off device must be placed before the pressuregauge. If the pump is driven by an electrical motor, voltmeter, ampmeter and protectionelements must be placed in the switchboard.
If the fluid to be pumped contains small quantities 1.2.11 Final verification
of solids, this connection could be relaced by a When the pipe installation is finished, check the grease cup in order to introduce grease once in alignment one more time; proceed according to the ruler and gage method above mentioned.
lubricated. Use yellow grease ALVANIA Nº. 3 After the stuffing box adjusting and alignment checking, the pump shaft should be hand rotated (free and soft rotation).
Service Connection Nº 2 (E) 1.3 Starting
Used to introduce water inside the chamberformed by the back part of the impeller (401)and the back cover (200), in order to Clean solids accumulations in this area.
Priming shoul be done before starting the pump, Normally solids accumulatios occur when the the suction pipes and the casing will be filled concentrations with dehydration tendency. This functioning of the pump without liquid, produces service connection uses a solenoid valve with a serious damage to the shaft or stuffing box.
timer to inject the water during 60 seconds fromtime to time. This water injection must be done 1.3.1.1 Positive Suction Pumps as frequent as needed.
Close the discharge valve and open the suction In vertical pumps this connection could be used valve so that the liquid fills the pump. Open the to evacuate the air accumulated in this area, drain valve or drain plug located on the top of especially when the fluid to be pumped has a the pump and release air until the pump is tendence to gasify.
completely filled with the liquid and air free.
Finally close the drain valve or screw the drain Service Connection Nº 3 (F) This is not a standard conection. It is used whenabrasive liquids or liquids with a crystallize MANUAL PUMP FOR SOLIDS 1.3.1.2 Negative Suction Pumps Close the discharge valve, open the priming Open the admission and discharge valves.
connection and fill the pump casing completely Check if the pump rotates hand free. Start the (drain plug) (424). Once the pump is primed, electrical motor and check the current with an wait 5 minutes observing the liquid level inside ammeter in order to avoid any overcharge.
the pump, the level should not vary. If the leveltends to diminish, proceed with the foot valve In the case that the pressure does not increase revision and repair it if necessary.
after pump start, it is a sign that air remains inthe suction. In such case, stop the pump immediately and prime the pump again.
The pump should rotate in the direction indicated The pump operation without water is harmful and by the arrow in the casing. The rotation is in could damage the pump in a short time.
clockwise direction, observing the pump from thedriver side.
1.3.5 Stopping
If the installation has a water hammer prevention
1.3.3 Stuffing Box
valve or if its T.D.H. is no major than 15 Mts., the In the pumps supplied with stuffing box, the detention of the motor is enough. In installations where the T.D.H. is major than the indicated, determinate application. Prior to the pump proceed with the partial closing of the discharge starting, verify the packing conditions, removing the stuffing box gland (202) (Figs. 1.8, 1.9 and necessary to avoid the reverse rotation of the 1.10). If the pump is not going to be used within the first 60 days after its dispatch, a packinginspection is needed. If the period of disuse is In automatic installations, if the detention is longer, the packing should be checked and produced by electrical energy failures, a new replaced when its lubricant properties are lost or manual starting is needed.
dryness occurs. In all cases it is important toremember to inspect the packings before pump 1.3.6 Initial and Periodical Checking
vibrations free.
2. Check the bearings temperature. Normally the excessive leakage and eventually the cause of temperature must be constant (maximun 70º).
shaft sleeve damages (208). An extra torque is If the temperature starts to rise, check the needed in the packing bolts in order to avoid an excessive leakage.
Once the packings conditions have been verified,
3. Check the stuffing box for leaking according start the pump as indicated in (1.3.4.) and adjust to point 2 of 1.3.3 and for any overheating the stuffing box as follows: 1. Make sure that the bolts in the stuffing box gland are hand adjusted. In the first 10 min.
of operation, plenty filtration should appear.
temperature of the outlet side and the inletside is no major than 10ºC.
2. Adjust carefully the stuffing box gland bolts (202) half turn every 10 min. until the spurt 5. Avoid any pump or motor overcharge.
turns into a constant dropping, approximately 6. When the pump works with negative suction, 20 drops/min.
installation is major than the NPSH required periodically verified during the first week of by the pump. The reservoir must be always operation and be adjusted up to 20 drops/ full and free of materials that could cause pump obstruction.
MANUAL PUMP FOR SOLIDS 7. The T.D.H. specified in the quotation must not is corrosive or abrasive you must contact our differ the installation T.D.H. In that case pump engineering department or your Hidrostal local failure could occur.
8. When a stand-by pump is available, it is convenient to use it in an alternate way.
1.4 Periodical Maintenance
1.3.7 Service Characteristic
The Hidrostal pump has been designed to operatewith a determinate speed, T.D.H. and flow, The bearings must be regularly lubricated. Use according to the given information. If the T.D.H. is good quality lithium soap grease, water resistant different than the one indicated in he order, a and appropriate for service temperatures between motor overcharging could occur. It is necessary -25ºC and 110ºC.
to fix this condition in order to obtain a goodequipment operation. Due to its special design Apply only the necessary amount of grease (0.025 the solids handling Hidrostal pumps cannot be kg. per bearing). Excessive grease application throttled to reduce the motor charge as standard could cause bearing overheating and failures. Use centrifugal pumps.
multi-purpose grease Shell Alvania EP-2, MobiloilMultiplex 48 or equivalents.
To reduce the motor overcharge a new impellermust be placed in the pump according to the new The bearings temperature measured in the hydraulic conditions. In any case consult our bearing frame external side should not exceed engineering department or your nearest Hidrostal local distributor.
1.3.8 NPSH
Before lubricating, establish the discharge of (Net Positive Suction Head)
grease amount of your gun grease per eachshooting as follows: If the pump does not comply with the specified flowrate, a variation in the NPSH available could be 1. Weight the grease amount obtained after 10 attributed to this condition. Each pump has its own NPSH requirement curve as showed in the 2. Calculate the weight in grams per each shooting characteristics pump curves. If the NPSH available and mark this data on your gun grease.
is less than the NPSH required by the pump, the Proceed to lubricate as follows: pump is cavitating. Pump cavitation generates a) Remove 134 and 154 plugs and start the pump noises, vibrations, motor overcharge and flow rate for at least 10 minutes in order to evacuate the old remaining grease from the equipmentby bearing heating. (Fig. 1.7) The liquid temperature and the altitude of the b) Set back 134 and 154 plugs.
installation also affect the NPSH available.
(Remember that the atmosphere pressure varies c) Clean up the lubricating points (G, G1 and G2).
with the altitude). An accurate calculation of NPSHavailable must be done when these conditions Note: Bearing frame E2S does not have appear. If the liquid to be pumped has a tendence lubricating point G.
to gasify a positve suction pump is required.
d) The necessary grease amount in grams must be injected in each lubricating point as 1.3.9 Corrosion and abrasion
indicated in the table 1.4.1.2.
When the fluid to be pumped has abrasive orcorrosive properties a correct pump material 1.4.2 Labyrinth seal
selection must be done. In this way costly pump The pumps sealed with stuffing box have a failures could be avoided. If the fluid to be pumped labyrinth seal in order to avoid water inlet to the MANUAL PUMP FOR SOLIDS bearings. This seal must be lubricated by a The pumps are supplied with the rings grease cup (132), using the same bearing quantities describied in the table 2.
grease according to the stuffing box conditions.
The grease cup must be adjusted until the Table 2: Packing Rings Quantity grease appears through the labyrinth seal.
(Fig. 1.7).
1.4.3 Sealing shaft system
It is necessary to check periodically that
the stuffing box dropping rate is in between 20 to 30 drops/min., allowing lubrication andrefrigeration of the stuffing box packing.
When the stuffing box gland (202) is beingadjusted in order to regulate the dropping rate; make sure to do a half turn per time boltsadjustment. The stuffing box packing must be replaced, when due to packing wear, the glandreaches the maximun adjustment.
1.4.4 Stuffing Box Packing Replace
Verify periodically that the liquid sealingconnection complies with the descriptions in 1. Loose and take away the stuffing box gland chapter 1.2.8.
bolts (220) and slip it towards the support.
MANUAL PUMP FOR SOLIDS 2. Take away the stuffing box (201) bolts (221) adjusted to the back cover (200) and slip istowards the bearing frame. take away thepacking ring (215) from the stuffing box.
3. Slip the lantern rings (204) along the shaft towards the support and take away the packingrings (215) placed inside the back cover (200).
4. Clean up and lubricate with waterproof grease the stuffing box cavities. Use yellow greaseA LVANIA Nº. 3, MOBIL-LUX Nº. 2 or itsequivalent.
5. Cut the packing rings according to the shaft diameters (rolling the packing around acylinder with the same diameter than the pump shaft). Avoid overtensioning the packings (around the pump shaft) because leakageamong free spaces could occur, due to cutfailures (Fig. 1.12).
It is convenient to effectuate the cut in 45º degrees way so that the packings will overlap.
6. Place the packing rings (215) inside the stuffing box cavity in the back cover (200).
Use the latern ring (204) to push and introduce the packing rings (215).
Place the packing rings 90º rotated (from the cut). Install only the quantity of packing ringsneeded in order to place the latern ring exactlyin the water inlet drill hole (Nº. 1) (Fig. 1.8).
7. Place again the stuffing box (201) and fix it with the stuffing box bolts (221). Do not forget toverify the packing (210) condition and location.
8. Place the missing rings (215) inside the stuffling box cavity pushing it with the stuffing box gland(202). The packing ring ends (215) must beplaced at 90º from the other one. A specialcare should be taken in order to avoid the last packing ring to overhang from the stuffing box,allowing in this way the correct placing of thestuffing box gland (202).
The lock nut should be tightened by hand.
9. Before pump starting, proceed as 1.3.3.
1.4.5 Impeller Clearance Adjustment
Check the clearence C between impeller and suction
casing must be 0.4-0.7 mm
MANUAL PUMP FOR SOLIDS Table 1: Grease quantity according to bearing frames requirement
Point "G" Point "G1" Point "G2" MANUAL PUMP FOR SOLIDS 1.4.6 Failure Causes
Failure Causes(Refer to the explanation below) Pump does not deliver water Pump priming loose after starting the pump.
Excessive pump power requirements.
Excessive stuffing box dropping.
Excessive packing ring wear.
Excessive pump vibrations or noises.
Pump clogging.
Bearig overheating (>70º) Solids damage.
Rotating part in contact with stationary part.
Clogged pump, sand, etc.
Incorrect pump or suction pipe priming.
Wear rings excessive clearance.
NPSH available minor than NPSH required.
Damaged impeller.
Excessive amount of gas or air dissolved Shaft sleeve (208) wear in packing rings in the liquid.
Air pocket in suction pipe.
Packing rings or mechanical seal Suction pipe air filtration.
Pump suction inlet does not have enought Incorrect packings for operation conditions.
Low pump velocity.
Misaligned pump shaft due to bearing wear.
High pump velocity.
Stuffing box gland bolts overtightened.
Wrong pump shaft rotation.
Poor lubrication.
System TDH major than pump TDH design.
Loose anchor of foundation bolts.
System TDH minor than pump TDH design.
Wrong lubrication.
Pumped fluid densify differs from design fluid density.
Small sized impeller.
Pumped fluid viscosity differs from design Pump has not been primed.
fluid viscosity.
High solids concentration in relation with Low flow pump operation.
pump velocity.
Incorrect pumps engagement not designed Cavitation (fluid with gas or air in pump to operate in parallel.
Impeller clogging by strange bodiespresence.
Pump and motor misalignment.
Bended shaft.
/110 1 Be aware that the failure causes above mentioned do not necessarily correspond to the real failure reasons.
400 Therefore we recommend checking the equipment by a pump equipment service expert.
MANUAL PUMP FOR SOLIDS Portada del Sol 722 - Lima 36, Perú Apartado Postal 3989 - Lima 1, Perú Página web: www.hidrostal.com.pe Servicio al Cliente: 0801 - 1 00 00

Source: http://www.hidrostal.com.pe/images_turbinas/manual-solids-type-f-v.b.10-11.pdf

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