Pump JLine M2

RUHRPUMPEN INC.SPECIFICATION

INSTALLATION, OPERATION, ANDMAINTENANCE MANUAL FOR HORIZONTAL

PROCESS J, JL, & JS PUMPS WITHBALL/BALL CONSTRUCTION

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Installation, Operation andMaintenance of J, JL, and JS

Pumps with Ball / BallConstruction

Ruhrpumpen, Inc.Tulsa, Oklahoma, USA




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DURING INITIAL STARTUP OF THIS EQUIPMENT, IT IS ESSENTIAL THAT ALL OF THEINSTRUCTIONS IN THIS MANUAL BE ADHERED TO STRICTLY. IT IS RECOMMENDED THATTHE SERVICES OF A RUHRPUMPEN SERVICE TECHNICIAN BE OBTAINED TO ASSURETROUBLE-FREE OPERATION.IN SOME CASES, START-UP IN THE PRESENCE OF A RUHRPUMPEN SERVICETECHNICIAN MAY BE A CONTRACTUAL REQUIREMENT FOR CONTINUATION OFWARRANTY. CHECK YOUR CONTRACT.TO SCHEDULE A SERVICE TECHNICIAN, CONTACT RUHRPUMPEN INC. SALES OFFICE AT1-800-334-2553.

PREFACEThis manual contains instructions for installation, operation, maintenance, and servicing of yourRuhrpumpen Centrifugal Pump. It has been designed to provide safe and reliable service. It isboth a pressure vessel and a rotating machine; therefore, the Operators must exercise goodjudgement and proper safety practices to avoid damage to the equipment, surroundings, andprevent personal injury.The instructions in this manual are intended for the guidance of personnel with a general trainingin operation and maintenance of centrifugal pumps. It is our hope that you will become acquaintedwith its content as an aid to better pump performance. This manual should be read in its entiretybefore installing and/or operating the equipment. The outline and assembly drawings should beconsulted for accurate details and determination of specific optional features that are furnishedwith your pump. All numbers in parenthesis () following part names corresponding to the partnumbers on the assembly drawing.

SAFETYIt is assumed that your Safety Department has established a safety program based upon athorough analysis of industrial hazards. Before installing, operating, or performing maintenance onthe pump and associated components described in this manual, the safety program must bereviewed to ensure that it covers the hazards arising from high-speed rotating machinery.It is important that due consideration be given to those hazards which arise from the presence ofelectrical power, hot oil, high-pressure high-temperature liquids, toxic liquids or gases, and/orflammable liquids or gases. Proper installation and care of protective guards, shutdown devices,and over-pressure protection equipment shall also be considered an essential part of any safetyprogram.Also essential are special precautionary measures to prevent the possibility of applying power tothe equipment at any time when maintenance work is in progress. The prevention of rotation dueto reverse flow must not be overlooked.In general, all personnel should be guided by all of the basic rules of safety associated with theequipment and the process.




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READ BEFORE PROCEEDING FURTHER:Throughout this manual you will encounter the words WARNING, CAUTION, and NOTE. Theseare intended to emphasize certain areas in interest of operator safety and satisfactory pumpoperation/maintenance. The definitions of these words are as follows:

NOTE: An operating procedure, condition, etc. which is essential to highlight.

CAUTIONAn operating procedure, practice, etc. which, if not strictly observed, could result indamage to, or destruction of, equipment.

WARNINGAn operating procedure, practice, etc. which, if not correctly followed, could result inpersonal injury or loss of life.




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TABLE OF CONTENTSEXTENDED STORAGE REQUIREMENTS FOR HORIZONTAL PUMPS 7

General 7Inspection Upon Arrival 7Storage Area 7Storage Preferred (Dry) 7Rotor Storage 8Inspection and Maintenance 8Storage Non-Preferred (WET) 9Painting and Preservation 9Start-Up 9Drivers 9

INTRODUCTION 10Description 10Detail Description 10Casing 10Impeller 10Casing Rings / Impeller Rings 10Shaft 10Ball Bearings 10Impeller Nuts 10Mechanical Seal Units 10Coupling 10

INSTALLATION 11Check Upon Arrival 11Care During Storage 12Rust Preventive 12Cleaning the Pump 12

LOCATION 12FOUNDATION 12

Lifting 13INSTALLATION SEQUENCE 14LEVEL THE BASEPLATE 14GROUTING 15SHAFT / COUPLING ALIGNMENT 16

Types of Misalignment 16Alignment 17Horizontal Move 19Vertical Move 19Check Coupling Alignment 20Assemble and Lubricate Coupling 20Dowel Pump and Driver 20Hot Alignment Check 21Alignment Data Sheet (Sheet 1 of 2) 22Alignment Data Sheet (Sheet 2 of 2) 22Example 23




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PIPING 24Main Piping 24Minimum Flow By-Pass 24Seal Piping 24

SUCTION STRAINER 24LUBRICATION 26

Make Periodic Inspections 26Oil Specifications 27ASTM Standards 27Constant Level Oiler 27Pure Oil Mist Lubrication 27

OPERATION 29Initial Start-Up 29Normal Start-Up 31Operating Checks 31Securing the Pump 31

TROUBLESHOOTING 32DISMANTLING PROCEDURE 33

Coupling Removal 33Radial Bearing Removal 33Thrust Bearing Removal 34

ROTOR REMOVAL 34Dismantling of Rotor 35Impeller for Removal 35

INSPECTION OF PARTS 36Casing Rings / Impeller Rings 36

BEARING HANDLING INFORMATION 37Handling 37Installation 37Removal 38Cleaning 38

REASSEMBLE 38Reassemble the Rotor 38Check Rotor for Run Out 38Installing Rotor Assembly in Casing 39Horizontal and Vertical Alignment 39Set Thrust Bearing End Play 40Initial Thrust Bearing Assembly 40Final Thrust Bearing Assembly 40Final Radial Bearing Assembly 41Final Assembly 41

ORDERING INSTRUCTIONS 42RECOMMENDED SPARE PARTS 42




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EXTENDED STORAGE REQUIREMENTS FOR HORIZONTAL PUMPSGENERALDuring extended periods of storage prior to installation and from the time of installation until commercial operation,precautions must be taken to protect the pump from deterioration. The various parts of the pump are protected prior toshipment by applying varied grades of preservative and paint. However, during shipment and handling, thepreservatives are subjected to conditions that can cause their removal. During extended periods of time, thepreservatives may deteriorate. The following procedures should be followed to prevent deterioration of the pumpduring the extended storage period. These procedures may also be supplemented by the experience of the person(s)performing the tasks.

It should be noted that unless otherwise agreed to, full responsibility and costs associated with the storage andinspection of this equipment rests with the customer.

CAUTIONIF PUMP IS EQUIPPED WITH A MECHANICAL SEAL AND IS STORED OR HAS NOT BEEN RAN FOR ONE (1)YEAR OR MORE, THE MECHANICAL SEAL MUST BE REMOVED BEFORE START-UP AND FACES RE-LAPPEDTO GUARD AGAINST THE POSSIBILITY OF SEAL LEAKAGE. WHEN REINSTALLING THE SEAL, NEW ORINGS AND GASKETS MUST BE USED.

INSPECTION UPON ARRIVALNOTE: The following information regarding receiving is only offered as a general guide to the customer.

Ruhrpumpen, Inc. requires that all receiving be conducted in accordance with the specifications setforth in Chapter 3 Jobsite Receiving and Protection from API Recommended Practices 686/PIP REIE686, First Edition.

When the pump is received, it should be inspected for damage or other signs of rough handling. Any damage foundshould be reported to the carrier immediately.

Inspect the preservative coating on the various parts. If necessary, renew the preservative in areas where it has beenrubbed off or scraped.

Inspect all painted surfaces. If necessary, touch up the areas where paint has been chipped or scraped.

Inspect all covers over pump openings and piping connections. If covers or seals for the covers are damaged or loose,they are to be removed and a visual inspection made of the accessible interior areas for accumulation of foreignmaterials or water. If necessary, clean and re-coat the interior parts with preservative to restore the parts to the asshipped condition. Install or replace covers and fasten securely.

STORAGE AREAWhen selecting a storage area, the following should be taken into consideration:

1. The deterioration of the equipment will be proportionate to the class/type of storage provided.2. The expenses involved in restoring the equipment at time of operation will be proportionate to the class/type of

storage provided.

STORAGE PREFERRED (DRY)If at all possible, the pump and its components should be stored indoors where they will be protected from theelements. If it is not possible to store the pump and its components indoors, precautions must be taken to protect themfrom the elements. Regardless of whether storage is inside or outside, the storage area should be vibration-free. Allboxes that are marked for inside storage must be stored indoors. The pump and components when stored outdoorsshould be protected from dirt, dust, rain, snow, or other unfavorable conditions by coverings of heavy-gauge plasticsheets, canvas, waterproof burlap or other suitable coverings.

All equipment must be placed upon skids or blocks to prevent contact with the ground and surface contaminants.Equipment must be adequately supported to prevent distortion and bending.




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ROTOR STORAGEIt is recommended that pump rotor be stored in the pump. Multistage diffuser-type pump rotors that cannot be storedin the pump must be supported at the channel rings so that rotor weight is evenly distributed. Single-stage and volute-type pump rotors not stored in pump must be supported close to impeller(s) to eliminate sag that may cause rotor totake a permanent set.

INSPECTION AND MAINTENANCE1. Customer Inspection and Maintenance

The stored equipment is to be placed on a periodic inspection schedule by the customer.

NOTE: The responsibility for setting up an inspection and maintenance schedule rests with the customer and willbe dependent upon the class/type of storage provided. It would be expected that initial inspection wouldoccur weekly. Then depending upon the inspection reports being favorable or unfavorable, inspectionwould continue weekly, monthly, or quarterly, as may be determined. Inspection reports must be kept onfile.

Each inspection should consist of a general surface inspection.a) Pump supports are firmly in place.b) Pump covers over openings are firmly in place.c) Pump covering, plastic or tarps, are firmly in place. Any holes or tears must be repaired to prevent entrance of dirt or

water.d) Pump rotors stored in pump should be rotated 1-1/4 revolutions at least once a week to prevent rotor from taking a

permanent set.

CAUTIONIF PUMP IS EQUIPPED WITH SLEEVE BEARINGS, THE OIL RING INSPECTION PLUG ON TOP OF THEBEARING HOUSING IS TO BE REMOVED AND A SMALL AMOUNT OF OIL POURED OVER THEJOURNALS BEFORE TURNING.

Single-stage and volute-type pump rotors stored separately should be rotated 1-1/4 revolutions weekly.e) Pump covers are periodically removed from openings and interior accessible areas inspection. If surface rusting has

occurred, clean and repaint or re-coat with preservative.f) If rusting occurs on exterior surfaces, clean, and repaint or re-coat with preservative.g) Loosen casing drain plugs to allow seepage of any accumulated moisture.h) Periodically remove bearing covers and inspect for accumulation of moisture, rust and foreign material. As required,

clean bearings and bearing housing and represerve. Install bearing cover and secure to assure maximum protection.Bearings removed for storage should be coated with preservative, wrapped in oil/wax paper, and stored in a warm dryarea.

i) Check individually wrapped parts for signs of deterioration. If necessary, renew preservative and wrapping.

2. Six Months Prior to Installation

Six months prior to the scheduled installation date, a Ruhrpumpen Representative is to be employed to conductan inspection. All costs involved during inspection, dismantling, restoration, replacement of parts, andreassembling will be the responsibility of the customer. The customer will supply all necessary labor, tools, andcranes. This inspection will include (not necessarily in its entirety), but not be limited to, the following:a) An inspection of all periodic inspection records as kept on file by the customer and all inspection reports that have been

compiled during the storage period.b) An inspection of the storage area to determine the as stored condition of the equipment prior to any protection covers

being removed.c) An inspection of the equipment with protection covers and flange covers removed.d) Depending upon the length of time the equipment was stored, the class/type of storage provided, (i.e. indoor, heated,

unheated, ground floor, concrete floor, out-of-doors, under roof, no roof, waterproof covering, on concrete, on ground)and as a result of the inspection of a, b, and c above, the Ruhrpumpen Representative may require a partial orcomplete dismantling of the equipment.




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e) Dismantling may necessitate restoration of painted or preserved surfaces and/or replacement of gaskets, o-rings,packing, and/or machanical seal and bearings.

Upon completion of the inspection, the Ruhrpumpen Representative shall submit a report to the customer and tothe Manager of Customer Service stating, in detail, the results of the inspection.

3. One Month Prior to Installation

One month prior to installation of the equipment, a Ruhrpumpen Representative is to be employed to conduct afinal inspection. This final inspection will be made to assure that the requirements of the six-month inspectionreport were satisfactorily completed and that the equipment is ready for installation.

Upon completion of this inspection, the Ruhrpumpen Representative shall submit a final report to the customerand to the Manager of Customer Service advising the results of the final inspection.

STORAGE NON-PREFERRED (WET)It is not recommended that the rotor be subjected to extended periods of submerging or wetting prior to start-up.However, it is recognized that in some cases, a long period of time may lapse from installation until commercialoperation.

If the pump must be stored after being installed and wetted, the following inspection and maintenance proceduresshould be performed.

1. Isolate the pump with valving tag (seal) all valves.

2. Preserve the pump internals.a) Corrosive Pumpage fill pump with a 1% solution of Immunol 1809 and water (or owner approved preservative).

Immunol is a water-phase corrosion inhibitor for ferrous and mixed-metal couples and is composed of 5% sodium nitritewith polyglycois, copper corrosion inhibitor, and other organic materials. The pump should be filled to highest levelpossible, affording the greatest protection possible to all internal parts of the pump. This solution, when drained, willresult in a thin residual oil film (less than .0005) on all internals after the water has evaporated. This residue providesadded corrosion protection until pump is again filled with liquid or put into service.

b) Non-Corrosive Pumpage fill pump with pumpage to the highest level possible. Periodically open drain connection todrain off any moisture that may have accumulated. Refill to highest level possible. Drain and inspect pump prior tostart-up.

3. Rotate pump rotor 1-1/4 revolutions at least once a week. Make sure bearings have adequate lubrication beforeturning rotor.

4. Periodically remove bearing covers and inspect for accumulation of moisture, rust and foreign material. Asrequired, clean bearings and bearing housing and represerve. Install bearing cover and secure to assuremaximum protection.

PAINTING AND PRESERVATIONPaints and preservatives used are either Ruhrpumpen standard or special as required by the contract specification.Refer to RUST PREVENTIVE for the description of paints and preservatives used on this order or contact the branchoffice through which the order was placed.

START-UPPrior to and during start-up, any requirement for the service of a Ruhrpumpen Representative will revert to the originalcontract agreement for the equipment that was purchased.

DRIVERSGenerally storage must be indoors and dry. See the specific manufacturers storage requirements.




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INTRODUCTIONThis instruction book was written for your guidance. It is our hope you will become acquainted with itscontents as an aid to better pump performance. The Sectional Assembly and General Arrangementdrawings furnished should be consulted for accurate details.

DESCRIPTION (Refer to Sectional Assembly Drawing)The pump is a single stage, double suction, dual volute pump with top suction and top discharge nozzles. Shaft sealingis accomplished via a mechanical seal unit (120 and 120-1) located in each pump stuffing box. The shaft is supportedon pure oil mist lubricated radial ball bearing and ball thrust bearings. Axial thrust of the pump is absorbed by a doublerow thrust ball bearing (654).

DETAIL DESCRIPTION (Refer to Sectional Assembly DrawingCASING (001) The case (001) is radial split and centerline mounted. The

casing contains side suction and discharge nozzles, plus drainconnections.

IMPELLER (176) The impeller is a cast in one piece to provide proper vane shapeand finish for high efficiency. The impeller is of the doublesuction type.

CASING RINGS (205)/IMPELLER RINGS (201) Replaceable type wear rings are provided. The casing rings(205) are mounted in machined fits in the casing (001) and pumpcover (051). Each casing ring is secured in position by headlessset screws. The impeller (176) front/back hubs are each filledwith an impeller ring (201) locked in position by headless setscrews.

SHAFT (167) The high strength shaft (167) is machined over its entire lengthfor close tolerances. The shaft is designed to transmit therequired power without vibration.

BEARINGS (654 & 655) The radial ball bearing (655) and thrust bearings (654) are eachlubricated by means of reclassifiers (612/612-1) which spray oilmist on ball bearings to provide lubrication (Pure Oil Mist) in theoil reservoir of each respective bearing housings (277/278).The radial ball bearing (655) is single-row, deep-groove bearing,free to adjust axially in the bearing housing. The radial bearingis held in place by a lock wahser (673) and lock nut (878).The thrust ball bearing (654) is of the duplex ball bearing with aslight interference fit on the shaft (167). The thrust ball bearingsare held in place by a lock washer (673-1) and lock nut (878-1).Each bearing housing (278) is equipped with a trico oiler.

SPACER SLEEVES (225) AND IMPELLER NUT(246)

Renewable spacer sleeves (225) form a portion of the hydraulicchannel at the eyes of the double suction impeller (176). Thesleeves are tubular type and keyed to the shaft (167) by theimpeller key (676). The spacing sleeves and shaft sleeve nuts(246) aid in locking the impeller in correct position on the shaft.

MECHANICAL SEAL UNITS (120 AND 120-1) Each pump stuffing box is equipped with a mechanical seal unit,(120 and 120-1) which control leakage to the atmosphere at thepoint where the shaft (167) protrudes through the pressureboundary.

COUPLING A flexible disc type coupling is provided with this pump.Coupling halves are keyed to their respective pump/driver shafts.




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INSTALLATIONNOTE: The installation/commissioning of this equipment must be conducted in accordance with API

Recommended Practices 686/PIP REIE 686 First Edition. Refer to API 610 Eighth Edition Appendix L for baseplate grouting requirements.

Copies of API Recommended Practices 686/PIP REIE 686 First Edition may be obtained from America Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Telephone: (202) 682-8000.

The following ASTM Specifications are furnished as references for test methods used in conjunctionwith installation of grouting materials and should be used to obtain proper results.

ASTM C78-84 Test Method for Flexural Strength for ConcreteASTM C109-90 Test Method for Compressive Strength of Hydraulic Cement Mortars ModifiedASTM C469-87a Test Method for Static Modulus of Elasticity and Poissons Ratio of Concrete in

CompressionASTM C496-90 Test Method for Splitting Tensile Strength of Cylindrical Concrete SpecimensASTM C531-85 Test Method for Linear Skrinkage and Coefficient of Thermal Expansion of Chemical

Resistant Grouts and Monolithic Surfacings (Modified)ASTM C666-90 Test Method for Resistance of Concrete to Rapid Freezing and ThawingASTM C939-87 Test Method for Flow of Grout for Preplaced Aggregate Concrete (Flow Cone

Method)ASTM C942-86 Test Method for Compressive Strength of Grouts for Preplaced Aggregate Concrete

in the LaboratoryASTM C1090-88 Test Method for Measuring Changes in Height of Cylindrical Specimens from

Hydraulic Cement GroutASTM C1107-91 Standard Specification for Packaged Hydraulic-Cement Grout (Non-Shrink)ACI 351 (CRD-C-621-92) Grouting for Support of Equipment and Machinery24-Hour Test MBT Test Method for Grout Performance

MINIMUM REQUIREMENTS FOR EPOXY GROUT(Typical Properties at 73F (23C)

ASTM D635 Fire ResistantASTM C579B Minimum Compressive Strength 12000 PSIASTM C827 Height Change @ 90F (38C) Positive Effective Bearing Area 95%ASTM C1181 Maximum Creep in one (1) year 1.6 x 10 -3in/in at 140F, 400 PSIASTM C307 Minimum Tensile Strength 1800 PSI (12.4 Mpa)ASTM C580 Minimum Flexural Strength 3800 PSI (26.2 Mpa)ASTM C580 Minimum Flexural Secant Modulus 1.8 X 106 PSI (1.2 x 104 Mpa)

ASTM C531 Maximum Coefficient of Expansion 17 x 10-6in/in/F.Maximum Peak Exotherm 1000 gm insulated - 95F (35C)Full Aggregate Must Be Used

CHECK UPON ARRIVALYour pump was carefully checked at our shops prior to shipment to assure its meeting the requirements ofyour order.

It is suggested that the pump be inspected upon arrival and that any irregularities arising due to shipping bereported immediately to the carrier.




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CARE DURING STORAGEIf it is necessary to store the unit any length of time before installation, find a location where it will beprotected from unfavorable weather.

The nozzle covers provided with the unit should be left in place during storage.

The pump driver should not be located/stored in damp places without special protection.

RUST PREVENTIVEInternal parts of the pump and bearing housings are protected prior to shipment with a thin film polar typerust preventive. This can be cleaned out by flushing with petroleum solvents.

External machined surfaces are protected with durable drying type rust preventive. This can be removedwith kerosene or safety solvent (TOWER NO. 392).

External non-machined surfaces have been prepared and painted as per specification.

Parts on parts order are protected with a thin film polar rust preventive. This can be removed withpetroleum solvents.

CLEANING THE PUMPBefore putting pump into operation, it should be thoroughly flushed out to remove the rust preventive aswell as any foreign matter which may accumulate during installation.

Take all possible care not to contaminate your system.

LOCATIONInstall the unit close to the source of the liquid to be pumped. When selecting the location, be sure to allowadequate space for operation as well as for maintenance operations involving dismantling and inspection ofparts. Headroom is an important consideration as an overhead lift of some type is required.

FOUNDATIONNOTE: The following information regarding foundation is only offered as a general guideline to the customer.

Ruhrpumpen Inc. requires that all foundation be designed/installed in accordance with specificationsset forth in Chapter 4 Foundations from API Recommended Practices 686/PIP REIE 686, First Edition.

The design of foundations is not the responsibility of Ruhrpumpen Inc. It is, therefore, recommendedthat the customer consult a competent specialist skilled in the field of foundations, to insure properdesign/installation of the foundation.

The foundation should be sufficiently rigid and substantial to prevent any pump vibration and topermanently support the baseplate at all points.

The most satisfactory foundations are made of reinforced concrete. These should be poured well inadvance of the installation to allow proper time for drying and curing.

The General Arrangement drawing will furnish anchor bolt locations, size of bolts, etc.




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TEMPLATE FOR HANGING FOUNDATION BOLTS

The sketch below illustrates a recommended foundation bolt arrangement. Notice the large washer withlugs 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 baseplate. The excess canalways be cut off if not needed.

A rough finish top surface is best when applying grout.

ARRANGEMENT OF FOUNDATION BOLT IN FOUNDATION

LIFTINGNOTE: The following information regarding lifting is only offered as a general guideline to the customer.

Ruhrpumpen, Inc. requires that all lifting and rigging be performed in accordance with specificationsset forth in Chapter 2 Lifting and Rigging from API Recommended Practices 686/PIP EEIE 686, FirstEdition.

WARNINGENSURE THAT LIFTING RIGS, CRANES, CHAINS, AND/OR STRAPS ARE CAPABLE OF LIFTING ANDSUPPORTING THE ENCOUNTERED WEIGHTS. REFER TO THE APPROPRIATE WEIGHTS SECTIONOF THIS MANUAL TO DETERMINE SUITABILITY OF LIFTING EQUIPMENT.




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INSTALLATION SEQUENCE1. Level Baseplate2. Preliminary Alignment3. Grout Baseplate4. Align Shaft/Coupling5. Piping6. Check Coupling Alignment

LEVEL THE BASEPLATENOTE: The following information regarding leveling of equipment is only offered as a general guideline to

the customer. Ruhrpumpen Inc. requires that all leveling of equipment be performed in accordancewith specifications set forth in Chapter 5 Mounting Plate Grouting from API RecommendedPractices 686/PIP ERIE 686, First Edition.

Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any loosepieces 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 halfcouplings before lifting baseplate with pumping element.

NOTE: When lifting pump and baseplate together, sling baseplate from four of the eight lifting eyesprovided. Select the four lifting eyes that will maintain levelness and stability during liftingoperation. Failure to do this may result in permanent deformation of the baseplate.

Prepare enough iron wedges or shims to be placed on each side of each foundation bolt. These wedgesshould be about 4 to 6 inches long, 2 to 3 inches wide, and thick enough to allow for 1-1/4 inches of groutunder the edge of the baseplate. Place wedges as shown in sketch.

Level the baseplate by using a machinists level on the machined surfaces of the pump and driver pads.When the baseplate is leveled, pull down the foundation bolts so they are snug. The baseplate may havebeen disturbed by tightening down the foundation bolts, therefore, recheck with level and make necessaryadjustments by wedges or shimming.

As a final baseplate alignment check on spacer type couplings, install a mounting bracket for dial indicatoron driver hub. Fasten or clamp indicator on mounting bracket so that dial indicator button is contacting faceon pump half coupling and zero the dial indicator. (Non-spacer type coupling should be checked withtapered wedge or feeler gages.) Make sure shaft end distance is per General Arrangement drawing.

Rotate the driver half coupling (in direction of pump rotation) 90. Record this reading. Repeat thisprocedure until readings have been taken at four (4) 90 positions.

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




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GROUTINGNOTE: The following information regarding grouting of equipment is only offered as a general guideline to the

customer. Ruhrpumpen Inc. requires that all grouting be installed in accordance with specificationsset forth in Chapter 5 Mounting Plate Grouting from API Recommended Practices 686/PIP ERIE 686,First Edition.

It is recommended that the customer consult a competent specialist skilled in the field of grouting toinsure the proper installation of all grouting.

Build a dam around the foundation. It is a matter of personal preference whether the leveling wedgesunder the baseplate should be removed after grouting. If you want to remove the wedges, carefully marktheir locations before pouring grout.

BUILD DAM AROUND FOUNDATION BEFORE POURING GROUTUse a quality, high strength, non-shrink epoxy grout mix and install per manufacturers instructions.

Holes are provided in the baseplate to permit pouring the grout and stirring. They also act as air vents. Fillunder the baseplate completely, stirring to assure proper distribution of the grout. Check to see that thegrout flows under the edges of the baseplate evenly.NOTE: Do not vibrate baseplate when grouting, make sure baseplate is vented properly and all areas as

indicated on General Arrangement drawing are thoroughly puddled to prevent any resonant problems.

When the grout is thoroughly hardened, remove the dam and wedges, if desired, filling in the holes theyleave with grout.




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SHAFT/COUPLING ALIGNMENTNOTE: The following information regarding shaft alignment is only offered as a general guideline to the

customer. Ruhrpumpen Inc. requires that all shaft alignment be performed in accordance withspecifications set forth in Chapter 7 Shaft Alignment from API Recommended Practices 686/PIPREIE 686, First Edition.

CAUTIONSHAFT ALIGNMENT MUST BE CORRECT FOR SUCCESSFUL OPERATION. RAPID WEAR,NOISE, VIBRATION, AND ACTUAL DAMAGE TO THE EQUIPMENT MAY BE CAUSED BYSHAFT MISALIGNMENT. THE SHAFTS MUST BE ALIGNED WITHIN THE LIMITS GIVEN.

NOTE: Adjustment to correct the alignment in one direction may alter the alignment in another direction.Always check in all directions after making any adjustment.

Coupling equipment must be aligned to minimuze unnecessary stresses in shafts, bearings, and coupling.Flexible couplings will not compensate for appreciable misalignment. Foundation settling, thermalexpansion, nozzle loads resulting in baseplate/foundation deflection and vibration during operation mayrequire the full coupling misalignment capability.TYPES OF MISALIGNMENT

There are two types of shaft misalignment: angular and offset. Therefore, two sets of measurements and correctionsare required. Both types of misalignment can occur in horizontal and vertical planes and are present in mostapplications.

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 misalignment, the shaft centerlines are parallel but do not intersect.

OFFSET MISALIGNMENT COMBINATION OFFSET & ANGULAR MISALIGNMENT




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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 coupling hubs must be in accordance with the certified General Arrangementdrawing and must be measured with pump and driver shafts in the center of their axial end float. Motor withsleeve 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 doweled before taking anyalignment measurements. This makes the pump the fixed machine and the driver the moveable machine. Incertain cases, however, it may be impractical to move the driver, therefore, the pump may have to be moved.When this case exists, the pump should not be doweled until after final alignment.

B. Measure Angular Misalignment

Refer to ALIGNMENT DATA SHEET and examples.

CAUTIONPUMP SHAFT SHOULD NOT BE ROTATED MORE THAN NECESSARY WHEN ALIGNMENT SHAFTS.DAMAGE COULD OCCUR TO INTERNAL WEARING PARTS WHICH ARE LUBRICATED BY THE PUMPEDLIQUID.

The angular misalignment can best be determined by the use of a hand-held inside micrometer, marked B onsketch. All measurements should be taken at the same radial distance from the shaft centerline, as close aspossible to the hub outside diameter. The location of these measurements is defined as the D dimension on theALIGNMENT DATA SHEET. Do not move the shaft axially while rotating the shafts and taken measurements.Both hubs must be rotated together to cancel possible hub face face run out. The relative measurement (topminus bottom, right minus left) is the important number.

1. Mark both coupling hubs at 3, 6, 9, and 12 oclock positions so they can be rotated together and at 90intervals.

2. Starting with the 12 oclock markings of both hubs in the top center position, measure the gap at top, bottom,right, and left side. Record these dimensions on ALIGNMENT DATA SHEET, Sheet 1, Part 1 in the0column.

NOTE: Right side and left side are determined when viewing the driver coupling from the pump.

3. Rotate both shafts 90 in the direction of pump rotation. Measure gap dimensions at the four (4) locations asin Step 2. Record on ALIGNMENT DATA SHEET, Sheet 1, Part 1 in the 90 column.

4. Repeat Step 3 until measurements have been taken at the four (4) 90 positions (0, 90, 180, 270).

5. Rotate both shafts to the starting position (12 oclock markings at top center) and recheck dimensionrecorded in Step 2.




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6. For 0, 90, 180, and 270 columns, subtract the bottom from the top and left from right. Record in theirrespective blocks on Data Sheet. Watch sign notations.

7. Total the different numbers (reading across), divide by four (4) and record the average ______. Record inOpen At ______ the shaft relative angular position.

NOTE: The inside faces of the driver and pump half hubs must be parallel within .001.

C. Measure Offset Misalignment

Offset misalignment is measured using a dial indicator on the outside diameter of the coupling hubs and rotatingthe hubs together to cancel rim surface inaccuracies.

1. Starting with the 12 oclock markings of both hubs on top center, 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 and take a reading. Record onALIGNMENT DATA SHEET, Sheet 1, Part 2 in the proper right side or left side blank (right or left sides aredetermined when viewing the driver half coupling from the pump).

4. Repeat Step 3 until readings have been taken at the four (4) 90 positions (top center, right, bottom, and left).

5. Rotate both shafts to the starting position (12 oclock markings at top center) and verify indicator returns tozero.

NOTE: The sum of the top and bottom readings should always equal the sum of the left and rightreadings. If the sums are not equal, check for indicator bracket deflection, hub surfaceirregularity, or loose radial bearings.

6. Using the formula on ALIGNMENT DATA SHEET, Sheet 1, Part 2, subtract the top from the bottomindicator reading, divide by two (2). This will yield the vertical misalignment.

7. Using the formula on ALIGNMENT DATA SHEET, Sheet 1, Part 2, subtract the left from the right indicatorreading, divide ty two (2). This 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 DataSheet.

NOTE: The outside diameters of pump and driver coupling hubs must be aligned within .003 TIR.

D. Movement Calculations (ALIGNMENT DATA SHEET Sheet 2)

1. Sketch the relative driver shaft position in the side and top views. These sketches will assistvisualizing the required equipment move.

2. Alignment depends upon the relationship between D, L1, and L0.

Use the formula GXL/D to determine the required move.NOTE: D = Diameter of the circle at which angular misalignment 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, Part 1.L1 = Distance from driver coupling hub to inboard driver foot.L0 = Distance from driver coupling hub to outboard driver foot.




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3. Record vertical offset from Sheet 1, Part 2 and vertical move obtained from calculations in the INBOARDand OUTBOARD DRIVER PEDESTAL SHIFT columns. Also record the required direction of shift (raise orlower).

4. Record horizontal offset from Sheet 1, Part 2 and horizontal move obtained from calculations in theINBOARD and OUTBOARD DRIVER PEDESTAL SHIFT columns. Also record the required direction ofshift (right or left).

5. Total the move requirements (watch move direction). This will yield the required hozizontal move (right orleft) and the vertical move (raise or lower) required at each mounting foot..

HORIZONTAL MOVE

The dial indicators, as shown in figure, are required to accurately measure the move in the horizontal direction. Movethe driver by bumping with soft hammer/mallet or using the jackscrews (if provided). The amount of horizontalrelocation required is the total of the horizontal move calculation (bottom of Sheet 2).

VERTICAL MOVE

Before moving the equipment vertically, it is important that the vertical thermal expansion be taken into consideration.The proceeding vertical move calculations are based on pump and driver shafts being set on the same plane. Refer togeneral arrangement notes and/or driver instructions for recommended cold vertical setting (if thermal expansion is afoactor).




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The shims between the equipment feet and mounting surface should be clean and dry. This is especially critical forpumps in service for some time and need to be realigned. Water, dirt, and rust may change the height of the shimpack over a period of time. Shims should be made large enough to support the weight of the equipment on itsmounting foot. Do not use many thin shims as this may result in a spongy mounting.

Move the equipment vertically by adding or removing the calculated thickness of shims. Torque equipment hold downbolting to required values.

NOTE: It is recommended, the completed ALIGNMENT DATA SHEET be retained as part of your permanentmaintenance file.

CHECK COUPLING ALIGNMENT

The angular and offset coupling alignment must be rechecked.

1. Coupling faces are to be parallel within a .001 TIR.

2. Coupling outside diameters are to be aligned within .003 TIR.

3. Bump the motor and check motor rotation.

ASSEMBLE AND LUBRICATE COUPLING

1. Assemble and lubricate coupling per the manufacturers instructions.

2. Install coupling guard.

DOWEL PUMP AND DRIVER

A. Cold Pumps

Pump hold down bolts are to be torqued to the proper valve and dowel pins are put in two (2) feet (diagonallyopposite).

B. Pump Driver

Refer to driver outline drawing and/or driver instructions for doweling information.




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HOT ALIGNMENT CHECK

A hot check can only be made after the unit has been in operation a sufficient length of time to assume its NORMALoperating temperature and conditions. If the unit has been properly cold set, the offset misalignment will be within .003TIR and the angular misalignment will be within .001 TIR when in operation. If not, make adjustments.

WARNINGDO NOT ATTEMPT ANY MAINTENANCE, INSPECTION, REPAIR, OR CLEANING IN THE VICINITY OFROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN INJURY TO OPERATING PERSONNEL.

WARNINGBEFORE ATTEMPTING ANY INSPECTION OR REPAIR ON THE PUMP, THE DRIVER CONTROLSMUST BE IN THE OFF POSITION, LOCKED AND TAGGED TO PREVENT INJURY TO PERSONNELPERFORMING SERVICE ON THE PUMP.




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PIPINGNOTE: The following information regarding piping is only offered as a general guideline to the customer.

Ruhrpumpen Inc. requires that all piping and related systems be designed/ installed in accordancewith specifications set forth in Chapter 6 Piping from API Recommended Practices 686/PIP REIE686, First Edition.

The design of piping and related systems is not the responsibility of Ruhrpumpen Inc. It is,therefore, recommended that the customer consult a competent specialist skilled in the field ofpiping to insure proper design/installation of all piping.

MAIN PIPING

Suction and discharge piping should be of ample size, be installed in direct runs, and have a minimum of bends. Referto the General Arrangement drawing for pertinent piping data.

NOTE: Do not connect any piping until the foundation bolts have been finally pulled down.

The piping should be independently supported and must not be drawn into position with the flange bolts.

Provision must be made to support the piping external to the pump in order to prevent excessive nozzle loads andmaintain pump-driver alignment.

MINIMUM FLOW BY-PASS

WARNING

CUSTOMER TO PROVIDE A SUITABLE MINIMUM FLOW BY-PASS SYSTEM CONNECTED TO PUMPDISCHARGE PRIOR TO FIRST VALVE. THE BY-PASS FLOW SHOULD BE DIRECTED TO THESOURCE OF PUMP SUCTION AND DESIGNED TO HANDLE A MINIMUM FLOW OF 291 M3/HR (1282GPM) WITH A PRESSURE BREAKDOWN OF 4,175 m(13,697 FT) AT DESIGNED SPEED. A BACKPRESSURE DEVICE LOCATED DOWNSTREAM OF THE MINIMUM FLOW VALVE MAY BE REQUIREDTO SUPPRESS VALVE CAVITATION OR DOWNSTREAM LINE FLASHING.

PUMP SHOULD BE STARTED WITH CLOSED DISCHARGE VALVE AND OPEN MINIMUM FLOW BY-PASS LINE.

SEAL PIPING

Refer to seal piping drawing for information pertaining to your system.

SUCTION STRAINERIn a new installation, great care should be taken to prevent dirt, scale, and welding beads from entering thepump. Even when piping has been previously flushed, it is difficult to break loose the oxides and mill scalewhich will become free when the pipe heats and cools several times. Numerous close running clearancesare vulnerable to abrasive matter present in new piping. Foreign material may be large enough, or ofsufficient volume, to jam a pump, with probable damage to both pump and drive equipment. Smallermaterial passing through the pump can cause rapid pump wear and premature pump failure.

This pump is provided with the exception that it will be pumping clean liquids (unless otherwise stated in theorder and addressed in the proposal). Ruhrpumpen pumps are provided with running clearances rangingtypically from 0.12 mm(0.005 inch) to 0.80 mm(0.030 inch), depending on the service. It is impractical toinstall a suction strainer to remove particulate of this size. Such particles will normally pass through thepump without causing damage, providing the concentrations are minor.




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The possibility exists that, on shutdown of the pump, such particles can become trapped in the closerunning clearances during coastdown, causing binding. Ruhrpumpen cannot recommend a procedure thatwill totally prevent such binding; however, we strongly suggest that systems be cleaned and thoroughlyflushed prior to connecting the pump to the piping to minimize particles entering the pump. Starting andstopping of the pump should be MINIMIZED as pumps are most susceptible to dirt during starts and stops.

In the event that binding on coastdown occurs, it is unlikely that the binding can be remedied by handrolling the rotor, and partial disassembly may be required to clean the affected parts. It should be notedthat increased particle concentrations increase the probability of coastdown binding and seizures, as wellas erosion damage.

CAUTIONEXCESSIVE FORCE USED TO TRY TO FREE A BOUND ROTOR MAY CAUSE DAMAGE BEYONDMINOR CLEAN-UP AND REPAIR OF ROTOR PARTS.

Generally, a pump should not be installed without strainer protection. The suction system should bethoroughly flushed before installing the suction strainer and making up the suction piping to the pump. Thestrainer should be installed in the inlet piping near the pump, making certain that it is located where it maybe readily serviced (cleaned). Be sure, however, that the installed strainer will not distort the flow to thepump suction.

Do not install the strainer directly on the pump suction nozzle. For a cone-type strainer, the downstreamend of the cone should be no closer than four (4) pipe diameters from the pump suction connection.Basket-type strainers typically introduce greater flow disturbances and should be installed at least six (6)pipe diameters from the pump suction nozzles.

The Ruhrpumpen standard for suction strainers consists of conical-shaped steel plate with 3.175 mm(1/8inch) perforations. The open area of the strainer should be a minimum of three times the area of the pumpsuction.

CONE TYPE STRAINERAt all times when using suction strainers, it is critical that the pressure drop across the strainer beconstantly monitored to ensure that the pump suction pressure does not fall below that required to preventpump cavitation. Pressure (or vacuum) gauges should be installed on both sides of the strainer so that thepressure drop across the strainer can be monitored. During startup of the system, the gauges should bemonitored continuously. Consult the plant engineer or system designer for the allowable pressuredifferential across the strainer prior to operating the pump. Pressure differential across the strainer and/orscreen is typically no more than 13.8 20.7 Kpa(2-3 psig). An increase in the differential pressure betweenthe two gauges indicates that the strainer or screen is becoming clogged with dirt and scale. Before the




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pressure drop becomes so severe that cavitation occurs, the pump should be shut down and the strainercleaned. Alarm settings to protect the pump from damaging cavitation and loss of suction need to besupplied by the plant engineer or system designer prior to operating the pump. Typically alarm settings toprotect the pump from damaging cavitation and loss of suction would be 5 psig differential pressure acrossthe strainer (screen). The suction piping should be arranged such that the ultimate strainer configuration(location) allows ready access for cleaning.

The strainer may be fitted with a finer screen to filter the inlet flow. When this is done, 40 mesh screen istypically used for start-up operation, at reduced flow rates. For final operation in a closed system, thesuction strainers are normally removed after the system is cleaned. For critical pump applications wherecontinuous screening of suction flow is desirable, and in open systems, 20 mesh screening is typically usedfor permanent strainers. At all times, when using screens and suction strainers, it is critical that pressuredrop across the screen and/or strainer be constantly monitored to ensure that the pump suction pressuredoes not fall below that required to pevent cavitation.

When dirt and scale have been removed from the system, as indicated by no further change in pressuredrop across the strainer with time, the startup strainer may be removed or the screen may be replaced withone having larger openings. If a permanent strainer will be used during normal operations, the pressuredifferential needs to be monitored on a continuous basis.

If a permanent strainer is not used, the startup strainer needs to be temporarily reinstalled whenever thesystem is opened up for repair or routine maintenance. As long as a suction strainer or screen remains inplace, the differential pressure should be monitored on a regular basis.

CAUTIONTHE PRESSURE DROP ACROSS THE STRAINER IS A DIRECT REDUCTION IN THE NPSH AVAILABLE TO THEPUMP. NPSH AVAILABLE MUST ALWAYS EXCEED THE NPSH REQUIRED BY THE PUMP. THISREQUIREMENT MAY LIMIT THE PUMP FLOW RATE, PARTICULARLY DURING STARTUP OPERATION.ALARMS OR AUTOMATIC PUMP SHUT-DOWN DEVICES SHOULD BE INSTALLED TO MINIMIZE THEPOSSIBILITY OF PUMP DAMAGE. IT IS THE RESPONSIBILITY OF THE PUMP OPERATOR TO OBTAIN THEALLOWABLE PRESSURE DROP ACROSS THE STRAINER FOR SAFE PUMP OPERATION FROM THE PLANTENGINEER OR SYSTEM DESIGNER PRIOR TO OPERATION OF THE PUMP.

LUBRICATION

WARNING

OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OFTHE BEARINGS, BEARING FAILURES, PUMP SEIZURES, AND ACTUAL BREAKUP OF THEEQUIPMENT, EXPOSING OPERATING PERSONNEL TO INJURY.

The plain end and thrust end housings (278) are equipped with a Trico Oiler. (See TRICO OILERSETTING page.)

MAKE PERIODIC INSPECTIONS

Remember that oil requires frequent replenishment at normal temperatures and very frequent replenishment at hightemperatures. Oil is always subject to gradual deterioration from use, and contamination from dirt and moisture. Intime, the accumulated sludge will be harmful to the bearings and cause premature wear. For this reason, draining andflushing are necessary at regular intervals. It is good practice to change the oil after three months of operation.




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OIL SPECIFICATIONSThe ideal bearing lubricant is a straight, well refined, neutral mineral oil, preferably of the turbine type. It should notcontain free acid, sulfur, chlorine, or more than a trace of free alkali. It is suggested that the oil conform to the followingphysical characteristics based on tests by ASTM Standard Methods.

ASTM STANDARDS (For Mineral Oils)

Sdff Operating Oil Temperature60-100F (16-38C) 101-180F (38-82C)

Saybolt Viscosity (SSU)100F (38C) 158 Seconds 335 Seconds

Pour Point 20F (-7C) 20F (-7C)

Flash Point 400F (204C) 400F (204C)Recommended ISO ViscosityGrade (VG) Number 32 68

In a majority of instances, ISO 68 (nominally equivalent to SAE 20 turbine oil) will meet the above specifications.

LUBRICANT MUST BE COMPATIBLE WITH ALL PARTS REQUIRING LUBRICATIONNote: The minimum bearing oil temperature is 60F. If necessary, the oil in the bearing housing(s) should be drained

and replaced with warm oil.When ambient temperature falls below 50F, it is recommended that the bearing housings be heated by use ofheating tapes.

CONSTANT LEVEL OILER SETTING BEARING HOUSING AND CAPS

Release thumb screw and remove bottle. Establish a measurement from the centerline of the shaft to the upper crossarm.

Fill bottle with recommended oil and install on holder. Remove and fill bottle as many times as is required to fill thebearing housing up to the cross arm level and no air bubbles appear in bottle.

Adjust upper cross as required and lock in place with lower arm.

INSPECTION OF OIL RINGS BEFORE START-UP

A problem can arise when pumps are transported by vehicle or when being lifted by a crane. Jarring or uneven lifting ofpumps can cause the oil rings to move out of position. If the oil rings are out of position at start-up, the bearings will notget lubrication and eventually will fail.

Before start-up takes place, remove the inch NPT plugs on the top of the housing and confirm that the oil rings are intheir proper position.

PURE OIL MIST DRY SUMP

When pure oil mist lubrication is supplied, the oil mist is the only lubricant provided. The oil mist generatormust be running before starting the unit.

When pure oil mist lubrication is supplied, a constant level oiler or oil rings are not supplied.

Basic oil mist system should include the following:1. An air-line filter-water separator to assure a clean air supply to oil mist generator.2. An air pressure regulator to control the oil mist generator atomizing air pressure.3. An oil mist generator which includes a venturi nozzle, oil lift tube, reservoir and oil flow adjustment screw.4. Mist distribution manifold to convey the oil mist application fittings.5. Spray application fitting to meter and convert the oil mist at each lubrication point.




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Provide oil mist spray directly to bearing balls by adjusting reclassifier length. Oil mist should be vented outoil mist outlet. (When pump is idle and mist generator is on, a mist should be visible exiting the vents.When pump is running, the windage associated with the shaft, bearing, and coupling makes it difficult tosee the mist.)

Periodically inspect the plastic sediment bottle underneath the bearing housings. Drain as required. Ifbearing housing is dismantled, flush bearing housing with a clean light oil. Be certain bearings have a lightcoating of oil before start-up.




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OPERATION

WARNINGTHE UNIT MUST NOT BE OPERATED UNLESS COUPLING GUARD IS IN PLACE. FAILURE TOOBSERVE THIS WARNING COULD RESULT IN INJURY TO OPERATING PERSONNEL.

CAUTIONPRIOR TO STARTUP, OIL MUST BE POURED OVER THE JOURNAL AREAS AT OIL RINGS. ASUFFICIENT AMOUNT OF OIL IS REQUIRED TO INSURE PROPER LUBRICATION OF BEARINGS ATSTARTUP.

CAUTIONCHECK TRICO OILERS TO ENSURE THAT THE PUMP BEARINGS HAVE BEEN FILED TO THEPROPER LEVEL WITH LUBRICATING OIL. (REFER TO TRICO OILER PAGE.)

INITIAL START-UP

1. Check all main and auxilliary piping making certain it is connected properly. (Piping must beindependently supported and must not be drawn into position with flange bolting.)NOTE: a. If the piping was connected after the unit was aligned, recheck alignment.

b. Provision must be made to support piping external to the pump to prevent excessive nozzleloads and maintain pump-driver alignment.

2. Ensure pump and piping is clean.

3. Check all bolting for tightness.

4. Ensure drain plugs are installed and tightened.

5. Check the trico oilers to be sure that the pump bearing housings have been filled to the proper level withlubricating oil. (See LUBRICATION section instructions.)

WARNING

OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OFTHE BEARINGS, BEARINGS FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THEEQUIPMENT EXPOSING OPERATING PERSONNEL TO INJURY.

CAUTION

WHEN THE AMBIENT TEMPERATURE FALLS BELOW 50F., IT IS RECOMMENDED THAT THE OIL INTHE PLAIN/THRUST BEARING HOUSINGS BE PREHEATED.

6. Warm up pump prior to starting. Casing temperature must be within 100F of available suction liquidtemperature prior to pump operation. The warming rate of the casing should not exceed 2F per minute.Customers to supply 50 gpm of warming liquid to the pump discharge. Customer to provide a warming liquidinlet line between pump discharge nozzle and first valve. Run outlet flow through pump suction back to source ofsuction.

Close valves in discharge and minimum flow lines to isolate pump during warm-up and hot standby.

The warming liquid inlet line must be closed immediately prior to pump operation. Suction and minimum flowlines must be opened immediately to pump operation.




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CAUTION

PRIOR TO PUMP OPERATION, CASING TEMPERATURE MUST BE WITHIN 100F OF AVAILABLESUCTION LIQUID TEMPERATURE. PUMP SHOULD BE STARTED WITH CLOSED DISCHARGEVALVE AND OPEN MINIMUM FLOW BY-PASS LINE.

WARNING

TO AVOID OVER PRESSURIZING PUMP SEALS AND SUCTION LINE, THE WARMING LIQUIDOUTLET LINE MUST ALWAYS BE OPEN WHEN THE WARMING LIQUID INLET LINE IS OPEN. OPENTHE WARMING LIQUID OUTLET LINE BEFORE OPENING THE INLET LINE. CLOSE THE WARMINGLIQUID INLET LINE BEFORE CLOSING THE OUTLET LINE.

7. Close discharge valve if valve is not already closed.8. Ensure pump suction valve is open, and pump is primed.

CAUTION

BEFORE STARTING OR WHILE OPERATING THE PUMP, THE CASING AND SUCTION LINE MUST BECOMPLETELY FILLED WITH THE LIQUID BEING PUMPED. THE ROTATING PARTS DEPEND ONTHIS LIQUID FOR LUBRICATION AND THE PUMP MAY SEIZE IF OPERATED WITHOUT LIQUID.

9. Ensure pump by-pass line is clear and free of obstructions, if provided.10. Turn pump rotor by hand to make sure it turns freely.

WARNING

ENSURE MOTOR CIRCUIT IS DE-ENERGIZED. RE-ENERGIZE CIRCUIT AFTER CHECK.

11. Check that pump is vented by observing leakage from vent line. Close vent when liquid is emitted.12. Check pump rotation by starting pump momentarily. Note the pump coasts to a gradual stop.

WARNING

THE DRIVER ROTATION MUST BE CHECKED BEFORE MAKING UP COUPLING. ACTUAL DAMAGETO THE EQUIPMENT AND PERSONAL INJURY COULD RESULT FROM OPERATING THE UNITWITH WRONG ROTATION.

CAUTION

IF PUMP STOPS ABRUPTLY ON SHUTDOWN OF DRIVER, INVESTIGATE FOR PUMP BINDING.TAKE NECESSARY REMEDIAL ACTION BEFORE RESUMING OPERATING.

13. Close motor circuit breaker.14. As soon as pump is up to rated speed, slowly open discharge valve.15. Perform the operating checks.

CAUTION

CUSTOMER TO PROVIDE A SUITABLE MINIMUM FLOW BY-PASS SYSTEM CONNECTED TO PUMPDISCHARGE PRIOR TO FIRST VALVE. THE BY-PASS FLOW SHOULD BE DIRECTED TO THESOURCE OF PUMP SUCTION AND DESIGNED TO HANDLE A MINIMUM FLOW OF 291 M3/HR (1282GPM) WITH A PRESSURE BREAKDOWN OF 4,175 M (13,697 FT) AT DESIGN SPEED. A BACKPRESSURE DEVICE LOCATED DOWNSTREAM OF THE MINIMUM FLOW VALVE MAY BE REQUIREDTO SUPPRESS VALVE CAVITATION OR DOWNSTREAM LINE FLASHING.

PUMP SHOULD BE STARTED WITH CLOSED DISCHARGE VALVE AND OPEN MINIMUM FLOW BY-PASS LINE.




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NORMAL START-UP

The starting procedure to be followed for normal start-up is the same as that for initial starting with the exception thatSteps 1 through 4, and Step 11 do not have to be repeated.

OPERATING CHECKS

WARNING

DO NOT ATTEMPT ANY MAINTENANCE, INSPECTION, REPAIR, OR CLEANING IN THE VICINITY OFROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN INJURY TO OPERATING PERSONNEL.

Systematic checks following start-up operations are a factor in avoiding costly shutdowns. Immediatelyafter startup, and frequently during running, check the following:1. Check suction and discharge pressure gauges to see that they indicate the proper operating conditions.

If at any time the suction/discharge gauges should drop to zero, shut down the pump immediately.

The discharge gauge should show an increase in the pressure as the pump picks up speed. If it does not, shutdown the pump and locate the cause of the trouble.

2. Mechanical Seal check for leakage; there should be not visible leakage.

3. Check for unusual noises.

4. Check bearings for vibration and/or excessive heat.

While bearings will run at a constant temperature, this temperature will rise or fall with changes in the roomtemperature. The bearing lubrication oil temperature should be maintained between 60F and 165F.

5. Any time unit is running, frequently check the oil mist lubrication system and the bearing lubrication.

6. Check pessure differential between the gauges located on each side of the suction strainer (when used).

7. Recheck alignment recheck pump alignment after the pump has been in operation for a few hous.

8. Check driver per manufacturers instructions.

Check ammeter reading determined by pump load factor. A reading that is too high might be caused by pumpoperating at run-out conditions.

SECURING THE PUMP

1. The pump should be shut down rapidly to protect wearing parts which are lubricated by the liquid being pumped.Lubrication is reduced when the unit is stopped slowly and seizure could result.

2. Trip the motor circuit breaker.

NOTE: If pump stops abruptly when motor is shut down, investigate for pump binding. Take necessary remedialaction before restarting pump.

Lubrication is reduced when a pump is stopped slowly and seizure could result.

3. Close the pump discharge valve.

CAUTION

TO PERMIT CONTROLLED COOL-DOWN, PUMP SHOULD BE ISOLATED IMMEDIATELY AFTERSHUT-DOWN FROM HOT OPERATION. CLOSE VALVES ON SUCTION, DISCHARGE, AND MINIMUMFLOW LINES. THE COOLING RATE OF THE CASING SHOULD NOT EXCEED 10F PER MINUTEWHETHER THE PUMP IS SHUT DOWN OR IN OPERATION.




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TROUBLESHOOTINGThe following chart presents the probable troubles that can occur to the pump along with the probablecauses and remedies for the troubles.TROUBLE SHOOTING CHART

TROUBLE CAUSE REMEDYSuction pressure or speed too low Open suction valve wide.

Check power supply for correct voltage to motor.

Incorrect direction of rotation Re-connect motor leads

Excessive amount of air or vapors in the fluid. Check suction system for air leakage and correct.Vent air.Tighten flange bolts

Foreign material in impeller. Dismantle pump and remove any foreign material.

Insufficient capacity and/or pressure

Mechanical defects Wearring rings worn. Impeller damaged Sheared impeller key

Dismantle pump and correct.

Insufficient liquid supply Ensure that suction valve is wide open.Check for proper supply of liquid to be pumped.

Excessive amount of air or vapors in the liquid. Check suction system for air leakage and correct.

Broken or damaged coupling Inspect and replace same.

Clogged impeller Dismantle pump and correct.

Pump loses prime after startting.

Suction pipe clogged Remove foreign material.

Loose mounting or coupling bolts Tighten bolts.

Air or gas in liquid Vent air and check suction for leaks. Tightenflange bolts.

Misalignment Check alignment and correct.

Foreign material in impeller causing unbalance Dismantle pump and remove any foreign material.

Pump vibrates

Mechanical Defects: Shaft bent Bearings worn

Dismantle pump and replace part or parts causingvibration.

Speed too high Refer to motor instruction manual and check powersupply for correct frequency.

Pump overloads driver

Pump bearing seize or rotating element binds Dismantle pump and replace part or parts causingseizures or binding.

Pump stops abruptly Pump binding at running fits Dismantle pump and correct.Improper lubrication Replenish oil with proper grade lubricant.High pump thrust bearing temperature

rise Insufficient oil Contaminated oil Add oil. Drain and clean bearing housing reservoir.Refill with clean oil.

Mechanical seal gland overheats Insufficient cooling water to seal Obstruction in seal water piping. Remove andclean.

Mechanical seal leakage Checked for cracked rotating face/ stationary face Remove, dismantle, and inspect seal unit perMECHANICAL SEAL page.

Cavitation Check pump is primed, check for high suctiontemperature, increase static head, check forobstruction in suction line.

Loose parts Tighten or replace defective part.

Pump is noisy

Noise in driver Check driver with stethoscope.Refer to driver manufacturers manual for checks covering the driver




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DISMANTLING PROCEDURE

WARNING

BEFORE ATTEMPTING ANY INSPECTION OR REPAIR ON THE PUMP, THE DRIVER CONTROLSMUST BE IN THE OFF POSITION, LOCKED, AND TAGGED TO PREVENT INJURY TO PERSONNELPERFORMING SERVICE ON THE PUMP.

WARNING

DO NOT ATTEMPT ANY MAINTENANCE, INSPECTION, REPAIR, OR CLEANING IN THE VICINITY OFROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN PERSONAL INJURY TO OPERATINGPERSONNEL.

WARNING

BEFORE ATTEMPTING TO DISASSEMBLE PUMP, PUMP MUST BE ISOLATED FROM SYSTEM BYCLOSING SUCTION AND DISCHARGE SYSTEM VALVES, DRAINED OF LIQUID AND COOLED IFPUMP IS HANDLING HOT LIQUID.

WARNING

WHEN PUMP IS HANDLING HOT LIQUID, EXTREME CARE MUST BE TAKEN TO ENSURE SAFETYOF PERSONNEL WHEN ATTEMPTING TO DRAIN PUMP. HOT PUMPS MUST BE ALLOWED TOCOOL BEFORE DRAINING. PROTECTIVE GLOVES OR OTHER SUITABLE PROTECTION MUST BEWORN.

Open and tag motor circuit breaker.

Disconnect the coupling and remove the spacer piece.

Remove all auxiliary piping.

Remove the drain plug(s) and drain the casing (1).

WARNING

USE EXTREME CAUTION WHEN DRAINING THE CASING OF HOT AND/OR CORROSIVE LIQUID.

COUPLING REMOVAL

Refer to manufacturer instructions and observe supplemental notes offered by the Manufacturer.

Remove coupling guard.

Release the two set screws and remove the pump half coupling nut (251) and coupling key (676-1). Apply heat anduse an approved type pulled to facilitate removal.

NOTE: Remove pump half coupling hub by heating to approximately 300F in successive stages from periphery ofcoupling towards center. NEVER APPLY AN OPEN FLAME TO COUPLING HUB TEETH.

INBOARD (RADIAL) BEARING REMOVAL

Step 1) Drain any oil accumulated at the bottom of the bearing housing by opening up the valve at the bottle (665).




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WARNING

USE EXTREME CAUTION TO PREVENT INJURY WHEN DRAINING BEARING HOUSING (278) OF HOT OIL.

Step 2) Remove outboard end cover to radial bearing housing bolting. Slide outboard end cover (281) with bearingguard (117-1) from shaft.

Step 3) Remove inboard end cover to radial bearing housing bolting. Slide inboard end cover (280) with bearingguard (117) back on shaft towards center of pump.

Step 4) Remove bolting which secures bearing housing (278) to pump cover (051).

Step 5) Carefully slice bearing housing (278) from the ball bearing (655).Step 6) Release locking tab of lockwasher (673). Loosen and remove locknut (878) and lockwahser from shaft.Step 7) Remove spacer sleeve (225) from shaft. Remove ball bearing (655) using a puller that will bring pressure

against the inner bearing race only.Step 8) Remove pump-side end cover (280) with bearing guard (117) from shaft.

OUTBOARD (THRUST) BEARING REMOVAL

Step 1) Drain any oil accumulated at the bottom of the bearing housing by opening up the valve at the bottle (665).

WARNING

USE EXTREME CAUTION TO PREVENT INJURY WHEN DRAINING BEARING HOUSING (278) OF HOT OIL.

Step 2) Loosen bolting and remove outboard end cover (279).

Step 3) Remove inboard end cover to thrust bearing housing bolting. Slide inboard end cover (280-1) back on shaft.

Step 4) Remove bolting which secures the bearing housing (277) to the case (001).

Step 5) Carefully slide bearing housing (277) from ball bearings (654).

Step 6) Release the locking tab of lockwasher (673-1). Loosen and remove locknut (878-1) and lockwasher (673-1).

Step 7) Remove ball bearings (654) using a puller that will bring pressure against the inner bearing race only.Remove shims.

Step 8) Remove bearing shims. Measure and record thickness of shims; the together for reassembly. Removeinboard end cover (280-1) with o-ring (747) and shims (262/262-1) from shaft.

REMOVE ROTOR FROM CASINGStep 1) Remove mechanical seals per MECHANICAL SEAL instructions found in the manual.

Step 2) Remove bolting holding pump cover (051) to casing (001). Jack screws are provided to separate jointbetween pump cover and case.

Step 3) Using eyebolt, rig to overhead hoist and remove pump cover (051). Remove gaskets (744 & 744-1).

NOTE: The outboard end of pump shaft must be supported during and after removal of pumpcover (051).

Step 4) Rig pump shaft with slings, using a protective devise to protect shaft from damage by slings. Slide shaftcomplete with impeller (176) from pump case and place on horses. Block the shaft to prevent rolling. It willbe necessary to re-rig the inboard end of shaft so that shaft is removed properly.

CAUTION

CARE MUST BE TAKEN NOT TO DAMAGE ROTOR WHILE PASSING THROUGH THE CASING.




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DISMANTLING OF ROTOR

Step 1) Release the set screws in each impeller nut (246 and 246-1), then remove impeller nuts from shaft (167).

Step 2) Measure and record the distance from the coupling end of the shaft (167) to the face of the impeller hub asshown in figure below. Record this dimension to ensure impeller (176) is properly positioned whenreassembling pump.

IMPORTANT

MARK THE IMPELLER (176) IN SOME MANNER SO THAT IT CAN BE INSTALLED FOR CORRECTROTATION AT THE TIME OF ASSEMBLY.

Step 3) Tap impeller hub lightly with rubber hammer and remove the impeller (176). Remove impeller key (676).

If the impeller does not move freely off the shaft (this is rare case), heat may be necessary. Heat impellerusing following procedure:IMPELLER REMOVAL (IF HEATING IS REQUIRED)

A. Apply heat (torch with rosebud tip) to periphery of impeller until temperature reaches 375 minimum to 400Fmaximum. Use tempilstick to determine temperature.

B. Maintaining temperature between 375-400F at the periphery, apply heat to the shrouds.

C. With periphery and shroud at temperature, apply a quick heat to the hub of the impeller.

D. With periphery, shroud, and hub at temperature remove impeller.

E. If the impeller does not move freely off the shaft, additional heat may be necessary. THIS HEATING SHOULDBE STARTED AT THE PERIPHERY OF THE IMPELLER, NOT THE HUB. (Additional heating of the hub area atthis time will tighten the impeller on the shaft, not loosen it.) If the impeller still fails to come free, the impeller andshaft should be allowed to cool completely, and the heating process repeated, starting at A.




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NOTE: It is recommended that two torches be used on double suction impellers.

This completes dismantling.

INSPECTION OF PARTS

WARNING

DO NOT ATTEMPT ANY MAINTENANCE, INSPECTION, REPAIR, OR CLEANING IN THE VICINITY OFROTATING EQUIPMENT. SUCH ACTION COULD RESULT IN PERSONAL INJURY TO OPERATINGPERSONNEL.

1. Having completely dismantled the rotor, place shaft on V blocks or rollers (positioned) under the normal bearingareas). Check shaft for run out using a dial indicator. Run out not to exceed .002 TIR.

2. Wire brush the pump parts thoroughly. Clean off all scale, carbon, etc. Examine parts for wear, corrosion, anderosion.

Check thrust bearing (654) for excessive wear, rust, and/or flat spots. Replace as necessary. (See page titledBEARING HANDLING INFORMATION.)

Check impeller nuts (246 and 246-1) for wear. Replace as necessary.

CASING RINGS (205) / IMPELLER RINGS (201)

The casing rings (205) / impeller rings (201) should be replaced when badly grooved and/or when pumpperformance does not meet the system requirements.

The casing rings (205) / impeller rings (201) are held in position with headless set screws and are renewable.Whenever it becomes necessary to replace either worn ring, both rings (201) and (205) must be ordered andreplaced as they are furnished standard size only. Be sure to re-establish original running clearance. (Refer toRUNNING CLEARANCES.)

To replace these rings, it will be necessary to remove the headless set screws.

Each headless set screw is peened to prevent its backing out nd this will have to be removed before theheadless set screw can be removed.




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3. CASING RINGS (205)Removal - After removing the set screws, press the casing ring (205) out of its fit in the casing (001) and/or pumpcover (051). If this method does not easily affect removal of the ring, it can be split apart after drilling one ormore holes in the face of the worn ring.Install Install new casing ring (205; make sure the ring casing fit in the casing (001) and/or pump cover (051) isfree of nicks and burrs. Shrink casing ring by freezing with dry ice or by use of a CO2 extinguisher (chilled to -20F). Set the casing new ring in its fit and using a flat plate across the casing ring, tap into place. Install setscrew to secure casing rings.

4. IMPELLER RINGS (201)Removal After removing the headless set screws, machine the impeller ring (201) off the impeller (176). If thisdoes not easily effect removal, groove the impeller ring with a grinder and split apart.Install Install new impeller ring (201), apply heat to the new impeller ring and place on impeller (176) hub. Thenew impeller ring will have to be drilled and tapped for set screws spaced half the circular distance from the usedholes.

Casing ring (205) and impeller ring (201) must be indicated for roundness and all high spots removed.

5. Clean the complete casing (001) and bearing housings (278) of all foreign matter.

6. Check mechanical seal (120) parts and replace as required.

7. Renew all gaskets (744 and 744-1) and o ring (747) during pump reassemble procedure.

BEARING HANDLING INFORMATIONThe thrust/radial ball bearings (654/655) require proper handling and installation to ensure optimumperformance. The following information is intended as a minimum to ensure that the bearings are handledand installed properly.BEARING HANDLING1. Do not remove new bearings from their storage package except to inspect the bearings, when stored for a long

period of time or just prior to their installation.2. Work area must be clean to ensure that no dirt or other contaminates will enter the bearings. Handle bearings

with clean, dry hand and with clean, lint-free rags. Lay bearing on clean paper and keep covered. Never exposebearings on a dirty bench or floor.

3. Do not wash a new bearing. It is already clean and the preservative should not be removed.4. Before mounting, be sure shaft bearing areas are clen and free of nicks and burrs. Check the dimensions of

these areas to ensure proper fit of bearings.

BEARING INSTALLATION

1. There are two simple methods of providing a heat source for expanding the inner race of the bearings to facilitatemounting. In the first method, bearings still wrapped in their original intimate wrape are placed on a shaft in atemperature controlled oven, or in an enclosure lined with foil and heated with foil and heated with electric lightbulbs. A temperature of 150F for one half hour should be sufficient.

A second method consists of locating a light bulb (100 to 150 watt) in the bore of the bearing. The light bulb willheat, prmarily, the inner ring and the bearing can usually be handled by the outer ring without special gloves.Care must be taken to keep the bearing clean and uncontaminated.

LIGHT BULBS ARE LOCATED IN THE BORE OF THE BEARING AS A HEAT SOURCE FOREXPANDING THE INNER RACES OF BEARINGS FOR MOUNTING.

NOTE: The old and popular method of heating bearings in an oil bath is DEFINITELY DISCOURAGED. HEATINGINNER RING WITH A GAS TORCH IS PROHIBITED. In either case, it is difficult to control the heating rateand final temperature and even more difficult to keep the oil and/or bearing clean.




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2. When bearings are installed on shaft, make sure bearing is installed squarely and is firmly seated. Hold bearingin place until it has cooled sufficiently so that it will not move from position. Cover bearings to protect them fromdirt.

NOTE: When installing the bearings, the mounting pressure should never be applied in such a manner that it istransmitted through the rollers. Apply the mounting force directly against, and only against, the inner ring.

3. When installing bearing and shaft in bearing housing, or installing outboard bearing on shaft, bearing housingbores and bearing outside diameter should be coated with grease or lubricating oil to be used to facilitateassembly.

BEARING REMOVAL

If the bearings cannot be removed with the tools available, never use a torch under any circumstances. Split the outerring with a small hand grinder, was through the ball/roller retainer, and split the inner ring about three quarters throughwith a grinder and break with a cold steel chisel.

BEARING CLEANINGNOTE: Do not attempt to inspect condition of bearings until they have been cleaned.

1. Solvent for cleaning bearings should be in a clean container. Place bearings in solvent and let soak for a shorttime. Slosh the bearing around near the top of the container, giving it a turn now and then until it is clean. Rinsein a clean container of clean solvent.

NOTE: Do not spin dirty bearings. Rotate them slowly while washing.

2. Dry the thoroughly cleaned bearings. If an air hose is used for drying, use clean, dry air.

NOTE: Do not allow the bearing to spin by force of air. Hold both the inner and outer rings to prevent bearing fromspinning.

3. Inspect bearings immediately. If there is any question as to the condition of a bearing, it must not be reused.There are many conditions that contribute to the deterioration of the bearings. A qualified bearing representativeshould be consulted if there is any question of bearing condition.

4. Inspected bearings which will be reused should be packed with new grease or dipped in clean lubricating oil,covered with clean lint free rags or other suitable covering and placed in a clean box or carton until ready forinstallation.

NOTE: Under no circumstances are the bearings to be left exposed.

REASSEMBLEREASSEMBLE THE ROTOR

Step 1) Install the impeller key (676) in shaft.

Step 2) Install impeller (167) as done for disassembly and install impeller over the outboard end of the shaft until theimpeller hub face is in contact with the face of the shoulder on the shaft.

CAUTION

MAKE SURE IMPELLER IS INSTALLED FOR CORRECT ROTATION.

Step 3) Install space sleeve (225) and impeller nut (246) on shaft. Tighten the set screws in impeller nut.

CHECK ROTOR FOR RUN OUT

Step 1) Place rotating element on rolls or V blocks and check runout of shaft. Run out not to exceed .003 TIR.

Step 2) With a dial indicator, check impeller rings (201) for runout or high spots. Run out not to exceed .003 TIR.




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ROTOR INSTALLATION

Step 1) Install shaft complete with impeller in casing. Care must be taken when inboard section of shaft passesthrough the casing. Avoid nicks and burrs to the shaft.

NOTE: Outboard end of pump shaft must be supported prior to installation of pump cover (051).

Step 2) Using eyebolt provided and an overhead hoist, install pump cover (051) with new gaskets (744 and 744-1)over shaft (167). DO NOT USE THE OLD GASKETS.

Step 3) Use a good grade of thread lubricant on studs. Replace nuts on pump cover (051) and tighten until flange isin metal-to-metal contact with casing. Do not exceed recommended torque value. (Refer to TORQUEVALUES, on page )

HORIZONTAL AND VERTICAL SHAFT ALIGNMENT

Step 1) Assemble radial (inboard) bearing housing (278).

NOTE: Do not install mechanical seals on shaft at this time.a. Install inboard end cover (278) with bearing guard (117) on shaft. Slide towards center of pump.b. Heat radial bearing (655) and install against shoulder of shaft.c. Install space sleeve (225-1), bearing lockwahser (673), and locknut (878) on shaft. Tighten locknut but

do not secure tabs on lockwasher at this time.d. Assemble radial bearing housing (278), with reclassifier (612), into position over bearing (655). Install

bearing housing to casing bolting and snug capscrews. Be sure both horizontal and vertical adjustingsetscrews are installed in bearing housing.

Step 2) Assemble thrust (outboard) bearing housing (277).

NOTE: Do not install mechanical seals on shaft at this time.a. Install inboard end cover (280-1), with bearing guard (117), shims (262/262-1), and o-ring (747), on shaft.

Slide towards center of pump.b. Assemble Dummy Bearing (not supplied) to shaft. (A Dummy Bearing can be mad by taking a used

set of ball bearings and opening up the bore so it has a .0005 to .0010 loose fit to the shaft). Comparewidth of outside bearing races with new bearing races. Differences must be compensated whenadjusting for .005 to .010 end play.

c. Install lockwasher (673-1) a

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Pump JLine M2