s 4

N O U N CODE 178 183

1W

PART. N A M E S T U F F I N G BOX STUDS CASING COMPLETE R O T O R COMPLETE

P A C K E D BOX 008 014 064 SHAFT SLEEVE SEAL CAGE GLAND PACKING CAP SCREW (GLAND} G L A N D WASHER GLAND NUT K E Y - S H A F T SLEEVE RETAINING RING PIPE P L U G O - R I N G (SHAFT S L E E V E )

016
2*6A 279 A 291 397 417
118

456A
2*6A 279A 429

C A R T R I D G E SEAL G L A N D WASHER GLAND NUT

M E C H A N I C A L SEAL COMPLETE

C O O L E D S T U F F I N G BOX E X T E N S I O N ?<6B 264 279B S T U F F I N G BOX BUSHING 'WASHER-' S T U F F I N G BOX E X T E N S I O N NUTS

4S6B O - R I N G (STUFFING BOX E X T E N S I O N ) USED O N L Y W I T H , A -PACKED BOX

(PLED

STAFFING B O X SEAL

EXTENSION

.RTR1W5E

r m

EXPLODED VIEW 1 STUFFING BOX PARTS DA PUHP 6-25

N O U N CODE
021 023 028

PART NAME
BEARING BODY B E A R I N G CAP ' / T H R U S T COLLAR

029 A

_ _ J X W E L - PIN.IB_BG, BODX TO_C ASIN G)

"7" D O W E L P I N ' I B R G , CAP T O B O D Y ) ' K E Y - THRUST COLLAR B R E A T H E R CAP CAP S C R E W . ( B R G . B O D Y T O C A S I N G ) CAP SCREW (BRG. CAP TO B O D Y ) CAP. SCREW (END COVER TO H O U S I N G ) CAP SCREW ( L A B Y R I N T H S L E E V E ) LOCK NUT-(THRUST COLLAR) B E A R I N G END C O V E R - SUPPORTING H E A D S T U D ( M A I N O I L PUMP) C O U P L I N G ( M A I N O I L PUMP) BEARING LINING M A I N OIL PUMP S H I M , - (THRUST COLLAR) S H I M ' - { T H R U S T BRG.J N U T (DOWEl PIN) . N U T ( M A I N Oil PIN) ' S E T SCREW (BRG BODY A D J U S T I N G ) SET SCREW (LOCK NUT) _ G A S K E T R,,{BRG B O D Y TO CAP) G A S K ' E T - ' (CNO C O V E R ) G A S K E T , - ( M A I N O I L PUMP) LABYRINTH\SLEEVE SEAL. R I N G ( T H R U S T B E A R I N G ) L O C A T I N G PI'N; (B'RG., L I N I N G ) ^ L O C A T I N G > ! N (END COVER) ''. K I N G S B U R Y . T H R U S T B E A R I N G VI EYE B O L T '' """ PIPE'PLUG : , ,. 0 : R I N G ( L A B Y R I N T H SLEEVE)

1-

029B 064 097 118A 118B 11BC. 118D 128 158 172 178 IBS 191 219 2S7A ?578 2S6A 2S8B 2S9A 259B 262A 262B 262C 294 308 315A 315B 325 333 417 456

333

NOON CODE 021 023 029A 029B 097 118A 1188 118C 11 268
259 294

PART NAME BEARING BODY BEARING CAP DOWEL PIN (BRG. BODY TO CASING) DOWEL PJN (BRG. CAP TO BOOY) BREATHER CAP CAP SCREW (BRG. BODY TO CASING) CAP SCREW (BRG. CAP TO BODY) CAP SCREW ( L A B Y R I N T H SLEEVE) BEARING LINING NUT {DOWEL PIN) SET SCREW (BRG, BODY ADJUSTING) GASKET L A B Y R I N T H SLEEVE LOCATING PIN EYE BOLT PIPE PLUG 0RING ( L A B Y R I N T H SLEEVE)

202

315 333 417 450

SLEEVE:

EXPLODED VIEW #s "PLAIN B E A R I N G BEARING - FORCE FEED LUBE

// /
6 - 2 6

NOUN CODE

PART N A M E LOWER H A L F CASING R I N G - CASING C H A N N E L RING (LOWER HALF) S T U F F I N G BOX BUSHING GASKET - M A I N PARTING FLANGE ROTOR COMPLETE L O C A T I N G PIN CENTER BUSHING (LOWER HALF) T H R O T T L I N G BUSHING

170 184 315 407 441 J

001 006 060 068

006

BOX BUSHING IS NOT USED "WITH B X ^ ^ O N INCOMBINATION

E X P L O D E D V I E W 92 A S S E M B L Y OF1 L O W E R HALF BUSHINGS AND ROTOR TO CASING DA PUMP

R

EXPLODED VIEW J6 THRUST BEARING SLEEYF./K . T . B , - F O R C E F E E D L U B E a. 9 7

N O U N CODE 021 023 028 029 A 029B 054 097 11BA 118B nee. 118D 128 158 172 178 185 191 219 257A 257B 2S8A 2S8S 2S9A 259B 262A 262B 262C 2S4 308 315A 315B 325 333
417

PART

NAME/

456

BEARING BODY . B E A R I N G CAP ' THRUST COLLAR ' . , - D O W E L ' P I N (BRG: B O D Y TO C A S I N G ) . ' D O W E L PIN,.(BRG, CAP T O B O D Y ) KEY - THRUST COLLAR ; . B R E A T H E R CAP CAP SCREW (BRG.; B O D Y T O / C A S I N G ) C A P SCREW (BRG. CAP T O B O D Y ) CAP SCREW ( E N D COVER T O - H O U S I N G ) CAP SCREW ( L A B Y R I N T H S L E E V E ) LOCK NUT (THRUST C O L L A R ) B E A R I N G END COVER SUPPORTING HEAD S T U D ( M A I N O I L PUMP) " C O U P L I N G ( M A I N OIL. PUMP) BEARING LINING M A I N O I L PUMP SHIM - (THRUST COLLAR) S H I M - ( T H R U S T BRG.) N U T ( D O W E L PIN) N U T ( M A I N O I L PIN) . SET SCREW (BRG ' B O O Y A D J U S T I N G ) SET SCREW (LOCK N U T ) G A S K E T - ( B R G BODY TO CAP) GASKET - (END COVER) G A S K E T - ( M A I N O I L PUMP) LABYRINTH-SLEEVE SEAL RING (THRUST BEARING) L O C A T I N G ' P I N (BRG. L I N I N G ) . L O C A T I N G ,PIN' { E : N D ' . C 0 V E R V ' j ;'1 KINGSBURY THRUST'BEARING EYE 8 0 L T : . . ' PIPE P L U G ' V ' ' ' O-RING ( L A B Y R I N T H SLEEVE)

N O U N CODE 003 A 0038

PART NAME I M P E L L E R ASSEMBLY L H . * I M P E L L E R ASSEMBLY R.H, R I N G - CASING SHAFT K E Y - IMPELLER R I N G - SPLIT KEY - THROTTLING StEEVE C E N T E R SLEEVE SLEEVE - THROTTLING

006

010
291 408 MO

011 262

' I M P E L L E R A S S E M B L Y 0C3A/B CONSISTS OF

00*
005 259

CC3

IMPELLER RING IMPELLER (FRONT! R I N G - IMPELLER (BACK) SET SCREW

EXPLODED VIEW. #1 TYPICAL ROTOR ASSEMBLY DA PUMP

N O U N CODE

PART N A M E LOWER HALF CASING UPPER HALF CASING RING - CASING DOWEL PIN (CENTER BUSHING! DOWEL PIN ( C H A N N E L ' R I N G ) DOWEL PIN (CASING) CHANNEL RING (UPPER HALF) S T U F F I N G BOX BUSHING CAP SCREW (CENTER BUSHING) SCREW - JACKING GASKET ( M A I N PARTING FLANGE) STUD ( M A I N . P A R T I N G FLANGE) CAP NUT (MAIN PARTING FLANGE). ROTOR COMPLETE WASHER (MAIN- PARTING FLANGE) CENTER BUSHING (UPPER HALF) ' PIPE PLUG THROTTLING BUSHING.

001 002 006

029 A 029B 029C

060

11BA 11BB 170 178 179 184 246 , 407 417 441

088

THIS STUFFING BOX BUSHING IS NOT USED W I T H A COOLED STUFFING BOX EXTENSION IN COMBINATION W I T H A PACKED BOX

164

.029C

^ .

EXPLODED

VIEW

#3

"ASSEMBLY OF U P P E R ' H A L F . BUSHINGS AND-CASING. '

SECURING THE PUMP .TROUBLE SHOOTING Trouble Shooting Chart SECTION 4 LUBRICATION . LUBRICATION SYSTEM Pressure Switch No. 8 pressure Switch No, 7 MAKE PERIODIC INSPECTIONS OIL.SPECIFICATIONS. ASTM Standards OIL TEMPERATURE CLEANING THE LUBRICATION 'SYSTEM PRIOR TO OPERATION SECTION 5 STUFFING BOX PACKING PACKING INSTALLATION STUFFING BOX PACKING REMOVAL SECTION 6 MAINTENANCE GENERAL PREVENTIVE MAINTENANCE .TORQUE VALUES -COUPLING REMOVAL DISMANTLING PROCEDURE STUFFING BOX

3-5 3-7 3-7

4-1 4-14-1 4-2

4-2 4-2-

5-1 5-2 5-3

6-1

6-2.
6-2

6-2
6-2

Plain Bearing Removal Removal Of Stuffing Box Parts Rotor Removal Dismantling The Rotor Heating Impellers For Removal

6-4 6-4 6-4

6-6

6-6

INSPECTION AND RENEWAL OF PARTS PARTING FLANGE GASKET HE BUILDING PUMP Re Building Rotor Indicate And Dynamic Balance Rotor Installing Rotor In Casing Assemble Stuffing Box Extension Check Rotor Vertical Lift Check Rotor Acial Float - Packed Box Check Rotor Axial Float - Mechanical Seal Horizontal And Vertical Shaft Alignment Centralize Rotor Axially Final Bearing Assembly Set Thrust Bearing Axial End Play Final -Asserab 1 y SECTION 7 PARTS ORDERING INSTRUCTIONS ORDERING INSTURCTIONS Rotor Assembly Drawing And Parts List Pump Assembly Drawing And Part3 List SECTION 8 DRAWINGS AND PURCHASED COMPONENT INSTRUCTIONS General Arrangement Drawing And L.N. Notes General Arrangement Drawing And L.N. Notes Lube Piping Drawing 4 P.L. Notes Lube Oil Console Drawing Kingsbury Thrust Bearing Tuthill Oil Pump (Main) DeLaval Oil Pump (Auxiliary) Yarway Valve Drawing Yarway Valve Instruction Sheet Waldron Coupling Drawing Waldron Coupling Drawing Waldron Coupling Instruction Sheet Motor Information Turbine Information .Outline Drawings Instruction Manual

6-8

6-11 6-12 6-12 6-13 6-13 -6-14 6-15 6-15 6-16 6-16
6-18
6-18 6-20
-6-20

7-1 62068127, 2 Pgs. 62068135, 4 Pgs.

Pgs. Pgs. Pgs. Pgs. 5JJ 62059175, 0RFD-1 C3E-87 62065735, 044399-5506 Series 5300 Item No. 1 62081278, 2 Pgs. Item No, 2 62081476, 2 Pgs. Type WSP, 25M0201 To Come X-664413, X-663416 No. 100-M

Item No. 1 Item No. 2

62068937, 62068945, 62063045, 62064100,

3 3 2 2

LIST OF EXPLODED VIEWS , #1 ROTOR ASSEMBLY 6-22 6-23 6-24 | 6-25 6-26 6-27

#2 ASSEMBLY OF LOWER HALF BUSHINGS AND ROTOR TO CASING #3 ASSEMBLY OF UPPER HALF BUSHINGS AND CASING #4 STUFFING BOX PARTS #5 PLAIN BEARING #6 THRUST BEARING

SECTION 1 INTRODUCTION

INTRODUCTION

This manual contains instructions for installation, operation and maintenance of your Ingersoll-Rand Centrifugal Pump. It has been designed to provide safe and reliable service. However, it is both a pressure vessel and a piece of rotating machinery. Therefore, the operator(s) must exercise good judgement and proper safety practices to avoid damage to the equipment and surroundings and prevent personal injury,
r

The instructions in this manual are intended for the guidance of personnel with a general training in operation and maintenance of Centrifugal Pumps. It. is our hope that you will be come acquainted with its content as an aid to better pump performance. This manual should be read in its entirety before installing, and/or operating the equipment. The Assembly Drawings (included in Section 7) and General Arrangement Drawing (included in Section 8) should be consulted for accurate details and determination of specific optional features that are furnished with your pump. All numbers in parenthesis () following part names correspond with "Exploded View" Noun Codes. EXAMPLE:"T1-003A) - Exploded "View f 1, Noun Code #003A - Impeller Assemb1y. Exploded Views are included in Section 6. SAFETY It is assumed that your-safety department has established a safety program based upon a thorough analysis of industrial hazards. Before installing and operating or. performing maintenance on the pump and associated components described in this manual, it is suggested that the safety program be reviewed to ensure that it covers the hazards arising from high speed rotating machinery. It is .also important that due consideration be given to those hazards which arise from the presence of electrical power, hot oil, high pressure and temperature liquids, toxic liquids and gases and flammable liquids and gase3. Proper installation and .care of protective guards, shutdown devices and over pressure protection equipment should also be considered an essential part of any safety program. Also essential are special precautionary measures to prevent the possibility of applying power to the equipment at any time when maintenance work is in progress. The prevention of rotation due to reverse flow should not be overlooked. In general, all personnel should be guided by all the basic rules of safety associated with the equipment and the process. DESCRIPTION 'The "DA n Pump is a multi-stage, single suction - opposed impeller, horizontally split volute pump. The suction and discharge nozzles are cast integral with the lower half

casing,
Rotating parts are accessible by removing the upper half casing which can be removed without breaking suction and discharge piping.

;CASING The casing provides for immediate containment of the liquid being pumped, while directing the flow of liquid from the suction nozzle to the impellers and subsequently through the volute to the discharge nozzle. The casing halves, are sealed by the use of a gasket and are joined together by studs, which are installed in the lower half casing and fastened with washers and cap nuts, IMPELLERS The Impellers are single suction, enclosed type, one piece construction and are dynamically balanced. They are fitted with renewable impeller held in place by headless set screws. rings (front and back) which are

The impellers are keyed, have a shrink fit to the pump shaft and are held in axial position by a split ring. CASING RINGS Casing rings are positioned over the impeller front rings. tubular and renewable, CHANNEL RINGS Renewable channel rings are positioned over the impeller back rings. They divide the casing into stages. These rings are horizontally split and are held together by dowel pins. CENTER SLEEVE The center These rings are

A renewable type center sleeve is used under the center bushing. sleeve is tubular and keyed to the shaft (via the impeller key). CENTER BUSHING

The renewable center bushing is horizontally split, the two halves are held together by socket head capscrews and taper dowel pins. It is held in position by the raised annular ring of the bushing engaging the annular 'groove in the casing. The center bushing in conjunction with center sleeve divide the casing at the center (back to back) impellers. THROTTLING SLEEVE Renewable type throttling sleeve is used under the throttling b u s h i n g . The throttling sleeve i3 tubular, keyed, has a shrink fit to the shaft, and are held in position by a split ring.

1-3

If

THROTTLING BUSHING Renewable type throttling bushing is used. It is held in position by the annular ring -of the bushing engaging the annular groove in the casing. The throttling bushing, in conjunction with the throttling sleeve, allows pressure to be blead off thru the balance line, so that pressure on the stuffing boxes is balanced. The throttling bushing also balance the axial thrust of the pump rotor, SHAFT The high strength shaft is ground over its entire length to close tolerances, The shaft is designed to transmit the required power without vibration and is stepped at each impeller fit for ease of assembly and disassembly. . SHAFT SLEEVES. Renewable shaft sleeves are provided with pumps equipped with packed stuffing boxes to protect the shaft at the stuffing box areas. The sleeves are tubular type, keyed to the shaft, and held in position by the retaining

ring3,
BEARING LININGS The bearings are carbon steel backed, babbitt lined, sleeve type insert bearings. The bearing inserts are mounted in the bearing bodies and kept from rotating by means of stop pins. The bearing inserts are renewable. THRUST BEARING (Refer to Kingsbury Thrust Bearing Drawing)
N

The Kingsbury thrust bearing is of the equalizing type having six thrust shoes on each side of the thrust collar and is consequently capable of transmitting the thrust load in either direction. The thrust is transmitted through the thrust collar to the shoes, by the 3hoes to the shoe supporting elements, and thence to the bearing body and the foundation, STUFFING BOXES The stuffing boxes are cast integral with the casing. The suction and discharge end stuffing boxes can be equipped with a cartridge type mechanical seal or stuffing box packing. COOLED STUFFING BOX EXTENSION A cooled stuffing box extension is offered on this type pump as an option. This extension is inserted into the stuffing box and has a cooling jacket through which cooling liquid is circulated.

1-4

CHECK UPON ARRIVAL Your pump was carefully checked at our shops pri'or to shipment to assure its meeting the requirements of your order. It is suggested that the pump be inspected upon arrival and that any irregularities arising due to s h i p p i n g be reported i m m e d i a t e l y to the carrier. CARE DURING STORAGE If it is necessary to store the unit any length of time before installation, find a location where it will be protected from unfavorable weather and is vibration free. The nozzle covers provided with storage. the unit should be.i"left in place during

Electric motors (pump driver) should not be stored in damp places"without special protection (refer to motor manufacturers instructions). RUST PREVENTIVE Internal parts of the .pump and bearing housings are protected prior to shipment with a thin film polar type rust preventive [pump internals (Ferrocote 5684), bearing housings (MILC16173 Grade 3)3. This can be removed out by flushing with petroleum solvents. External machined surfaces are protected with durable drying type . rust preventive (MIL-C-16173 Gr ade 1). This can be removed with kerosene or safety solvent (TOWER NO. 392). External non-machined surfaces are painted with one coat followed by a coat of multi-color speckle lacquer. of gray enamel

Exception: External non-machined surfaces of the pimp (if operating above 200 Degrees F.) are painted with a high temperature aluminum base paint. Parts on parts orders are protected with a thin film polar type rust preventive, This can be removed with petroleum solvents.

LIFTING EQUIPMENT

MAKE SURE THAT ANY EQUIPMENT USED TO LIFT THE PUMP OR ANY OF ITS COMPONENTS IS CAPABLE OF SUPPORTING THE WEIGHTS ENCOUNTERED, MAKE SURE THAT ALL PARTS ARE PROPERLY RIGGED BEFORE ATTEMPTING TO LIFT, TO LIFT UNIT pump, driver and bedplate can NOT be lifted as a unit. removed from bedplate before lifting. Driver must be

To lift punp and bedplate or just bedplate, sling bedplate from all lifting eyes. Failure to do this will result in permanent deformation of bedplate, TO LIFT DRIVER Refer to .driver manufacturers instructions. TO LIFT PUMP Install sling from overhead hoist and under bearing housing mounting brackets (cast portion of casing that bearing housings attach).

DO NOT. LIFT ENTIRE PUMP FROM CAST LIFTING LUGS ON UPPER HALF CASINGS. LUGS ARE FOR LIFTING UPPER HALF CASING ONLY. TO LIFT UPPER HALF CASING Rig to overhead hoist from cast lifting lugs provided. TO LIFT PUMP ROTOR Using slings that will not damage shaft, rig around shaft close to the impellers and to overhead hoist. Carefully lift rotor from lower half casing.

THESE

1-6

SECTION 2 INSTALLATION

"JLl

LOCATION Inatill th unit cloae to the souroe of the liquid to be pumped. When selecting the location, be sure to allow adequate space for operation as well as for maintenance o p e r a t i o n s involving d i s m a n t l i n g and inspection of parts. Head room is an important consideration as an overhead.lift of some type is required. FOUNDATION The foundation should be sufficiently rigid and substantial to prevent any pump vibration and to permanently support the bedplate at all p o i n t s . The most satisfactory foundations are made of reinforced concrete. These should be poured well' in advance of the"installation to allow proper time for drying and curing. The General Arrangement Drawing will furnish anchor bolt locations, size of bolts, etc. ALLOW &OUS TO WOJfCT (QA Gl OUTING UNDf KDPl>Tt

TEMPLATE FOR HANGING FOUNDATION BOLTS

2-1

The sketch below illustrates a recommended foundation bolt arrangement. Notice the large washer with lugs at the bottom. It should be welded to the bolt and' pipe sleeve to prevent turning. Allow a little more than the specified threaded bolt length above the rail of the bedplate. The excess can always be cut off if not needed, A rough finish top surface is best when applying grout.

INSTALLATION CHECK LIST 1. 2. 3. Level Bedplate Grout Bedplate Align Shaft/Coupling '

4 , Piping 5.

Check Coupling Alignment LEVEL THE BEDPLATE

Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any loose pieces of cement and roughen the top with a chisel to afford a good hold for grout. NOTE Coupling bolting and spacer piece (when used) must be removed from between pump/driver half couplings before lifting bedplate with pumping element. NOTE When lifting bedplate with pumping element, sling bedplate from all lifting eyes provided. Failure to do this may result in permanent deformation of bedplate.

2-22

P r e p a r e enough iron w e d g e s or shims to be placed on each side of each foundation b o l t . These w e d g e s should be about 4 to 6 inches l o n g , 2 to 3 inches wide and thick enough to allow for 1 1/4 inches of grout under the edge of the bedplate. Place wedges as shown in sketch.

Level the bedplate by using a machinist's level on the machined surfaces of the pump and driver p a d s . When the b e d p l a t e is l e v e l e d , p u l l down the foundation bolts so they are 3nug, The bedplate may have been disturbed by tightening down the foundation bolts, therefore, recheck with level and make necessary adjustments by wedges or shimming. As a final bedplate a l i g n m e n t check on spacer type couplings, install a mounting bracket for dial indicator on driver hub. Fasten or clamp indicator on mounting bracket so that dial indicator button is contacting face on p u m p h a l f coupling and zero the dial i n d i c a t o r , ( N o n - s p a c e r type coupling should be checked with tappered wedge or feeler gages.) Rotate the driver half coupling (in direction of pimp rotation) 90 degrees. Record this reading. R e p e a t this procedure until r e a d i n g s have been taken at (4) positions. 90 d e g r e e

Using this procedure shim and/or wedge bedplate until pump and driver are within ,003 inch.

GROUTING Build a dam around the f o u n d a t i o n . It is a matter of personal preference whether the leveling wedges under the b e d p l a t e should be removed after grouting. If you do w a n t to remove the w e d g e s , c a r e f u l l y m a r k their locations before pouring grout.

BUILD DAM AROUND FOUNDATION BEFORE POURING GROUT Use a q u a l i t y , high strength, non-shrink grout - mix and install per manufacturers instructions. Holes are provided in the b e d p l a t e to permit pouring the grout and stirring, They also act as air v e n t s . Fill under the b e d p l a t e c o m p l e t e l y , s t i r r i n g to assure proper d i s t r i b u t i o n of the g r o u t . Check to see that the grout flows under the edges of the bedplate evenly. NOTE Do not vibrate bedplate" when grouting, make sure bedplate is vented properly and all areas as indicated on G e n e r a l Arrangement Drawing are thoroughly puddled to prevent any resonant problems. W h e n the g r o u t is t h o r o u g h l y h a r d e n e d , remove the dam and w e d g e s , desired, filling in the holes they leave with grout. if

24

x o

SHAFT/COUPLING ALIGNMENT
CAUTION

SHAFT ALIGNMENT M U S T BE C O R R E C T FOR SUCCESSFUL O P E R A T I O N . RAPID WEAR, N O I S E , VIBRATION AND ACTUAL DAMAGE TO THE EQUIPMENT MAY BE CAUSED BY SHAFT MISALIGNMENT. THE SHAFTS MUST BE ALIGNED WITHIN THE LIMITS GIVEN. NOTE Adjustment to correct the alignment in one direction nay alter the alignment in another d i r e c t i o n . Always c h e c k in all d i r e c t i o n s a f t e r making any adjustment. Coupled e q u i p m e n t m u s t be aligned to m i n i m i z e u n n e c e s s a r y s t r e s s e s in s h a f t s , bearings and coupling, Flexible couplings will not compensate for appreciable m i s a l i g n m e n t . Foundation settling, thermal expansion, nozzle loads resulting in b e d p l a t e / f o u n d a t i o n d e f l e c t i o n and v i b r a t i o n during operation may require the full coupling misalignment capability, TYPES OF MISALIGNMENT There are two types of shaft misalignment; angular and offset. Therefore, t w o sets of m e a s u r e m e n t s and c o r r e c t i o n s are r e q u i r e d . Both types of m i s a l i g n m e n t can occur in horizontal and vertical planes and are present in most applications. A, Angular Misalignment

In angular misalignment, the centerline of the shafts intersect, but are not on the same axis.

ANGULAR MISALIGNMENT B. .Offset Misalignment In offset m i s a l i g n m e n t , intersect. ! the shaft c e n t e r l i n e s are p a r a l l e l but do n o t

OFFSET MISALIGNMENT

COMBINATION OFFSET AND ANGULAR MISALIGNMENT 2-5 2

ALIGNMENT A. Measure Gap

The first step in shaft/coupling alignment is to bring the pump and driver shafts into their proper axial position. The shaft gap or distance between c o u p l i n g hubs m u s t be in accordance with the certified General Arrangement Drawing and must be measured with pump and driver shafts in the center of their axial end f 1 o a t . Motor with sleeve bearings are to be aligned with rotor at magnetic center. Move driver to insure proper gap distance. NOTE It is recommended that the pump hold down bolting be torqued and pump be dowelled before taking any alignment m e a s u r e m e t s . This makes the pump the fixed machine and the d r i v e r the movable machine. In certain cases, however, it may be impractical to move the driver, therefore, the pump may have to be m o v e d . When this case exists, the pump should not be dowelled until after final alignment. B, Measure Angular Misalignment

Refer to "ALIGNMENT DATA SHEET'1 and examples. CAUTION PUMP. SHAFT' SHOULD NOT BE ROTATED MORE THAN 'NECESSARY WHEN ALIGNING SHAFTS, DAMAGE COULD OCCUR TO INTERNAL W E A R I N G PARTS WHICH ARE LUBRICATED BY THE PUMPED LIQUID. , The angular m i s a l i g n m e n t c a n ' b e s t be determined by the use of a hand-held i n s i d e m i c r o m e t e r , marked "B" on sketch. All measurements should be taken at the same radial distance from the shaft centerline, as close as possible to the hub outside diameter. The location, of these measurements is defined as the n D" dimension on the "ALIGNMENT DATA SHEET". Do not move the shafts a x i a l l y while rotating the shafts and taking measurements. Both hubs must be rotated together to cancel possible hub face runout. The relative meas u r e m e n t (top minus b o t t o m , r i g h t m i n u s left) is the i m p o r t a n t number. 1. Mark both coupling hubs at 3.6,9 and 12 o'clock positions so they can be rotated together and at 90 Degree intervals.

2. Starting with the 12 o'clock m a r k i n g s of both hubs in the top center position, measure the gap at top, bottom, right and left side. Record these d i m e n s i o n s oh "ALIGNMENT DATA SHEET" Sheet 1, Part 1 in the 0 Degree Colunn, NOTE Right side and left side are determined when viewing the driver coupling from the pump. 3. R o t a t e b o t h shafts 90 degrees in the d i r e c t i o n of pump r o t a t i o n . Measure gap d i m e n s i o n s at the four (4) l o c a t i o n s as in Step 2. Record on "ALIGNMENT DATA SHEET" - Sheet 1, Part 1 in the 90 Degree Column. H. Repeat Step 3 until m e a s u r e m e n t s have been taken at the four (4) 90 Degree po sit ions.(0,90,180. and 270 Degrees), 5 Rotate both shafts to the starting position (12 o'clock markings at top center) and recheck dimension recorded in Step 2. 6. For 0,90,180 and 270 Degree Columns, subtract the bottom from the top and left from r i g h t . Record in their r e s p e c t i v e blocks on Data Sheet. Watch sign notations! 7. Total the d i f f e r e n t numbers (reading across), divide by 4 and record the average . Record in "Open At " the shaft relative angular position NOTE The inside faces of the d r i v e r and pump half hubs must be parallel within

.001".

C.

Measure Offset Misalignment

Offset m i s a l i g n m e n t is measured using a dial indicator on the outside diameter of the coupling hubs and rotating the hubs together to cancel rim surface inaccuracies. 1. ' Starting with the 12 o'clock m a r k i n g s of b o t h hubs on top c e n t e r , fasten or clamp an indicator on driver hub, marked "A" on sketch, with dial indicator button contacting alignment surface on the pump hub.
*

2.

Zero the dial indicator,

3. Rotate both coupling hubs (in the direction of pump rotation) 90 Degrees and take a r e a d i n g . Record on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2 in the proper right side or left side blank (right or left sides are determined when viewing the driver half coupling from the punp) . 4. Repeat Step 3 until readings have been taken at the four (4) 90 Degree positions (top center, right, bottom and left).

2-7 2

5. Rotate both shafts to the starting position (12 o'clock markings at top center) and verify indicator returns to zero. NOTE The sum of the top and bottom r e a d i n g s should a l w a y s e q u a l the sum of the left and right'readings. If the sums are not equal, check for indicator bracket d e f l e c t i o n h u b s u r f a c e i r r e g u l a r i t y o r l o o s e r a d i a l bearings, 6. Using -the formula- on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2, subtract the top from the b o t t o m i n d i c a t o r r e a d i n g , divide by two (2), Thi3 will yield the vertical misalignment. 7. Using the formula on "ALIGNMENT DATA SHEET" - Sheet 1, Part 2, subtract the left from the right indicator reading, divide by two (2), Thi3 is the horizontal misalignment. 8. Circle the proper high or low and left or right position of the driver hub, using the rules given on the Data Sheet. NOTE The outside d i a m e t e r s of pump and d r i v e r c o u p l i n g h u b s m u s t be aligned LOCATION within .003" TIB. D. Movement Calculations ("ALIGNMENT DATA SHEET" - Sheet 2)

1. Sketch the r e l a t i v e d r i v e r shaft position in the side and top views. These sketches will assist visualizing the required equipment m o v e . 2. Alignment depends upon the relationship between D, L I and L 0 G X L Use the formula D determine the required move. NOTE D = Diameter of the c i r c l e at which angular m i s a l i g n m e n t readings were taken (not coupling diameter). Gy = Gap difference (top minus bottom) taken from Sheet 1, Part 1. GH
=

Gap difference (right minus left) taken from Sheet 1, Part 1.

L I = Distance from driver coupling hub to inboard driver foot. L 0 = Distance from driver coupling hub to outboard driver foot.

PUMP SHAFT (FIXED)

2-82

3. Record vertical offset from Sheet 1, Part 2- and vertical move obtained from c a l c u l a t i o n s in the " I N B O A R D , and OUTBOARD DRIVER PEDESTAL SHIFT" columns. Also record the required direction of shift (raise or lower). 4. Record horizontal offset from Sheet 1, Part 2 and horizontal m o v e obtained from calculations in the "INBOARD, and OUTBOARD DRIVER PEDESTAL SHIFT" o o l u m n s . Also record the required d i r e c t i o n of shift (right or left). 5. Total the move requirements (watch move direction)". This will yield the required horizontal m o v e (right or left) and the vertical move (raise or lower) required at each mounting foot. HORIZONTAL MOVE J

The d i a l indicators as shown in figure are required to accurately measure the m o v e in the horizontal direction. Move the driver' by bumping with soft h a m m e r / m a l l e t or using the Jackscrews (if provided). The amount of horizontal relocation required is the total of the horizontal move calculation (bottom of Sheet 2).

TOP VIEW DIRECTION OF SHIFT COUPLING

DRIVER (MOVABLE)

DIAL INDICATORS AT DRIVER FEET

VERTICAL MOVE Before m o v i n g the equipment vertically, it is important that the vertical thermal expansion be taken into consideration. The preceeding vertical move c a l c u l a t i o n s are based on pump and driver shafts being set on the same plane. Refer to General Arrangement Notes and/or driver instructions for r e c o m m e n d e d cold vertical setting (if thermal expansion is a f a c t o r ) .

'9

The shims between the e q u i p m e n t feet and mounting surface should be clean and dry. This is especially critical for purcps in service for some time and need to be r e a l i g n e d . W a t e r , d i r t and rust may change the height of the shim pack over a period of t i m e . Shims should be made large enough to support the weight of the equipment on its mounting foot. Do not use many thin shims as this may result in a spongy mounting.

RECOMMENDED SHIM DESIGN Move the equipment vertically by adding or removing the calculated thickness of shims. Torque equipment hold down bolting to required values. NOTE It is recommended, the completed "ALIGNMENT DATA SHEET" be retained as part of your, permanent maintenance file. CHECK COUPLING ALIGNMENT The angular and offset coupling alignment must be rechecked. 1. 2. 3. Coupling faces are to be parallel within .001" TIK. Coupling outside diameters are to be aligned within .003" TIR, "Bump" the motor and check motor rotation,

ASSEMBLE AND LUBRICATE COUPLING 1. Assemble and l u b r i c a t e coupling per the manufacturer's instructions included in "Section 8"_of thi3 manual, 2. Install coupling guard,

DOWEL PUMP AND DRIVER A. Cold Pumps (Below 200 Degrees F.)

Pump hold down b o l t s are to be. torqued to the proper value and dowel pins are put in two (2) feet (diagonally opposite). B. Hot Pumps

Pumps handling liquid-s of 200 Degrees F. and over are designed to permit the casing to expand with temperature away from coupling end of pump. The units that come under this classification must have the pump supports or feet dowelled to the b a s e p l a t e at the coupling e n d . This maintains the coupling gap at the desired amount.
2 - 1 0 2

The pump feet at the opposite end are held from moving vertically by the use of a self locking n u t . The clearance between the base of the nut and the top of the pump foot should be .002". The h o r i z o n t a l m o v e m e n t is controlled by a "Gib Block" running parallel to the l e n g t h of the pump at each of the outboard feet. The "Gib Blocks" are bolted and dowelled to the baseplate at the time of mounting at the factory. A .010" gap is maintained between the "Gib Block" and pump foot, IMPORTANT The self locking n u t s which hold the pump from moving in a vertical motion a r e c l a m p e d tight to the pump foot at time of shhipment. The .002" clearance must be established at time of installation.

FLEX LOCK NUT

002" CLEARANCE PUMP FOOT GIB BLOCK

C,

Pump Driver a n d / o r driver instructions for dowelling

Refer to d r i v e r o u t l i n e d r a w i n g information. HOT ALIGNMENT CHECK

A hot c h e c k can only be made after the unit has been in operation a sufficient l e n g t h of time to assume its NORMAL operating temperature and conditions, If the unit has been p r o p e r l y cold s e t , the offset misalignment w i l l be within ,003" TIR and the angular misalignment will be within ,001" TIR when in operation. If not make adjustments. WARNING 8

DO NOT A T T E M P T ANY M A I N T E N A N C E , I N S P E C T I O N , REPAIR OR C L E A N I N G IN THE VICINITY OF ROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN PERSONAL INJURY TO OPERATING PERSONNEL.

M U S T BE IN THE "OFF" P O S I T I O N , L O C K E D A N D T A G G E D TO P R E V E N T INJURY TO P E R S O N N E L PERFORMING SERVICE ON THE PUMP. 2-11

ALIGNMENT DATA SHEET HORIZONTAL PUMPS NAME ALIGNMENT DATA FOR FUMP TEMPERATURE DATE TIME SERIAL NUMBER

SHEET 1 OF 2

PART 1 POSITION TOP. BOTTOM E V C I T R L A 00

ANGULAR ALIGNMENT CHECK 270 TOTALS

90

100

Open At
Averace

DIFF. (T-B) O H RIGHT SIDE I R LEFT SIDE Z O DIFF. N (R-L) Open At Average

Right au,d Left are determi ned when viewing the driver hub from the pump. PART 2 OFFSET ALIGNMENT CHECK TOTAL INDICATOR READINGS RULES TO APPLY TO THE RESULTS BELOW: With Indicator Mounted On The Driver Neg = Driver Coupling Is High & Left Pos = Driver Coupling Is Low & Right

Driver Coupling Is (Circle Correct One): High Or Low And Right Or Left VIEW OF DRIVER HALF COUPLING HUB VIEWED" FROM PUK? Vertical Offset" Misalignment Horizontal Offset Misalignment = Bottom 2 Top = = " = = = =

= ' Right - Left 2

2-1 2

ALIGNMENT DATA SHEET HORIZONTAL PUMPS

SHEET 2 OF 2

S I D E VIEW

(VERTICAL M O V E )

TOP VIEW ( H O R I Z O N T A L M O V E )

VERTICAL ANGULAR MOVE CALCULATION Driver Inboard Pedestal Shift Gy X L J

MOVE DRIVER TO CORRECT ALIGNMENT

Driver Outboard Pedestal Shift OUTBOARD DRIVER PEDESTAL SHIFT MILS DIRECTION

INBOARD DRIVE) PEDESTAL SHIFT \ KILS OFFSET MOVE ANGULAR MOVE TOTAL DIRECTION

HORIZONTAL ANGULAR MOVE CALCULATION Driver Inboard Pedestal Shift =

G

. HOVE DRIVER TO CORRECT ALIGNMENT H

x L

Driver Outboard Pedestal Shift

= OUTBOARD DRIVER PEDESTAL SHIFT KILS DIRECTION

INBOARD DRIVE R PEDESTAL SHIFT KILS OFFSET MOVE ANGULAR MOVE TOTAL DIRECTION

"

1 3

3 H

EXAMPLE

rj v I

3<T

PIPING

SUCTION AND DISCHARGE PIPING These units are furnished for a particular service condition. the hydraulic system may affect performance adversely. This is true if the changes reduce the pressure at the suction or if temperature is increased. In case of doubt contact the nearest Rand Office. Changes in especially the liquid Ingersoll-

Suction and dischrge piping should be of ample size, be installed in direct runs, and have a minimum of bends, NOTE PROVISION. MUST BE MADE TO SUPPORT PIPING EXTERNAL TO THE PUMP TO- PREVENT EXCESSIVE NOZZLE LOADS AND MAINTAIN PUMP-DRIVER ALIGNMENT. Install a check valve and a gate valve in the discharge pipe on the pump. When the pump is stopped, the check valve will protect the pump against excessive pressure and will prevent the pump from running backward. The check valve should be installed between the gate valve and the pump nozzle in order.to permit its inspection. The gate valve is also useful in priming and starting the pump. Keep the suction pipe short and direct. size larger than the pump suction nozzle. air pockets. IMPORTANT A SPOOL PIECE S H O U L D BE I N S T A L L E D IN SUCTION L I N E ' S O T H A T THE S U C T I O N SCREEN MAY BE INSTALLED AND REMOVED. BY PASS LINE
WARNING

Use a suction pipe at least one Keep the suction pipe free of all

OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE BY PASS MAY BE REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT REFER TO LOCAL INGERSOLL-RAND BRANCH TO DETERMINE IF A BY PASS MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS PERCENT OF THE DESIGN OPERATING POINT OF THE PUMP. Refer to rangement Drawing Notes and nameplate rating. MINIMUM FLOW
WARNING

LIQUID. A PUMP DAMAGE. IS REQUIRED. LESS THAN 25 General Ar-

OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY-PASS LINE IS REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT PUMP DAMAGE. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 210 GPM.

Customer to install a yarway "ARC" valve (Automatic Recirculation Control), furnished by Ingersoll-Rand Company per drawing 62061460 in discharge line between pump discharge and first valve. Customer to provide a 1.50" by-pass line from y a r w a y n A R C " valve to source of suction. A paddle orifice, furnished by Ingersoll-Rand Company per drawing no. X-150D438JX3,.is to be installed in by-pass line as close to source of suction as possible to prevent vaporization in line. WARM-UP LINE NOTE Customer to install 1.00 muffled type orifice furnished by Ingersoll-Rand Company per drawing Y-3HMTA438AX1 in line, by-passing main discharge valve. Direction of flow is from discharge to suction at 20 GPM, STUFFING BOX Customer to inject for each box, LUBE OIL COOLER Customer to inject 3,5 GPM of cooling water at 85.Degrees F. maximum to lube oil cooler inlet. SUCTION SCREEN i and 150 PSI 1/2 GPM cooling water at 10 PSI above suction pressure

In a new installation,- great care should be taken to prevent dirt, scale and welding beads from entering the' pump, as it is particularly important to protect the numerous close running fits from abrasive matter present in new piping. The suction system should be t h o r o u g h l y f l u s h e d before i n s t a l l i n g the suction strainer and making .up suction piping to the pump. The suction strainer should be installed as close to the pump suction as possible. THE OPEN AREA OF THE STRAINER SHOULD HAVE A MINIMUM OF A 3 TO 1 RATIO TO THE AREA OF THE PUMP SUCTION.

The Ingersoll-Rand standard for suction strainers consists of a conical shaped steel plate. The plate has 1/16" perforations and is of sufficient size and thickness for the required flow. Other type strainers may be used as long as they conform to the requirements stated above. Pressure gauges should be installed on both sides of the screen so that the pressure drop across the screen can be measured. When the unit is being started, the gages on each side of the screen should be carefully watched. An increase in the differential pressure between the two gauges indicates that the screen is becoming clogged with dirt and scale. At this point, the pump should be shut down, and the screen cleaned and replaced. When the scale and dirt have been removed from the system as indicated by no further pressure from across ther screen, it may be removed. The screen should be used until all foreign material is removed from the system. COUPLING ALIGNMENT CHECK Refer to the section entitled "SHAFT/COUPLING ALIGNMENT" and perform a coupling alignment check as outlined. This check is recommended to insure the alignment has not been disturbed during the grouting of the bedplate or while installing suction and discharge piping.

SECTION 3 OPERATION

39

TECHNICAL DATA These pumps are furnished for a particular service condition. Changes in the hydraulic system may affect the pump's performance adversely. This is especially true if the changes reduce the pressure at the suction flange or if the liquid t e m p e r a t u r e is i n c r e a s e d . In case of d o u b t , contact the nearest Ingersoll-Rand Office, EFFECTS OF SPECIFIC GRAVITY The capacity and total head in feet of liquid developed by a centrifugal pump are fixed for every point on the curve and are always the same for the same speed. Neither capacity nor total head will be affected by a change in the specific g r a v i t y of the liquid p u m p e d . However, since the developed pressure is PSIG (pounds per square inch) and the brake horsepower to drive the pump are a function of the specific gravity of the liquid, both will be affected in direct proportion by any change in specific gravity. Therefore, a change in -specific gravity will affect the discharge gage pressure. Any c h a n g e s should be n o t e d , in that they may o v e r l o a d the purap'3 d r i v e r . EFFECTS OF VISCOSITY The pump is designed to deliver rated capacity at rated head for a liquid with a particular viscosity. When contemplating operation at some viscosity other than for which the pump w a s o r i g i n a l l y d e s i g n e d , the changed c o n d i t i o n s should be r e f e r r e d to Ingersoll-Rand Company for our recommendations, CHANGING PUMP SPEED Changing the speed of a centrifugal pump changes the capacity, total head and brake h o r s e p o w e r . The capacity will vary in a direct ratio with the s p e e d , w h e r e a s the total head will vary as the ratio of the speed squared. The brake h o r s e p o w e r will vary as the ratio of the speed cubed .except in c a s e s where the speed change also r e d u c e s the efficiency of the p u m p . NET POSITIVE SUCTION HEAD (NPSH) Any l i q u i d , hot or c o l d , m u s t be pushed into the impeller of the pump by some absolute p r e s s u r e , such as the atmosphere or the vessel pressure from which the pimp takes its' suction, The head in feet of liquid necessary to push the required flow into the pump is called the Net Positive Suction Head. This value, more commonly called N P S H , is measured above the vapor pressure of the liquid at the pumping temperature. There are two kinds of NPSH: the NPSH required by the pump, as shown on the pump curve, is the head needed to cover the losses in the pump suction; the second NPSH is that available in the system taking into account friction l o s s in auction p i p i n g , v a l v e s , f i t t i n g s , e t c . In all c a s e s the NPSH A v a i l a b l e , measured above vapor pressure, must exceed the NPSH Required in order to push the liquid into the pump,

3 - 1

OPERATING PRECAUTIONS
WAINING

DO NOT WIPE DOWN IN THE V I C I N I T Y OF ROTATING PARTS, VIBRATIO.NS OCCUR, SECURE THE PUMP AS SOON AS POSSIBLE.
WARNING

IF UNUSUAL NOISE OR

THE UNIT MUST NOT BE O P E R A T E D U N L E S S COUPLING GUARD IS BOLTED IN PLACE. F A I L U R E TO OBSERVE THIS WARNING COULD RESULT IN INJURY TO OPERATING PERSONNAL. 1. Never operate the pump with suction valve closed.

2. Never operate pump u n l e s s it is c o m p l e t e l y filled w i t h liquid and vented. 3. Never operate the pump unless a liquid source is availble. PRE OPERATIONAL CHECKS The following s t e p s should be followed at initial start-up and after the equipment has been overhauled: 1. Ensure pump and piping is clean. Before putting the pump into operation,- it should be thoroughly flushed out to remove the rust preventive as w e l l as any foreign matter which may have accumulated during installation. Take all possible care not to contaminate your system, 2. Clean and flush l u b r i c a t i o n s y s t e m . Fill reservoir with oil to the proper l e v e l . Ensure lube system is o p e r a b l e . (Refer to "LUBRICATION" section,) 3. Ensure pump r o t o r is p r o p e r l y aligned within casing (refer to "MAINTENANCE" section). 4. Turn pump rotor by hand or w i t h strap wrench to m a k e sure it turns freely. 5. Check Stuffing Box

A. If pump is equipped with a mechanical seal, ensure it is properly assembled and tightened (refer to "STUFFING BOX" section).
CAUTION

HOST CARTRIDGE SEALS ARE EQUIPPED WITH A SPACER BETWEEN THE GLAND PLATE AND DRIVE COLLAR. THIS SPACER MUST BE REMOVED BEFORE STARTING UNIT. B. If pump is equipped with a packed b o x , insure box is properly packed (refer to "STUFFING BOX" section).
3 - 2

6. Ensure coupling is properly aligned and lubricated, and pump and driver is properly dowelled (refer to " S H A F T / C O U P L I N G ALIGNMENT" p r o c e c u r e ) . 7. 8. Ensure coupling guard is in place. Check torque of all bolting and plugs for tightness. INITIAL START UP PROCEDURE 1. Close discharge valve if valve is not already closed.

2. Prepare the driver for start up in accordance with the manufacturer's instructions, 3. Warm-Up Pump

Avoid severe thermal shocks to the pump as a result of sudden liquid temperature c h a n g e s , The pump m u s t be p r e h e a t e d prior to s t a r t - u p . Unless otherwise specified the external temperature of the casing must be within 100 Degrees F. of the temperature of the liquid to be pumped at time of start-up. Due to the heavy metal sections, the casing will lag the liquid temperature during such changes, and severe temperature stresses and subsequent misalignment of machined fits may result. Pre-heating is accomplished by circulating a small amount of hot, fluid through the casing by utilizing vents, drains or by pass from discharge. Preheat pump slowly at a rate not to exceed 100 Degrees F. per hour. Prime pump and ensure pump suction valve is open.
CAUTION
I

BEFORE STARTING OR WHILE OPERATING THE PUMP, THE CASING AND SUCTION LINE MUST BE COMLETELY FILLED WITH THE LIQUID BEING PUMPED. THE ROTATING PARTS DEPEND ON THIS 'LIQUID FOR LUBRICATION AND THE PUMP MAY SEIZE IF OPERATED WITHOUT LIQUID. 5. Ensure pump recirculating line (if required) is open, clear and free of obstructions. 6. Check that pump is vented by observing leakage from casing vent and seal piping vent. Close vent when liquid is emitted, 7A. If pump is equipped with a mechanical seal, make sure seal piping is turned on. 7B. If pump is equipped with a packed box; turn on cooling water to lube oil cooler (when s u p p l i e d ) , stuffing box j a c k e t and s m o t h e r i n g g l a n d . 8. Start auxiliary oil pump.

3 - 3

9. Check pump rotation by starting unit momentarily. The direction of rotation is clockwise when facing pump shaft from coupling e n d . Note the pump coasts to a gradual stop.
CAUTION

IF PUMP STOPS A B R U P T L Y WHEN DRIVER IS SHUT D O W N , I N V E S T I G A T E FOR PUMP BINDING. TAKE NECESSARY REMEDIAL ACTION BEFORE RESUMING OPERATION, 10A. Starting the driver (motor driven)

Prepare the d r i v e r for start up in accordance with the m a n u f a c t u r e r ' s instructions. Start the driver. 10B, Starting the driver (turbine driven) for start up in accordance with the manufacturers

Prepare the turbine instructions.

Start the turbine and bring it up to speed quickly. 11. As soon as pump is up to rated speed, slowly open discharge valve. This will avoid a b r u p t c h a n g e s in velocity and p r e v e n t s u r g i n g in the suction line. 12. Check to see that a u x i l i a r y oil pump has shut d o w n . operating checks. OPERATING CHECKS
. WARNING

Perform the

IN THE INTEREST OF OPERATOR SAFETY THE UNIT MUST NOT BE OPERATED ABOVE THE NAMEPLATE CONDITIONS. SUCH OPERATION COULD RESULT IN UNIT FAILURE CAUSING INJURY TO OPERATING PERSONNEL. CONSULT INSTRUCTION BOOK FOR PROPER OPERATION AND MAINTENANCE OF THE PUMP AND ITS SUPPORTING COMPONENTS.

OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY-PASS MAY BE REQUIRED TO PREVENT VAPORIZATION AND SUBSEQUENT PUMP DAMAGE. REFER TO LOCAL INGERSOLL-RAND BRANCH TO DETERMINE IF A BY-PASS IS REQUIRED. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 25 PERCENT OF THE DESIGN OPERATING POINT OF THE PUMP - REFER TO THE NAMEPLATE RATING. Immediately after start up, and frequently during running check the following: 1, 2. Check suction and discharge pressure gauges. Check pressure gages on each side of suction strainer.

3.

Check for excessive leakage at stuffing box gland area,

A. If pump is equipped with a mechanical seal, there should be no visable leakage to the naked eye. B. If p u m p is equipped with stuffing box packing, leakage should be 1 - 2 ounces per m i n u t e . 4. Check for unusual noises. 5. 6. Check oil pressure at bearing inlets and sight flow indicators. Check for adequate flow of cooling liquids,

7. After unit has been operated a sufficient length of time to reach normal o p e r a t i n g temperature, and conditon, the unit is to be shut down and a "HOT" c o u p l i n g a l i g n m e n t check must be made (refer to "SHAFT/COUPLING ALIGNMENT" procedure).
WARNING

O P E R A T I O N OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE B E A R I N G S , BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT EXPOSING OPERATING PERSONNEL TO PERSONAL INJURY. NORMAL START UP The s t a r t i n g p r o c e d u r e to be f o l l o w e d f o r normal start up is the same as t h a t for i n i t i a l starting with the exception that Steps 9 does not have to be repeated. 'SECURING THE PUMP IA. Motor Driven. De-energize driver circuit. IB, Turbine Driven t u r b i n e d r i v e n p u m p s by m a n u a l l y tripping, the o v e r s p e e d trip.

S t o p the

2. The pump should be shut d o w n r a p i d l y to protect the internal wearing parts which are lubricated by the liquid being pumped. L u b r i c a t i o n is r e d u c e d w h e n a p u m p is s t o p p e d slowly and s e i z u r e could result. NOTE If pump s t o p s a b r u p t l y when d r i v e r is shut d o w n , i n v e s t i g a t e binding, Take necessary remedial action before restarting p u m p . 3. Close, the pump suction and discharge valve. 4. 3-5 Close valve in by pass l for pump

5.

Turn off auxiliary oil pump and cooling liquid.

6. If pump is subjected to freezing temperatures the pump must be drained of liquid to prevent damage to pump.

3-6

H5

TROUBLE SHOOTING Chart p r e s e n t s the probable troubles that can occur to the pump along with the probable causes and remedies for the troubles. TROUBLE SHOOTING CHART TROUBLE Insufficient capacity and/or pressure CAUSE Suction pressure or speed too low. Incorrect direction of rotation. A. If pump is motor driven; Refer to motor instruction manual and reconnect motor leads. Contact turbine manufacturer. Check suction system for air leakage and correct. Vent air. Tighten flange bolts. Dismantle pump and remove any foreign material. Dismantle suction line and and remove foreign material. Dismantle pump and correct . REMEDY Open suction valve wide. Check power supply for correct voltage.

B. If pump is turbine driven; Excessive amount of air or vapors in the fluid.

Foreign material in impeller Foreign material in suction line. Mechanical Defects: Impeller damaged. Sheared impeller keys. Broken or damaged coupling, Pump loses prime after starting Insufficient liquid supply. Excessive amount of air or vapors in the liquid, Clogged impeller, Suction pipe clogged. Pump vibration Loose mounting or coupling bolts.

Ensure that suction valve is wide open. Check for proper liquid level. Check suction system for air leakage and correct. Dismantle pump and correct. Remove foreign material. Tighten bolts.

3 - 7

TROUBLE,

CAUSE Coupling. Air or gas in liquid-

REMEDY Check alignment and correct. Vent air and check suction for leaks. Tighten flange bolts. Dismantle pump and remove any foreign material. Dismantle pump and replace part or parts causing vibration.

Pump vibration (Continued)

Foreign material in impeller causing unbalance. Mechanical Defects: Shaft bent. Bearings worn..

Pump overloads driver

Speed too high. A. If pump is motor driven: Refer to motor instruction manual and check power supply for correct frequency. Check steam pressure to turbine. Dismantle pump and replace part or parts causing seizures, or binding. Dismantle pump and realign rotor in casing. Replenish oil with proper grade lubricant.

B. If pump is turbine driven: Pump bearings seize or rotating element binds. Pump stops abruptly High pump thrust bearing temperature rise Pump binding at running fits. Improper lubrication.

Rotor not centered in volutes, Insufficient oil. Contaminated oil.

Check rotor centralization . Add oil. Drain and clean reservoir . Refill with clean, oil. Connect cooling liquid to lube oil cooler. Tighten gland nuts. Replace packing.

High oil temperature. Stuffing box gland (when used) excessive leakage Gland nuts loose. Packing worn.

TROUBLE Mechanical seal gland (when used) overheats

CAUSE Insufficient cooling water to seal, Mechanical seal not properly set. Check for cracked stationary face/rotating face.

REMEDY Obstruction in seal water piping. Remove and clean. v, Refer to- "STUFFING BOX 1 ' pages.

Pump is noisy

Cavitation.

Check that pump is primed, check for high suction temperature, increase static head, check for obstruction in suction line. Tighten or replace defective part. Check driver with stethoscope .

Loose parts. Noise in driver.

Check driver instruction book for trouble-shooting instructions.

3 - 9

SECTION 4 LUBRICATION

LUBRICATION SYSTEM
WARNING
I

OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE BEARINGS, BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT EXPOSING OPERATING PERSONNEL TO PERSONAL INJURY. REFER TO LUBE OIL PIPING DRAWING. Oil is supplied to the pressure lubrication pumps. The main oil pump is mounted on bolted to the thrust end bearing body and the main pump shaft via a Lovejoy coupling system by one of the two (2) oil a support head (6-172) which is cap (6-021/023).and is driven by (6-185).

A motor driven auxiliary oil pump is furnished to supply oil to the pressure lubrication system during starting and stopping periods. At time of start up, the auxiliary oil pump must be started manually. When the main oil pump supplies the required oil pressure, the auxiliary oil pump will automatically stop by action of an auxiliary oil pump pressure switch mounted in the lubrication system. The auxiliary oil pump will remain in the standby state until such time as the lubricating oil pressure falls to a pre-determined value, at which time the auxiliary oil pump pressure switch will automatically start the auxiliarly oil pump. During operation oil is taken from the oil reservoir by the oil pump and is directed to the oil cooler. From the oil cooler the oil is directed through the oil filter and is then supplied to the pump and driver bearings. A back pressure relief v a l v e m o u n t e d in the lubrication system m a i n t a i n s the required system oil pressure of 15 PSI, The system is additionally equipped with a low pressure, pressure switch which trips the unit when the oil pressure in the lubrication system decreases to a pre-determined value or prevents the starting of the unit until adequate oil pressure is established. A gravity assisted, sloped oil return line conducts the oil from the pump and driver bearings back to- the system reservoir. A check valve is mounted in the auxiliary oil pump discharge line to prevent oil from returning to the oil reservoir when the main oil pump is running and the auxiliary oil pump is shut down. The oil reservoir has a capacity of 35 gallons. The functions and control pressures of the pressure switches mounted in the lubrication system are as follows: (Refer to your Lube Piping Drawing,) PRESSURE SWITCH NO. 8 Starts the auxiliary oil pump on falling oil pressure (10 PSI) and stops the auxiliary oil pump on rising pressure (20 PSI). PRESSURE SWITCH NO. 7 Permits the start, of main pump driver at adequate oil pressure (11 PSI), Trips main punp driver on falling oil pressure (8 PSI),

MAKE PERIODIC INSPECTIONS Remember that oil requires frequent replenishment at normal temperatures and very frequent, replenishment at high temperatures. Oil is always subject to gradual deterioration from use and contamination from dirt and moisture. In time, the accumulated sludge will be harmful to the bearings and cause premature wear. For this r e a s o n , draining and flushing with a safety solvent are necessary at six month intervals. OIL SPECIFICATIONS The ideal bearing lubricant is a straight, well refined, neutral mineral oil, preferably of the turbine type. It should not contain acid, chlorine, sulphur or more than a trace of free alkali. It is suggested that the oil conform to the following physical characteristics based on tests by ASTM Standard Methods. ASTM STANDARDS Oil Characteristics Flash Point Saybolt Viscosity 100 Degrees F. Pour Point Naphthene Base 300 Degrees F. Min. 150 (Min.) Seconds 200 (Max.) Seconds 5 Degrees F. Max. SAE number 4 Paraffin Base 360 Degrees F. Min. 140 (Min.) Seconds 185 (Max.) Seconds 35 Degrees F. Max.

In a majority of instances specifications,

10 motor oil will meet the above

LUBRICANT MUST BE COMPATIBLE WITH ALL PARTS REQUIRING LUBRICATION. Refer to Lube Piping Drawing and Notes for information pertaining to your system. OIL TEMPERATURE Oil' temperature entering the plain/thrust end bearings should be maintained between 60 Degrees F. (16 Degrees C.) and 160 Degrees F. (71 Degrees C). Alarm temperature is 170 Degrees F. (77 Degrees C.) with shut down temperature set at 180 Degrees F. (82 Degrees C.). If bearing oil temperature exceeds the above mentioned liquid to the lube oil cooler will have to be increased. IMPORTANT If necessary, to maintain the minimum bearing oil temperature at start u p , oil in the lube oil reservoir may have to be heated or drained and replaced with warm oil. limits, cooling

3-2

CLEANING THE LUBRICATION SYSTEM PRIOR TO OPERATION Before operating the pump, the lubrication system should be thoroughly cleaned to remove any f o r e i g n matter that m a y h a v e a c c u m u l a t e d during shipment, storage or installation. To clean the lubrication system proceed as follows: 1, Remove the bearing caps, bearing linings, thrust shoes and drain plugs, (Refer to "MAINTENANCE" section.) 2, 3, Flush out the bearing bodies with kerosene. Wash the bearing linings and thrust shoes with a suitable solvent.

Flush the entire lubrication system with flushing oil. should be compatible with lubricating oil that will be used.

Flushing oil

5. During flushing operation examine the piping for leaks and correct as necessary. Also check for any obstructions that will interfere with free flow of oil to the bearings. 6. After flushing, replace drain plugs and piping. Reassemble bearings.

SECTION 5 S T U F F I N G BOX

STUFFING BOX PACKING Your pump is shipped without packing in the stuffing boxes. A complete set of packing is shipped in a separate box attached to the pump crate. Preserve the wrapper on the packing so that r e p l a c e m e n t s can be o r d e r e d accordingly.
CAUTION

STUFFING BOXES THAT ARE PACKED TOO TIGHT OFTEN RESULT IN BURNED PACKING, SCORED SHAFT SLEEVES AND POSSIBLE ROTOR SEIZURE. Eight (8) rings of 1/2 inch wide preformed packing (4-064) and a seal cage (when used) (4-014) must be installed in each stuffing box (refer to pump "Assembly Drawing" for proper sequence). This packing is specifically designed to have an initial clearance between the I.D. of. the packing ring and 0.D, of the shaft sleeve. As the packing is gradually compressed by tightening the gland nuts, this clearance is decreased thus reducing the leakage, rate. In this fashion, the leakage can be precisely controlled without having the packing burn, cut off the leakage and damage the shaft sleeve. Properly packed stuffing boxes are a must for efficient pump operation.

Note the directions with the packing and proceed as follows:

LIQUID ESCAPING HERE DOES NOT PROPERLY LUBRICATE

GLAND CORRECTLY POSITIONED IMMEDIATELY AFTER NEW PACKING INSTALLATION

PACKING

SHAFT

SHAFT SLEEVE

GLAND TOO FAR OUT

INCORRECT

CORRECT

TYPICAL VIEW OF CORRECT AND INCORRECTLY PACKED STUFFING BOX

3-5

PACKING INSTALLATION 1. Install one ring of packing. Note that a clearance should exist between the shaft sleeve and the packing I.D., which insures a proper liquid flow for cooling and lubrication. Intimate contact between packing ring 0,D. and stuffing box I.D. should be o b t a i n e d w i t h o u t forcing p a c k i n g into the stuffing box. If too large, trim the butts slightly to obtain a good fit without overlapping. Press this ring of packing into stuffing box as far as it will go by installing gland halves (4-0165 and bearing down until gland contacts stuffing box. Remove gland halves. NOTE The successive packing ring j o i n t s m u s t be staggered a p p r o x i m a t e l y 90 degrees from the proceeding ring. 2. If seal cage (4-014) is used, install and seat the next three (3) rings of packing (4-064), the seal cage (4-014) and the final four (4) rings of packing (4-064). Install gland halves to seat each ring, one at a time, and once again push them as far into the box as they will g o . Remove gland halves, NOTE The packing cross-section may be slightly rectangular and, thus, may not allow insertion of all p a c k i n g r i n g s , No force should be e x e r t e d to compress the rings. After the exterior ring is in place, at least 1/8 inch clearance should exist between the face of the exterior ring and the face of the stuffing box, 3. Install the gland halves (4-016) and bolt together. Install the gland washers (4-246A) and nuts (4-279A). With the gland true to the shaft, hand tighten the gland nuts until the gland contacts the last ring of packing. Do not attempt to tighten gland nuts until suction pressure is applied to the pump, Following application of suction pressure to pump, allow liquid to flow freely from stuffing box for a short period of time. This will provide time for the packing to absorb liquid which will provide lubrication during start up and protection against burn out. 4. Operate the unit for a minimum of one half hour, allowing the gland to leak f r e e l y . This is n e c e s s a r y to " b r e a k - i n " the p a c k i n g and p r e v e n t over-heating. After "break-in" gradually reduce gland leakage with the pump in operation. Leakage will decrease when pump, is rotating. 5. If the last ring of packing was left out in Step 2 above, secure pump and install the additional ring at this time, or when convenient. Do not force packing rings into stuffing box at any time.

5 2

55

6. Continue o p e r a t i o n of the pump gradually reducing the leakage. If the flow d e c r e a s e s too r a p i d l y during the procedure, slack off gland nuts to increase f l o w . If leakage is stopped, secure pump for a short period, to a l l o w gland to c o o l . Slack off gland n u t s a p p r o x i m a t e l y 1/2 turn and restart. Repeat as n e c e s s a r y , until m i n i m u m required leakage is reestablished.
CAUTION

WHEN M A K I N G G L A N D A D J U S T M E N T S , NEVER TURN GLAND NUTS MORE THAN ONE OR TWO FLATS, S U F F I C I E N T TIME SHOULD BE ALLOWED BETWEEN EACH ADJUSTMENT SO THAT C O M P R E S S I O N OF THE PACKING BY THE GLAND CAN BE REFLECTED THROUGH ALL OF THE PACKING RINGS. 7. If l e a k a g e is cut o f f c o m p l e t e l y and smoke issues from stuffing box, secure the pump, remove packing and repack with a new set, 8. Packing m u s t be replaced when gland adjustment can no longer control leakage.
CAUTION

PACKING MUST ALWAYS BE REPLACED AS A COMPLETE SET. STUFFING BOX PACKING REMOVAL 1. 2. Remove gland nuts (4-279A), washers (4-246A) and packing gland (4-016). Remove old p a c k i n g ( 4 - 0 6 4 ) and seal cage (4-014) with a packing hook.

3. Saturate a- strong absorbent piece of cloth with solvent. Using a piece of wood push cloth down and around inside of stuffing box until it is clean. 4. Check s h a f t sleeve (4-008) for wear. A small mirror and a flashlight c a n be used to check the condition of the l e n g t h of the shaft s l e e v e . If scoring is .010 inch to ,020 inch deep, the shaft sleeve must be replaced.

5 - 3

SECTION 6 MAINTENANCE

GENERAL Your pump is a precision machine. Take every precaution to avoid damage or even slight "burrs to the shaft bearing areas, as well as any other ground finished surface .when dismantling your pump. It should be understood that the i n f o r m a t i o n contained in t h i s m a n u a l does not relieve operating and maintenance personnel of the responsibility of exercising normal good . judgement in operation and care of the pump and its components, Before performing any d i s a s s e m b l y , m a i n t e n a n c e and/or inspection on the unit, the following steps should be taken and warnings observed. 1. Tag driver controls in the "off" position.

BEFORE ATTEMPTING ANY INSPECTION OR REPAIR ON THE PUMP, THE DRIVER CONTROLS M U S T BE IN THE "OFF" P O S I T I O N , LOCKED AND TAGGED TO PREVENT INJURY TO PERSONNEL PERFORMING SERVICE ON THE PUMP. 2. W A R N I N G Isolating pump.

BEFORE ATTEMPTING TO DISASSEMBLE PUMP, PUMP MUST BE ISOLATED FROM SYSTEM, BY CLOSING SUCTION AND DISCHARGE SYSTEM VALVES, DRAINED OF LIQUID AND COOLED, IF PUMP IS HANDLING HOT LIQUID. 3. A. Draining pump. If handling hot liquids.
WARNING

WHEN PUMP IS HANDLING "HOT" L I Q U I D , EXTREME CARE MUST BE TAKEN TO ENSURE S A F E T Y OF PERSONNEL WHEN A T T E M P T I N G TO DRAIN P U M P . HOT P U M P S MUST BE ALLOWED TO COOL BEFORE DRAINING. B. If handling caustic liquids.
WARNING

WHEN PUMP IS HANDLING "CAUSTIC" LIQUID, EXTREME CARE MUST BE TAKEN TO ENSURE SAFETY OF P E R S O N N E L WHEN ATTEMPTING TO DRAIN PUMP. PROTECTIVE DEVICES OF SUITABLE PROTECTIVE MATERIALS MUST BE WORN WHEN DRAINING PUMP.

6-1

C.

If on vacuum service.
WARNING

BEFORE ATTEMPTING A N Y M A I N T E N A N C E WORK ON PUMPS IN VACUUM SERVICE, PUMPS MUST BE ISOLATED FROM SUCTION AND DISCHARGE SYSTEM THEN CAREFULLY VENTED TO RETURN PRESSURE IN PUMP CASING TO ATMOSPHERIC PRESSURE. PREVENTIVE MAINTENANCE Avoid serious or t r o u b l e s o m e problems by s y s t e m a t i c maintenance checks. Study the "TROUBLE SHOOTING CHART" and "PRE OPERATIONAL CHECKS" as an aid to your maintenance program, TORQUE VALUES Torque values are listed on the Assembly Drawings included in the "PARTS ORDERING" section of this manual, They are selected to achieve the proper amount of p r e - s t r e s s in the threaded fastener. Maintenance personnel mu3t insure that threads a r e in good c o n d i t i o n Cfree of burrs, galling, dirt, e t c . ) and that c o m m e r c i a l thread lubricant is u s e d . T o r q u e should be periodically checked to assure that it is at the recommended value.
WARNING

WHEN R E A S S E M B L I N G PUMP, ALL FASTENERS MUST BE TIGHTEN TO THE PROPER TORQUE VALUE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN PERSONAL INJURY TO OPERATING PERSONNEL. COUPLING REMOVAL Remove coupling g u a r d . Remove coupling bolting and r e m o v e the s p a c e r piece (if used). Loosen set screws in coupling nut and remove n u t . The coupling hub has a shrink fit to the pump shaft. and heat will be required to remove it from the shaft. NOTE Remove pump half coupling hub by heating to approximately 300 Degrees F. in successive stages from p e r i p h e r y of coupling toward center. If equipped with a gear type coupling, NEVER APPLY AN OPEN FLAME TO COUPLING HUB TEETH. DISMANTLING PROCEDURE 1. Remove all auxiliary piping and instrumentation that will interfere with disassembly and drain oil from bearing housings.
WARNING

The use of a puller

USE EXTREME CAUTION NOT TO EXPOSE MAINTENANCE PERSONNEL TO HOT LIQUIDS WHEN REMOVING AUXILIARY PIPING OR DRAINING BEARING HOUSINGS.

6 - 2

2. Disconnect and remove temperature detectors (when supplied) from plain/ thrust end bearing housings. 3. When mechanical seal is used, loosen seal gland bolting.

THRUST BEARING REMOVAL 1. R e m o v e c a p s c r e w s (6-118C) (6-158). from support head (6-172) or end cover

Remove support head (6-172) or end cover (6-158) with gasket (6-262B) and place on blocking on floor. Remove shim pack (6-257B), NOTE Shim pack (6-257B) should be wired together for reassembly purposes. If pump is equipped with a supporting head (6-172) and a shaft driven main oil pump (6-219) the "Driver Half" and "Rubber Spider" of coupling (6-185) should be removed and wired to the supporting head. 2. Loosen cap screw (6-1 18D) in labyrinth sleeve (6-294) and slide labyrinth sleeve toward stuffing box until the "0" ring (6-456) of the labyrinth sleeve clears the bearing body and cap. 3. Remove capscrews (6 118B) and dowel pins (6-029B) from bearing cap (6-023). Remove bearing cap by rigging to eyebolt (6-333). 4. Remove out-board sealing ring (6-308), The inboard and outboard Kingsbury thrust bearing assembly .(6-325) can now be removed from the bearing body ( 6 - 0 2 1 ) . Tag a s s e m b l i e s to insure they will be returned to their original position. Refer to Kingsbury drawing and instructions in Section 8 of this manual, Remove upper half of bearing lining (6-191). Using a bar and a block of wood under pump s h a f t , raise shaft slightly and roll out the lower half bearing lining (6-191K 5. Install 1/2 inch eyebolt (provided) into bearing body (6-021) and rig to overhead h o i s t . Remove dowel pins ( 6-029 A) , capscrews (6-118A) holding bearing body (6-021) to casing and remove bearing body and place on blocking on the floor. 6. Loosen set screws (6-259B) in locknut (6-128) and remove locknut using a pin spanner wrench (not provided). 7. Remove thrust collar (6-028) and key (6-054). It may be necessary to apply heat to thrust collar to remove it. Do not allow temperature to rise above 220 Degrees F. when heating thrust c o l l a r . T e m p e r a t u r e can be checked with tempil stick. Remove shims (6-257A). Record thickness of shims and tie together to prevent shims from being separated. Remove inboard thrust bearing oil sealing ring (6-308) and labyrinth sleeve (6-294) with "0" ring (6-456) from pump shaft.
6 3

PLAIN BEARING REMOVAL 1. Loosen cap screws (5-118C) in labyrinth sleeve (5-294) and slide out of bearing body and cap until the "0" ring ( 5 - 4 5 6 ) of the labyrinth sleeve clears the bearing body and cap. Remove the coupling side labyrinth sleeve (5-294) with "0" ring (5-456) from pump s h a f t . Slide the pump side l a b y r i n t h s l e e v e (5-294) back on shaft towards stuffing box. 2. Remove bearing cap bolting (5-118B) and dowel pins (5-029B).

Remove the bearing cap (5-023), by rigging to eyebolt (5-333). Remove upper half of b e a r i n g lining (5-191). Using a bar and a block of wood under pump s h a f t , raise shaft slightly and roll out the lower half bearing lining (5-191). 3. Install 1/2 inch eyebolt (provided) into bearing body (5-021) and rig to overhead h o i s t . Remove bolting (5-118A) and dowel pins (5-029A) holding bearing body-to casing and remove bearing body (5-021). Remove the inboard labyrinth sleeve (5-294)- with "0" ring (5-456) from the pump shaft. REMOVAL OF STUFFING BOX PARTS 1. If pump is equipped with a m e c h a n i c a l seal ( 4 - 4 2 9 ) or stuffing box packing ( 4 - 0 6 4 ) , refer to "STUFFING BOX" section of this manual and remove the seal or stuffing box packing. 2. If pump is equipped with cooled stuffing box extensions (4-264), remove nuts (4-279B) and w a s h e r s (4-246B). Stuffing box extensions (4-264) with their "0" rings (4-456B) can now be removed from pump. ROTOR REMOVAL 1, Remove cap nuts (3-179) holding upper half casing to lower half. Remove dowel pins (3-029C). Using jack screws (3-118B) in lower half casing, break the seal between upper and lower half casings. Rig upper half casing to overhead hoist using two cast lifting lugs.
WARNING

THE CAST LIFTING LUGS PROVIDED ON UPPER HALF CASING ARE FOR LIFTING UPPER HALF CASING ONLY. DO NOT LIFT PUMP FROM THESE. LUGS. Carefuly lift upper half casing and place on b o a r d s to protect machined surfaces.

6 - 41

2. Using slings (that will not d a m a g e shaft) rig around shaft close to impellers. Rig rotor slings to overhead h o i s t . C a r e f u l l y lift rotor ( 3 - 1 8 4 ) from lower half casing and place on horses for further dismantling. NOTE y

Casing' wearing rings ( 3 - 0 0 6 ) , c h a n n e l rings (3-060), throttling bushing ( 3 - 4 4 1 ) , center bushing (3-407) and stuffing box bushings (3-088) (if used) will be removed with rotor.
' CAUTION

C H A N N E L RINGS ARE H O R I Z O N T A L L Y S P L I T AND ARE HELD T O G E T H E R BY MEANS OF T A P E R E D DOWEL PINS. TAKE CARE WHEN LIFTING ROTOR CHANNEL RINGS DO NOT FALL FROM ROTOR AND BECOME DAMAGED. Block rotor to prevent rolling, 3, Remove stuffing box bushings (3-088) and throttling bushing (3-441) from inboard and outboard shaft ends, . 4, Remove casing rings ( 3 - 0 0 6 ) from first stage impellers on each bank.

5, Remove channel ring3 (3-060) from impeller back ring at each impeller. Channel rings are h o r i z o n t a l l y split and are held together by taper dowel pins ( 3 - 0 2 9 B ) , It may be necessary to use a drift pin to loosen the taper dowel pins. NOTE 1-

Channel rings .are precision machined as a set, after being dowelled. They should be match marked and numbered for reassembly purposes. It is suggested that the two halves be placed back together immediately, with dowel pins (if reusable), 6, Remove center b u s h i n g ( 3 - 4 0 7 ) from center (back to back) impellers. C e n t e r bushing is h o r i z o n t a l l y split and held together by s o c k e t head capscrews (3118A) and dowel pins (3-029A).

6 - 51

DISMANTLING THE ROTOR 1, If pump.is equipped with a packed box remove the plain/thrust end shaft sleeves (4-008). A. Remove outboard retaining rings (4-397). This will

B. Pull shaft sleeve towards shaft end as far as it will go. move the shaft sleeve key (4-291) over the retaining ring groove, C. D. E. F. 2, Push shaft sleeve (4-008) back into position. Remove shaft sleeve key (4-291). . Shaft sleeve can now be removed from shaft. Remove inboard retaining rings (4-397). Remove throttling sleeve (1-440).

The throttling s l e e v e s have a shrink fit to the shaft and will have to be heated to be r e m o v e d . ' Heat throttling sleeve O.D. evenly through out its length to a p p r o x i m a t e l y 300 D e g r e e s F . r using a torch with a fine tip. A, B, C, D, Push throttling sleeve inboard (toward impeller). Remove split rings (1-252), Throttling sleeve can now be removed from end of shaft. Remove throttling sleeve key (1-291), impeller ( 1 - 0 0 3 B ) , split ring

3, Heat and remove the first right hand (1-252) and impeller key (1-011).

After impeller is heated it will have to be pushed toward the center of the p u m p , the split r i n g s (1-252) removed and the impeller quickly pulled from the end of the shaft. NOTE if

The shaft is step machined at each i m p e l l e r fit to ease the disassembly process. It is recommended that each impeller be marked with stage number to insure proper reassembly. Heat impeller per the following procedure: HEATING IMPELLERS FOR REMOVAL A, Apply h e a t (torch with fine tip) to p e r i p h e r y (outer 1.5 inches) of impeller until temperature reaches 375 Degrees F. (minimum) to 400 Degrees F, (maximum). Use tempilstick to determine temperature.. B. M a i n t a i n i n g temperature between 375 - 400 Degrees F. at the periphery, apply heat down through the vane passages, thus heating the hub.

C. Do not apply heat directly to the shaft as this will cause the shaft to expand, D. With periphery, shroud and hub at temperature, remove impeller,

E. If the impeller does not move freely off the shaft, additional h e a t m a y be n e c e s s a r y . THIS H E A T I N G SHOULD' BE STARTED AT THE P E R I P H E R Y OF THE IMPELLER NOT THE HUB. (Additional heating of the hub area at this time will t i g h t e n the impeller on the shaft, not loosen it.) If the impeller still fails to come f r e e , the impeller and shaft should be allowed to cool' comp l e t e l y and the h e a t i n g p r o c e s s repeated starting at Step A on preceeding page.

SINGLE SUCTION IMPELLER impeller bank. 5. Repeat Steps 3 and 4 until all impellers are removed on the right hand impeller bank. 6.' Remove center sleeve (1-408). 7. Continue to disassemble the impellers by repeating Steps 3 and 4 until all left hand impellers are removed from the shaft.

6-7 1

INSPECTION AND RENEWAL OF PARTS 1, Having c o m p l e t e l y dismantled the r o t o r , c h e c k the shaft for runout using n V " blocks or rollers placed under the normal bearing areas. Runout not to exceed .002" TIR. " 2. W i r e b r u s h the pump parts t h o r o u g h l y . Clean off all scale, carbon, etc, Examine parts for wearing, corrosion and erosion. 3. Check shaft s l e e v e , t h r o t t l i n g sleeve and center sleeve for w e a r . Replace if required. 4. The casing r i n g s / i m p e l l e r rings are renewable and should be replaced when b a d l y g r o o v e d , and/or when pump performance does not meet the system requirements. Whenever it becomes necessary to replace either wearing ring, both rings involved (casing ring and impeller ring) must be ordered and replaced as they are furnished standard size only (impeller rings approximately ,08 inches o v e r s i z e ) . Be sure to re-establish the original running clearance between the two wearing rings involved. A, If new casing rings are used, make sure that they seat in both the upper and lowr half c a s i n g and that the anti-rotation device is properly located in its r e s p e c t i v e lower half casing fit. The use of a scraper on the ring to casing fit will help to fit the ring to the casing, B. Impeller ring removal and installation.

Remove impeller r i n g s by removing the set screws (1-259) and machining o f f ; o r , grind two slots diametrically opposite across the face of the ring so it can be split apart. Exercise caution if. rings are removed by grinding so as not to damage impeller hubs. See sketch below.

IMPELLED RING

HAND GRINDER

IMPELLER IMPELLER RING REMOVAL

6 - 81

M a k e s u r e ring fit on impeller is free of n i c k s and b u r r s . Heat new ring to 225 Degrees F. and install on impeller. Drill and tap two new holes in impeller (located from clearance holes in ring) for N o . 10-24X1/4" set screws spaced half the circular distance from the previously used holes in the impeller. See sketch below.

SET SCREW

TYPICAL SCREW INSTALLATION FOR IMPELLER RINGS NOTE Impeller rings m u s t be m a c h i n e d to re-establish o r i g i n a l d i a m e t e r and running clearance, which can be found on Assembly Drawing. C. Dynamic balance impeller.

W h e n e v e r an impeller is tampered w i t h , (i,e, new i m p e l l e r , wear r i n g s installed etc,) the impeller must be dynamic balanced before being reassembled to shaft.

To b a l a n c e , remove m e t a l from the front or back shroud of the Impeller at the point of unbalance, The metal must be removed in such a manner that it will not d i s f i g u r e the contour of the surface from which it is removed.

GROUND

AREA

GRINDING IMPELLER FOR DYNAMIC BALANCE 5. If pump is equipped with a cooled stuffing box extension (4-264) and has a packed box a r r a n g e m e n t , the stuffing box extension will have a stuffing box bushing (4-088) tack welded in the bottom of the box. If this bushing has to be removed for any reason the tack welds will have to be ground off and bushing pressed from the extension. Do not reuse stuffing box bushing (4-088) if removed from extension for any reason. 6. 7. Clean the casing of all foreign material, Renew all gaskets and packing.

6 - 1 0 1

PARTING FLANGE GASKET R e m o v a l all t r a c e s of old gasket (2-170) material. When using any tool to remove gasket material, do not gouge or marr machined surfaces. 1. Using proper r e c o m m e n d e d 1/64" thick gasket material, locate and cut stud holes, using upper half casing as a template. 2. Lay g a s k e t on l o w e r h a l f c a s i n g , using either a gasket adhesive or a band of s h e l l a c approximately 1/2" wide on the outer edge of lower casing. 3.' P l a c e upper half c a s i n g on top of g a s k e t and a l l o w t i m e adhesive or shellac to set up. 4. Remove upper half c a s i n g . for gasket

5. Using a sharp k n i f e , cut gasket with downward strokes o n l y . Make sure all, c u t s are neat and e x a c t , e s p e c i a l l y on internal edges of casing. If t h i s is n o t d o n e , the high pressure liquid will by-pass and erode the ring fits, IMPORTANT Do not use any hammering device to cut gasket.

W H E N C U T T I N G P A R T I N G F L A N G E G A S K E T , DO NOT FORGET TO CUT OPENING FOR DISCHARGE PASSAGE.

PASSAge VIEW OF PARTING FLANGE

0,$
6-1 1

 RE-BUILDING PUMP When reassembling pump, all fasteners must be tightened to the proper torque values. Refer to "TORQUE VALUE" section of this manual. REBUILDING ROTOR

1, I n s t a l l c e n t e r stage i m p e l l e r key (1-011), into key way in shaft and p r e - f i t split rings ( 1 - 2 5 2 ) to shaft. Split rings to fit snug In g r o o v e . 2. All impeller b o r e s and s h a f t o u t s i d e d i a m e t e r s are t o b e " m i k e d " .
CAUTION

T H E I M P E L L E R TO S H A F T FIT MUST BE A MINIMUM OF .001" TO ,003" INTERFERENCE

3. H e a t the last right in the "IMPELLER REMOVAL" ler p a s t the split ring (1-252) and pull impeller

hand (1-003B), using heating procedure as outlined section, and assemble to shaft, moving the impelg r o o v e in the shaft. Quickly install split ring back to seat against split ring, NOTE /

MAKE SURE IMPELLERS ARE INSTALLED FOR PROPER ROTATION. sleeve is to be seated against the impeller hub installed in Step 35. Place casing ring (1-006) on impeller front ring,,

6. C o n t i n u e to assemble remaining right hand impellers (1-003B) per Steps 1,3 and 5 . NOTE Make sure impellers are Installed for proper rotation, 7.Assemble left hand .impellers (1-003A) per Steps 1,3 and 5, ~

8. Due to the h e a t required to assemble impellers to shaft, the "Loctite" used to secure the impeller ring set screws may have broken d o w n ,
CAUTION

ALL S E T S C R E W S ( 1 - 2 5 9 ) U S E D TO H O L D IMPELLER R I N G S TO IMPELLERS MUST BE REMOVED, "LOCTITE GRADE A W " IS TO BE APPLIED TO SET SCREWS AND SET SCREWS REPLACED. 9, I n s t a l l t h r o t t l i n g sleeve key (1-291) to shaft and pre-fit split rings ( 1 - 2 5 2 ) in shaft to fit snug in g r o o v e . Heat the throttling sleeve and slide onto shaft far'enough to expose split ring groove, Install split ring (1-252) and pull sleeve back to seat against split rings.

3 - 1 2

10. If pump is equipped with a packed box, install retaining ring (4-397) to shaft at inboard side of shaft s l e e v e . Lubricate "0" ring (4-456A) with s i l i c o n e grease and install to bore of shaft sleeve (4-008). Install shaft sleeve to shaft,
NOTE

Extreme care is to be taken when sliding shaft sleeve onto shaft not to d a m a g e "0" ring when it p a s s e s over retaining ring groove and k e y w a y . Install shaft sleeve key ( 4 - 2 9 1 ) to shaft and push into keyway in shaft sleeve, Install retaining ring ( 4 - 3 9 7 ) to shaft at outboard side of shaft sleeve. INDICATE AND DYNAMIC BALANCE ROTOR 1. Place the rotor a s s e m b l y on "V" blocks or rollers. The runout of all impeller wear rings and bushings is not to exceed .003" TIR. 2. All pump r o t o r s with m o r e than six (6) stages and/or pumps running at speeds in excess of 3600 RPM are to be dynamic balanced. The following formula is given as a guide for acceptable unbalance. N U = Accepable Unbalance in ounce inches. W = Rotor Weight, Lbs. N s Maximum Rotor Speed Refer to "INSPECTION OF PARTS" section for Grinding For Balance information. INSTALLING ROTOR IN CASING ' 1. T h e s t u f f i n g box b u s h i n g s (2-088) (if u s e d ) , t h r o t t l i n g b u s h i n g s ( 2 - 4 4 1 ) , channel rings (2-060) and center bushing (2-407) should be checked to make sure they seat in both the upper and. lower half casing and that the locating pins ( 2 - 3 1 5 ) are properly located in their respective lower half casing fits. The use of a scraper on the bushing to casing fit will help to fit the bushing to the casing. 2. Install main parting flange gasket (2-170). GASKET" instructions page. Refer to "PARTING FLANGE

3. Place the lower half of the center bushing (2-407) in lower half casing (2-001),

6 - 1 3

4. P l a c e the lower half of all channel rings (2-060) in lower half casing, in the same sequence as they were removed, NOTE C h a n n e l rings are p r e c i s i o n m a c h i n e d as a set, after being dowelled, Be sure they are reasembled as a set and with the larger end of the taper dowel pin in the upper half casing. 5. Place casing rings (2-006), throttling bushing (2-441) and stuffing box bushings (2-088) (if used) in their proper positions on pump rotor. 6. Rig rotor (2-184) to an overhead hoist. section of this manual, Refer to "LIFTING EQUIPMENT"

P o s i t i o n rotor over lower half casing and p o s i t i o n b u s h i n g s and casing r i n g s , making sure anti-rotation holes and slotts are in the down position and that they enter their respective fits in lower half casing.
CAUTION

W H E N LOWERING ROTOR INTO CASING, BUSHINGS AND CASING RINGS MUST BE PROPERLY L O C A T E D TO INSURE THE L O C A T I N G PINS (2-315) ARE ENGAGED, IF THIS IS NOT DONE, PINS COULD BE BENT OR CRUSHED. 7. Lower rotor into casing s l o w l y making sure it is seated p r o p e r l y ,

8. Install the upper half of center bushing (3-407) and seat taper dowel pins (3-029A). Install cap screws(3-118A) and tighten, 9. Install upper half of c h a n n e l rings (3-060) and seat taper dowel pins (3-029B). 1 0 . Rig upper half casing (3-002) to. an overhead hoist. EQUIPMENT" section. Refer to "LIFTING

P o s i t i o n upper half casing over lower half and lower carefully, making sure all rings and bushings enter their proper fit. Install main parting flange dowel pins (3-029C) and seat, I n s t a l l main parting flange washers (3-246) and nuts (3-179) and torque to the recommended value, NOTE M a k e sure parting flange jack screws (3-118B), in lower half casing, are backed out far enough, so as n o t to protrude above parting flange machined surface, ASSEMBLE STUFFING BOX EXTENSION If pump is equipped with a cooled stuffing box extension (4-264). it must be assembled to pump at this time. 1. Renew "O" ring (4-456B) and assemble to "O" ring groove on stuffing box extension. 6-14

2. Assemble stuffing box extension (4-264) to the casing. Assemble washers ( 4 - 2 4 1 B ) and nuts ( 4 - 2 7 9 B ) . Tighten nuts to the proper torque v a l u e .
/

CHECK ROTOR VERTICAL LIFT It is necessary to check and record the vertical lift of the rotor within the casing. "U Place a dial indicator on the upper half casing with the indicator tip resting on the top of the shaft. Zero the indicator. 2. Using a bar and a block of wood under the shaft, lift the shaft and record the movement. Take measurements at both ends of the pump. 3. The minimum c l e a r a n c e on the clearance on the assembly drawings a c c e p t a b l e vertical m o v e m e n t is the m i n i m u m back ring suction end of the pump and the minimum throttling bushing d i s c h a r g e end of the pump. For clearances, refer to the included in Section 7 of this manual.

4. If this minimum movement Is not obtained the cause must be Investigated and corrected. CHECK ROTOR AXIAL FLOAT - PACKED BOX 1. Push the rotor (3-184) toward the coupling end as far as it will g o . CAUTION DO NOT FORCE ROTOR. NOTE Some of the rotor weight may have to be supported externally. The rotor at t h i s point, is being supported by the impeller rings contacting the channel rings, 2. Place a piece of masking tape on the shaft sleeve, in the stuffing box area, at the coupling end of the pump. Place a scale across the face of the stuffing box and make a line on the masking tape. 3. Push the rotor toward outboard end as far as it will g o . mark another line on masking tape. Using s c a l e ,

4. Measure and record the total rotor end float between the two lines. The acceptable minimum end float is given on the pump assembly drawing (included in Section 7). If this minimum end float is not obtained the cause m u s t be investigated and corrected. Two of the most likley causes could be; A. B. Impellers not properly seated against their split ring, Improperly machined part ie. impeller ring or channel ring.

5. Mark another line m i d w a y between the first two lines. This "Center" l i n e r e p r e s e n t s the centering of the i m p e l l e r s within their v o l u t e s . Masking tape is to be left on shaft for use in the "CENTRALIZE ROTOR AXIALLY" instructions.
6 - 1 5

CHECK ROTOR AXIAL FLOAT - MECHANICAL SEAL 1. Push the rotor (3-184) toward the coupling end as far as it will go.
CAUTION

DO NOT FORCE ROTOR. NOTE Some of the rotor weight may have to be supported externally. The rotor at t h i s point is being supported by the impeller rings contacting the channel rings, 2. Place a piece of masking tape on the shaft in the mechanical seal (429) area, at the coupling end of the pump. Place a scale across the face of the mechanical seal and mark a line on the masking tape, 3. * Push the rotor toward outboard end as far as it will g o . mark another line on masking tape. Using scale,

4. Measure and record the total rotor end float between the two lines. The acceptable minimum end float is given on the pimp assembly drawing (included in Section 7). If this minimum end float is not obtained the cause must be investigated and corrected. Two of the most likley causes could be: A. B, Impellers not properly seated against their split ring. improperly machined part ie, impeller ring or channel ring.

5. Mark another line m i d w a y b e t w e e n the first two lines. This "Center" l i n e r e p r e s e n t s the c e n t e r i n g of the impellers within their v o l u t e s . M a s k i n g tape is to be left on 'shaft for use in the "CENTRALIZE ROTOR AXIALLY" instructions, HORIZONTAL AND VERTICAL SHAFT ALIGNMENT 1. If pump is equipped with a packed stuffing box and a seal cage (4-014) is u s e d , the seal cage is to be assembled to shaft and temporarily postioned on shaft sleeve, 2. Assemble Plain Bearing

A. Install new "0" ring (5-456) to pump side labyrinth sleeve (5-294) and slide labyrinth sleeve onto pump shaft and place in approximate position. NOTE If pump is equipped with a mechanical seal, labyrinth sleeve (5-294) should not be assembled at this time,

6-16

B. Rig bearing body (5-021) to overhead hoist as done during disassembly. A s s e m b l e bearing body ( 5 - 0 2 1 ) to c a s i n g . I n s t a l l dowel p i n s ( 5 - 0 2 9 A ) and snug down capscrews (5-118A). Install both the horizontal and vertical adjusting screws (5-259) in the bearing body mounting flange. Remove dowel pins (5-029A). . NOTE When assembling bearing body to casing, ensure labyrinth sleeve is properly positioned with the inner part of the bearing housing (refer to Assembly Drawings). C. Wipe a film of oil on lower half of b e a r i n g lining (5-191) and pump shaft Journal area, Roll in lower half bearing lining, 3. Assemble Thrust Bearing

A. Install shim pack ( 6 - 2 5 7 A ) against s h o u l d e r of shaft. If shim pack t h i c k n e s s was not recorded at disassembly or if rotor was rebuilt completely, install approximately 1/16" of shims, B. Install new "0" ring ( 6 - 4 5 6 ) to l a b y r i n t h sleeve ( 6 - 2 9 4 ) and slide labyrinth sleeve onto pump shaft and place in approximate position, NOTE If pump is equipped with a mechanical seal, labyrinth sleeve (6-294) should not be assembled at this time. C. Assemble thrust collar key (6-054) and "dummy thrust collar" to shaft. Secure "dummy thrust collar" with locknut (6-128). NOTE It is recommended a "Dummy T h r u s t Collar" (not f u r n i s h e d ) be used when making rotor settings. "Dummy Thrust Collar" - A thrust collar with the same 'physical dimensions as thrust collar (6-028) e x c e p t the bore is opened up so it has a slide fit with pump shaft (.0005 to .0010 loose), D. Rig the thrust b e a r i n g body (6-021) to overhead hoist as done during disassembly. Assemble thrust bearing body (6-021) to casing. Install dowel pins (6-029A) and snug down capscrews (6-118A). Install both the horizontal and vertical adjusting s c r e w s (6-259A) in b e a r i n g body mounting flange. Remove dowel pins (6-029A). NOTE When assembling bearing body to casing, ensure labyrinth sleeve is properly positioned with the inner part of the bearing housing (refer to Assembly Drawings),

6 - 1 7

E. Wipe a film of oil o n - l o w e r half of bearing lining (6-191) and pump shaft Journal area. Roll in lower half bearing lining. Using a a d j u s t the b e a r i n g end stuffing box set of inside spring calipers and the adjusting screws (5-259A), horizontal and vertical position of the shaft at the plain so that the distance between the shaft sleeve or shaft and the bore is the same all the way around,

5. Repeat Step 4 on thrust end then recheck plain end. Pump shaft should turn free with no indication of binding or rubbing. This should be taken into consideration when making adjustments. 6, When vertical and h o r i z o n t a l alignment is obtained, tighten bearing h o u s i n g bolting except the two top bolts at the adjusting screws. Ream d o w e l h o l e s and install d o w e l pins (5-029A) and (6-029A). Loosen adjusting screws and tighten the two top bearing housing bolts. CENTRALIZE ROTOR AXIALLY 1. Pour a small amount of oil on "Dummy Thrust Collar"'and thrust shoes. I n s t a l l inboard Kingsbury t h r u s t bearing assembly ( 6 - 3 2 5 ) . Push rotor toward coupling as far as it will go (tight against inboard thrust bearing assembly). NOTE Refer to Kingsbury Drawing and Instructions in Section 8 of this manual.

2. Place a scale across the face of the coupling end stuffing box. Measure the d i s t a n c e from the edge of the scale to the "Center" line on the masking tape as marked ,in Step 5 of "CHECK ROTOR AXIAL FLOAT" instructions. T h i s d i s t a n c e is how far the rotor is to be moved either inboard or outboard , 3. To move rotor inboard (toward coupling end), shims (6-257A) will have to be added between thrust c o l l a r and shoulder of shaft. To move rotor outboard (toward thrust end) shims will have to be removed. Add or remove shims until rotor is centralized and r e m o v e m a s k i n g tape, 5. If pump is equipped with a packed box, skip Steps 2,3,5,6,10,12 and 15 of the "FINAL BEARING ASSEMBLY" instructions, FINAL BEARING ASSEMBLY 1. 2. 3. Remove inboard thrust bearing assembly (6-325). Remove both lower half bearing linings (5-191) and (6-191). Remove both bearing bodies (5-021) and (6-021). Remove thrust' collar lock nut (6128) and "Dummy Thrust Collar".

6 - 1 8

5. Install both c o m p l e t e l y assembled mechanical seals (4-429) to shaft. Insert into stuffing box. Do not tighten gland nuts (4-279A) or mechanical seal drive collar set screws at this time.
CAUTION

CARE MUST BE TAKEN NOT TO DAMAGE SHAFT SLEEVE r 0 n RING WHEN SLIDING MECHANICAL SEAL. (4-429) OVER SHAFT KEYWAYS-AND SPLIT RING GROOVES. 6. Position inboard labyrinth sleeves (5-294 and 6 - 2 9 4 ) and o u t b o a r d labyrinth sleeve (5-294) on shaft at their approximate positions. 7. Slide inboard thrust bearing seal ring (6-308) over shaft. shaft in its proper position. (Refer to Pump Assembly Drawing.) Rest it on

8. Insure the proper t h i c k n e s s of shims ( 6 - 2 5 7 A ) are seated against the shaft shoulder. 9. Install t h r u s t c o l l a r key (6-054), thrust collar (6-028) and lock nut (6-128). Tighten lock nut and tighten set screws (6-259B) in lock n u t . NOTE Before installing thrust collar (6-028) onto shaft, heat the thrust collar to 220 Degrees F, (max,) in successive stages working from periphery toward center, 1 0 . Rig bearing b o d i e s (5-021 and 6 - 0 2 1 ) to overhead h o i s t . Assemble bearing bodies (5-021 and 6-021) to casing. Install dowel pins (5-029A) and (6-029A) snug down bolting (5-118A and 6-118A). Seat dowel pins. NOTE When assembling b e a r i n g b o d i e s to casing, ensure labyrinth sleeves (6-294 and 5 - 2 9 4 ) are properly positioned with the inner part of the b e a r i n g housing (refer to Assembly Drawing). 11. Tighten b e a r i n g body to casing bolting ( 5 - 1 1 8 A ) and (6-118A) to the proper torque value, NOTE Insure dowel pins (5-029A) and (6-029A) are properly seated. 12. Pour a small amount of oil on bearing lining (5-191) and shaft journal area. Roll lower half of bearing lining under shaft, 13. Place upper.half of bearing lining (5-191) in position on top of shaft. 14. Ensure bearing body ( 5 - 0 2 1 ) and bearing cap (5-023) parting flange surfaces are clean and free of previous gasket (5-262) material. Install new gasket (5-262). Assemble bearing cap (5-023) to bearing body. Install dowel pins ( 5 - 0 2 9 B ) and tighten capscrews (5 118B) to the proper torque value.

6 - 1 9

15. Assemble*lower half of bearing lining (6-191) to thrust bearing body in same manner as Step 12. 16. Position upper half of bearing lining (6-191) in same manner as done in Step 13. 1 7 . Assemble outboard t h r u s t b e a r i n g oil seal ring (6-308) to shaft and temporarily assemble s u p p o r t head (6-172) or end cover (6-158) to bearing body. Secure with two capscrews (6-118C). 18. Pour a small amount of oil on thrust collar (6-028) and thrust bearing assembly (6-325). Assemble inboard and outboard thrust bearings to bearing body. (Refer to Kingsbury Drawing and Instructions included in Section 8 of this manual,) NOTE Rotate base ring so the "keys" of the base ring enter their keyways at the parting flange in the bearing body. 19. Ensure bearing body ( 6 - 0 2 1 ) and bearing cap ( 6 - 0 2 3 ) parting flange surfaces are clean and free of previous gasket (6-262A) material. Install new gasket (6-262A). A s s e m b l e bearing cap (6-023) t o bearing b o d y . Install dowel pins ( 6 - 0 2 9 C ) and tighten capscrews (6-118C) to the proper torque value. SET THRUST BEARING AXIAL END PLAY 1. Remove end cover (6-158) or support head (6-172) from bearing body. If pump is equipped with a support head and shaft driven main oil pump (6-219), assemble "driver half" of coupling (6-185) to pump shaft. 2. Place shims (6-257B) a g a i n s t outboard thrust b e a r i n g "base r i n g " . Assemble end cover to bearing body and cap. Tighten capscrews (6-118C) to proper torque value. 3. Install a dial indicator on coupling end bearing housing so the indicator contacts the end of the shaft. Push the rotor outboard (towards thrust b e a r i n g ) and set indicator at zero. Push rotor inboard. Indicator should read ,010" (0.25mm) to .015" ( 0 . 3 8 m m ) . Add or remove shims (6-257B) to obtain proper end play, Coat end of bearing body and cap with permatex and reassemble end cover, torque and recheck end play. FINAL ASSEMBLY 1. Position labyrinth sleeves (5-294 and 6-294) in their proper locations in the plain/thrust end bearing body/caps. Install capscrews (5-118C and 6-118D) and tighten to proper torque value. 2. If pump is equipped with shaft driven oil pump (6-219). assemble "driven half" of coupling ( 6 - 1 8 5 ) to oil pump. Position "coupling spider" in the driver half coupling. Assemble oil pump (6-219) with its gasket (6-262C) to supporting head. Tighten nuts (6-258B) to the proper torque value.

6 - 2 0

3. If pump is equipped with a mechanical seal (4-429), insure mechanical seal gland is seated properly in stuffing box bore. Assemble gland washers (4-246A) and tighten gland nuts (4-279A) to the proper torque value, NOTE Refer to "STUFFING BOX" section of this manual. 4, Using a strap, rotate pump shaft to be sure rotor is properly aligned and does not bind. CAUTION DO NOT ROTATE PUMP SHAFT EXCESSIVELY, BEING PUMPED FOR LUBRICATION. INTERNAL PARTS DEPEND ON THE LIQUID

5. If pump is equipped with a packed box, refer to "STUFFING BOX" section of this manual and assemble stuffing box packing (4-064), seal ca'ge (4-014) if used, and packing gland (4-016), Install washers (4-246A) and nuts (4-279A). 6. Install coupling key, pump half coupling, coupling nut and set coupling nut set screws. (Refer to "COUPLING REMOVAL" section). 7. Check coupling/shaft alignment as described under "ALIGNMENT PROCEDURE" and assemble coupling. 8. 9. Install coupling guard. Replace all auxiliary piping, instrumentation and pipe plugs.

10. Install -the rmo coup lies (when supplied) in plain/thrust end bearing housings and have an electrician reconnect wiring, 11. Fill oil r e s e r v o i r (refer to " L U B R I C A T I O N " section i n s t r u c t i o n s ) ,
I

12. Refer to "OPERATION" Section for starting procedure.

6 - 2 1

NOUN CODE 003A 0038 006 010 011 262 291 408 440

PART NAME
4

IMPELLER ASSEMBLY UK I M P E L L E R A S S E M B L Y R.H. R I N G - CASING SHAFT KEY - IMPELLER R I N G - SPLIT KEY - THROTTLING StEEVE C E N T E R SLEEVE SLEEVE - THROTTLING

* I M P E L L E R A S S E M B L Y 0C3A/B CONSISTS OF 0C3 034 006 259 IMPELLER RING - IMPELLER (FRONT) RING - IMPELLER (BACK) SET SCREW

EXPLODED VIEW #1 T Y P I C A L ROTOR ASSEMBLY DA PUMP

N O U N CODE 021 023 028 029A 029B 054 097 118A 118B 118C. 118D ' 128 158 172 178 185 191 219 2S7A ?57B 2SSA 2S8B 259A 259B ?62 A 262B 262C 294 308 315A 3 ) SB 325 333 417 456

PART NAME B E A R I N G BODY . B E A R I N G CAP THRUST COLLAR D O W E L PIN IBRG. BODY T O C A S I N G ) " D O W E L PIN IBRG, CAP TO B O D Y ) K E Y - THRUST C O L L A R B R E A T H E R CAP CAP SCREW (BRG. B O D Y TO C A S I N G ) CAP SCREW (BRG. CAP TO B O D Y ) , CAP SCREW (END COVER TO H O U S I N G ) CAP SCREW ( L A B Y R I N T H S L E E V E ) L O C K NUT ( T H R U S T C O L L A R ) B E A R I N G END COVER SUPPORTING HEAD S T U D ( M A I N OIL PUMP) C O U P L I N G ( M A I N OIL PUMP) BEARING LINING M A I N O I L PUMP S H I M - (THRUST C O L L A R ) S H I M - { T H R U S T BRG.) N U T {DOWEL PIN) N U T ( M A I N OIL PIN) SET SCREW (BRG BODY A D J U S T I N G ) SET SCREW (LOCK N U T ) G A S K E T - (BRG BODY TO CAP} G A S K E T - (END C O V E R ) G A S K E T - ( M A I N OIL PUMP) L A B Y R I N T H SLEEVE S E A L R I N G (THRUST B E A R I N G } L O C A T I N G PIN (BRG. L I N I N G ) L O C A T I N G PIN ( E N D COVER) KINGSBURY THRUST BEARING EYE B O L T PIPE P L U G O-RING ( L A B Y R I N T H SLEEVE)

"

-1

.EXPLODED VIEW #6 THRUST BEARING SLEEYF/K.T.B. - FORCE FEED

LUBE

-2?

noun code 006 170 194 315 407 441

p a r t name LOWER HALF CASING R I N G - CASING CHANNEL RING {LOWER HALF) STUFFING BOX BUSHING GASKET - MAIN PARTING FLANGE ROTOR COMPLETE LOCATING PIN CENTER BUSHING (LOWER HALF) T H R O T T L I N G BUSHING

001 060

oea

t h i s STUFFING BOX BUSHING IS NOT USED WITH A COOLED STUFFING BOX EXTENSION IN COMBINATION w i t h a PACKED BOX

E X P L O D E D V I E W 02 ASSEMBLY OF LOWER HALF BUSHINGS AND ROTOR TO CASING DA P U M P

N O U N CODE 001 002 006 029A 029B 029C 060 088 H8A 11BB 170 178 179 184 246 4Q7 417 441

PART N A M E LOWER H A L F CASING UPPER H A L F CASING RING - CASING DOWEL PIN (CENTER BUSHING) DOWEL PIN ( C H A N N E L RING) DOWEL PIN (CASING) C H A N N E L RING (UPPER HALF) S T U F F I N G BOX BUSHING CAP SCREW (CENTER BUSHING) SCREW - JACKING GASKET ( M A I N PARTING FLANGE) STUD ( M A I N PARTING FLANGE) CAP N U T ( M A I N PARTING FLANGE) ROTOR COMPLETE WASHER ( M A I N PARTING FLANGE) CENTER BUSHING (UPPER HALF) PIPE PLUG THROTTLING BUSHING-

' THIS S T U F F I N G BOX BUSHING IS NOT USED W I T H A COOLED S T U F F I N G BOX E X T E N S I O N IN COMBINATION WITH A PACKED BOX

2 >

246

029C

002

EXPLODED VIEW #3 A S S E M B L Y O F UPPER- H A L F B U S H I N G S AND C A S I N G DA P U M P 6-24

'

ST

333

NOUN CODE 021 023 029A 029B 097 118A 118B 118C 191 258 259 262 333 417 466

PART NAME BEARING BODY BEARING CAP DOWEL PIN (BRG. BODY TO CASING) DOWEL PIN {BRG. CAP TO BODY) BREATHER CAP CAP SCREW (BRG, BODY TO CASING) CAP SCREW (BRG. CAP TO BODY) CAP SCREW (LABYRINTH SLEEVE) BEARING LINING NUT (DOWEL PIN) SET SCREW (BRG, BODY ADJUSTING) GASKET 294 LABYRINTH SLEEVE 315 LOCATING PIN EYE BOLT PIPE PLUG O-RING (LABYRINTH SLEEVE)

294

417

EXPLODED SLEEVE BEARING -

VIEW FORCE

#5 FEED LUBE 6-26

N O U N CODE 178
183

part

name

S T U F F I N G BOX STUDS CASING COMPLETE ROTOR COMPLETE PACKED BOX

008
016
014 064 118 2*6 A 279 A 417 456A
291 397

S H A F T SLEEVE SEAL CAGE GLAND PACKING CAP SCREW ( G L A N D ) G L A N D WASHER GLAND NUT K E Y - SHAFT SLEEVE retaining ring PIPE PLUG O - R I N G (SHAFT SLEEVE)

CARTRIDGE SEAL 279A 429

246A

G L A N D WASHER GLAND NUT M E C H A N I C A L SEAL COMPLETE

COOLED S T U F F I N G BOX EXTENSION

88 264B 279B 456B

* S T U F F I N G BOX BUSHING WASHER S T U F F I N G BOX EXTENSION NUTS O - R I N G (STUFFING BOX EXTENSION)

USED O N L Y W I T H A P A C K E D BOX

pacced BOX: COCLed STUFFING BOX

SEAL

EXTENSION

CARTRIDGE

EXPLODED VIEW STUFFING BOX P A R T S DA PUMP

6-2 5

.J