Operation & Maintenance Manual

CUSTOMER APPLICATION DATA SHEET

NAME:
PO. NO:

DATE:

INVOICE NO:

DATE:

OPERATING DATA:
LIQUID NAME:

VISCOSITY:

SP. GRAVITY:
CAPACITY

OPERATING PRESSURE

SUCTION PRESSURE

OPERATING TEMPRETURE

PUMP MODEL

PORT SIZE

PUMP SPEED

DIRECTION OF ROTATION

MOTOR RATING

BHP @ PUMP SHAFT

COUPLING TYPE
BARE SHAFT PUMP

Authorised by :

MOTORISED PUMP SET

INDEX
Chapter

Page No.

General Description

Installation
2.1 Handling & Storage
2.2 System Design & Installation

2
3

Maintenance
3.1 Cleaning in Place (CIP)
3.2 Maintenance Schedule
3.3 Disassembly
3.4 Assembly

4
5
6
9

Clearance Chart

13

Trouble Shutting

14

Part List

16

Pumps Speed Selection Chart

17

Test & Warrantee Certificate

18

GENERAL DESCRIPTION

Bare Shaft Pump

Lifting hook

Lobe Pump

Geared Motor

Base Frame

Pump with drive unit

Installation

Installation
Discharge Line
Pump-1

Pump-2

Suction Line

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

Maintenance

10

Maintenance

Filler Gauge

11

Maintenance

12

CLEARANCE TABLE
es

en

b
lo

e
tw

4.1 Lobe rotor clearance Table

Rear
0.150
0.150
0.150
0.200
0.300
0.350

Side
0.250
0.250
0.250
0.250
0.350
0.400

Between Lobe @ 1800

0.150
0.150
0.150
0.200
0.300
0.350

radial clearance

ALB 100 S/L

ALB 150 S/L
ALB 200 S/L
ALB 250 S/L
ALB 300 S/L
ALB 400 S/L

Front
0.150
0.150
0.150
0.200
0.300
0.350

Front

Rear

0.200mm

Pumps Model

be

ra

ea

Cl

e
nc

All dimensions are in mm

Parralel alignment

4.2 Pump shaft Alignment :

0.2mm max

Inclination alignments:

1 max

Parallel alignment:

Angular alignment

13

Trouble Shutting

No flow
Under capacity
Irregular discharge
Low discharge pressure
Pump will not prime
Prime lost after starting
Pump stalls when starting
Pump overheats
Motor overheats
Excessive power absorbed
Noise and vibration
Pump element wear
Seizure
Mechanical seal leakage
Packed gland leakage

Problem

Probable Causes

Solutions

Incorrect direction of rotation

Reverse motor.

Pump not Primed.

Expel gas from suction line and pumping chamber

and introduce fluid.

Insufficient NPSH available.

Increase suction line diameter.

Increase suction head.
Simlify suction line configuration and resuce length.
Reduce pump speed.

Fluid vaporising in suction line.

Increase suction line diameter.

Increase suction head.
Simplify suction line configuration and reduce length.
Reduce pump speed.

Air entering suction line.

Remake pipework joints.

Service fittings.

Strainer or filter blocked.

Fluid viscosity above rated figure.

Increase fluid temperature.

Decrease pump speed.
Check seal face viscosity limitations.

Fluid viscosity below rated figure.

Decrease Fluid temperature.

Increase pump speed.

Fluid temp. above rated figure.

Cool the pump casing.

Reduce fluid temperature.
Check seal face and elastomer temp. limitations.

Fluid temp. below rated figure.

Heat the pump casing.

Increase fluid temperature.

Unexpected solids in fuid.

Clean the system.

Fit strainer to suction line.

Discharge pressure above rated

figure

Check for obstructions i.e. closed valve.

Service system and change to prevent problem recurring.
Simplify dicharge line to decrease pressure.

Gland over-tightened
Gland under-tightened
Pump speed above rated figure.
Pump speed below rated figure.

Slacken and re-adjust gland packing.

adjust gland packing.
Decrease pump speed.
Increase pump speed.

Pump casing strained by

pipework.

Check alignment of pipes.

Fit flexible pipes or expansion fittings.
Support pipework.

Flexible coupling misaligned.

Insecure pump drive mountings.
Shaft bearing wear or failure.
Insufficient gearcase lubrication.
Metal to metal contact of
pumping element.
Worn pumping element.
Suction lift too high.
Fluid pumped not compatible
with materials used
No barrier system to prevent
flow passing.

Check alignment and adjust mountings accrdingly.

Fit lock washers to slack fasteners and re-tighten.
Refer to pump maker for advice and replacement parts.
Refer to pump maker's instructions.
Check rated and duty presures.
Refer to pump maker.
Fit new components.
Lower pump or raise liquid level.
Use optional materials.

Pump allowed to run dry.

Ensure system operation prevents this.

Fit single or double flushed mechanical seals.
Fit flushed packed gland.

Faulty motor.
Pumping element missing

Check and replace motor bearings.

Fit pumping element.

14

Ensure discharge pipework higher than suction tank.

17

16
15

18

13

11

20

36

21

10

14

22

35

12

15

38

34

37

33

40

19

39

41

32

24

25

23

31
30

28

27

29

26

6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Parts list
nut, front cover
front cover
O'Ring, Front cover
stud
hex cap nut
O'Ring for lobe sealing
lobe
nut, pump casing
washer
dowel
stud, pump casing
shims
pump casing
bolt, clamp plate
seal clamp plate
mechanical seal,
stationary parts
mechanical seal,
rotary parts
seal spacer
drain
bolt, bearing cover
16

21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.

Bearing cover
oil seal bearing cover
bolt, back cover
back cover
oil seal, back cover
bolt, clamp plate
clamp plate
locking ring outer
locking ring inner
timing gear
ring nut, bearing lock
bearings, rear
bearing spacer
bearings, front
stator shaft
rotor shaft
gear casing
oil inlet
oil indicator
blot, base
base

Pump Speed Selection Chart

* Speed of the pump should not exceed from the chart

* Pump operating speed depends upon liquid viscosity

pump speed chart

pump operating speed (rpm)

liquid viscosity (cst)

upto 1500

1000

1500 - 5000

750

5000 - 15000

500

15000 - 30000

380

30000 - 50000

300

50000 - 100000

200

100000 - 200000

150

17

TEST & WARRANTEE CERTIFICATE

TEST RESULT
PUMP NO :
RATED CAPACITY

MODEL :
RATED PRESSURE

PRESSURE

TEST DURATION :
TEST
TEMP.

TEST
MEDIA
KGF/CM2
LPM

CAPACITY
POWER
CONSUMED

HP

SPEED

RPM

Signature :
QC DEPARTMENT
18

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ANI ENGINEERS
Plot no. 2716, G.I.D.C. Estate, Phase-IV, Wadhwan 363 035. Surendranagar (Guj.) India.
Ph.: +91-2752-241479, Fax : +91-2752-242479
Web : www.anivaryapumps.com, E-mail : mail@anivaryapumps.com