VI Rev07 PDF

TABLE OF CONTENTS
GUARANTEE ............................................................................................................ 3
HOW TO USE THIS MANUAL .................................................................................. 4
1. SAFETY PRECAUTIONS..................................................................................... 7
1.1 General.........................................................................................................................................7
1.2 Major warnings .............................................................................................................................8
1.3 Components and auxiliaries .........................................................................................................9
1.4 Pump to be scrapped ...................................................................................................................9
2. GENERAL DESCRIPTION OF VI PUMPS......................................................... 10

2.1 Casings and impellers ................................................................................................................ 10
2.2 Rotating Assembly and Bearings ............................................................................................... 10
2.3 Technical Data ........................................................................................................................... 11
2.4 Pump serial number ............................................................................................................... 11
3. TRANSPORT AND INTERMEDIATE STORAGE .............................................. 12

3.1 Shipping preparation / Crating....................................................................................................12
3.2 Lifting..........................................................................................................................................12
3.3 Short term...................................................................................................................................13
3.4 Long term optional storage.........................................................................................................13
3.5 Preservation........ .......................................................................................................................13
3.6 Uncrating and inspection ............................................................................................................13
3.7 Installation and stops..................................................................................................................14
4. INSTALLATION.................................................................................................. 15
4.1 General....................................................................................................................................... 15
4.2 Pump installation and foundation ............................................................................................... 15
4.3 Pump - motor alignment ............................................................................................................. 17
5. START- UP AND OPERATION.......................................................................... 18

5.1 Warnings .................................................................................................................................... 18
5.2 General....................................................................................................................................... 19
5.3 Start-up procedure ..................................................................................................................... 20
5.3.1 Lubrication requirements ..................................................................................................... 20
5.3.2 Flushing and filling of bearing housings............................................................................... 21
5.3.3 Initial start-up procedure...................................................................................................... 22
5.4 Pump operation.......................................................................................................................... 23
5.4.1 Standby operation ............................................................................................................... 25
5.4.2 Re-rating and Upgrades ...................................................................................................... 26
5.5 Pump shutdown.......................................................................................................................... 26
6. MAINTENANCE AND SERVICING .................................................................... 27

6.1 Introduction................................................................................................................................. 27
6.2 Maintenance and Inspection schedule .......................................................................................28
6.3 Major Inspection checklist .......................................................................................................... 29
6.4 Factory replacement parts.......................................................................................................... 30
7. FAULTS: CAUSES AND REMEDIES ................................................................ 31
8. DISASSEMBLING AND PARTS REPLACEMENT: Bearings & Seals ............ 33
8.1 Warnings / Cautions ................................................................................................................... 33
8.2 General....................................................................................................................................... 36
8.3 Bearings removal and replacement ............................................................................................ 36
8.3.1 Bearings - removal ............................................................................................................. 36
8.3.2 Bearing housing - removal................................................................................................. 37
8.3.3 Bearings - replacement ..................................................................................................... 37
8.3.4 Bearing housing - replacement.......................................................................................... 37
8.4 Mechanical seal - removal and replacement ............................................................................38
9. VI PUMPS: INNER PARTS REPLACEMENT .................................................... 40

9.1 Pump disassembly ..................................................................................................................... 40
9.2 Wear rings - removal and replacement (closed impeller version)............................................... 41
9.3 Balancing.................................................................................................................................... 42
9.4 Rotor replacement ...................................................................................................................... 42
Table 1: Recommended Bolt Torque............................................................................................. 43
Table 2: Minimum Running Clearances ........................................................................................ 43
Attachment 1: VI Cross Section................................................................................................ 44
Guarantee
GUARANTEE
Seller, Weir Gabbioneta srl, guarantees to Buyer that the equipment at the time of
shipment is free from defects in material and workmanship and conforms in all
respects to the agreed technical specifications. This guarantee shall be ineffective
and shall not extend to:
equipment subjected to misuse, neglect, accident;

equipment which has been improperly installed or maintained;
equipment which has been altered or repaired by anyone other than the
Seller or its authorized representative;
equipment which has been repaired using non-original repair parts;
equipment which has been installed and used under climatic and
environmental conditions that differ from those stated in the Purchase
Order.
This guarantee shall not cover normal wear parts (as per API 610 - IX edition - par.:
3.33), such as wearing rings, bushings, shaft seals and bearings, nor gaskets / O
rings, after pump disassembling.
This guarantee shall be ineffective if the guarantee period indicated in the Purchase
Order, with reference to the time of shipment, has elapsed.
Sellers sole obligation under the foregoing guarantee is limited, at Sellers option, to
replacing or repairing defective equipment.
The guarantee contained herein is made only to and for the exclusive benefit of
Buyer and does not extend to any subsequent purchaser or user of the equipment,
unless specifically mentioned in the Purchase Order.
EngMan00.doc - rev04 - jul04 3

How to use this manual
HOW TO USE THIS MANUAL
This instruction manual contains installation, operation and maintenance instructions

for the pump identified in the Pump Data Sheet included in this manual. It should be
reviewed carefully by the user before attempting to install and operate the pump,
and should be kept in a location convenient to the user for ready reference during
operation and maintenance.
A complete reading of this manual by personnel

in contact with the pump is essential to safety.
INCORRECT INSTALLATION, OPERATION AND MAINTENANCE
OR PARTS REPLACEMENT CAN RESULT IN INJURY TO THE PERSONNEL
AND DAMAGE TO THE PUMP, DRIVING MACHINERY AND PLANT.
This Instruction Manual consists of several sections, as listed in the table of

contents. Since this is a general instruction manual, describing the general pump,
the description and illustrations contained herein may differ in minor details from the
unit actually supplied. However, all general installation, operation and maintenance
procedures are applicable.
For those pumps supplied with optional lubrication systems, control systems
accessories/instrumentation and/or driver, refer to the combined description,
operation and maintenance procedures in the Documentation supplied with
this manual.
The instructions contained in this manual do not attempt to cover all details, nor
provide for every possible contingency to be met in connection with installation,
operation and maintenance.
The supplying of instructions does not imply in any manner that Weir Gabbioneta srl
accepts liability for work carried out by a customer or contractor personnel. Liability
is limited to and as stated in our Terms and Conditions of Sale.
Should further information be desired, or should particular problems arise which are
not covered sufficiently for the purchasers purposes, the matter should be referred
to Weir Gabbioneta srl. All inquiries regarding installation, operation and
maintenance, spare parts or service should be directed to:
Weir Gabbioneta srl

Viale Casiraghi, 68
20099 SESTO SAN GIOVANNI (MI) - ITALY
Tel: +39 02 24 1001 ; Fax: +39 02 24 24550
E-mail: after.sales@weirgabbioneta.com

A typical pump nameplate is given below.

The actual nameplate data can be found in the Final Pump Documentation.
SESTO S. GIOVANNI - ITALIA
2 G c T1/T51
2
RICEVUTA ORG. NOTIFICATO2
ATEX/ITA/40.2003.4876/ 0081
receipt notified body
ANNO DI COSTRUZIONE
year of construction
POSIZIONE
item
TIPO POMPA
pump type
MATRICOLA
serial number
PORTATA
m3/h
capacity
PREVALENZA
m
total head
VELOCITA
rpm
speed
TIPO CUSCINETTI
bearing type
MASSA TOTALE
kg
total mass
TEMPERATURA AMB.
C
ambient temperature
MAWP barg at C
CORPO POMPA
pump casing
HYDROTEST barg
MAWP barg at C
CAMICIA VAPORE
steam jacket
HYDROTEST barg
1
The marking herein reported is to be intended as an example. See the note reported on the
following page about the temperature class.
2
This information is indicated only for category 2 equipment.

STATEMENT
If CE marking is included in the nameplate, the pump complies with the following
European Directives:
Machinery Directive 98/37/CE
PED1 97/23/CE
Electro Magnetic Compatibility Directive 89/336
and amendments.
If x marking is included in the nameplate, the pump complies with the following
European Directives:
ATEX 94/9/CE
Note about temperature class: (EN 13463-1:2001 - par 14.2)

Complete unit temperature class:
Complete unit temperature class can be obtained considering the most limiting
temperature class of the components on the skid (pump, motor, gear box, etc.).
Please refer to the respective instruction and operational manuals.
Pump temperature class:

Pump temperature class is the most restrictive one between the temperature
class due to pump superficial temperature and the temperature class of the
mechanical seal (please refer to its instruction and operational manual).
The following table lists the temperature class of the pump only, assuming that
the maximum superficial temperature is reached on the casing.
Pump superficial temperature depends strictly on the temperature of the pumped
fluid. In normal operational conditions pump temperature class depends on
pumped fluid temperature as reported below:
Pump temperature class Pumped fluid maximum temperature:

(according PrEN 13463-1) [C] [F]
T5 [100C] 80 176
T4 [135 C] 115 239
T3 [200 C] 180 356
T2 [300 C] 280 536
T1 [450C] 430 806
Note: the plant responsible must assure that the pumped fluid temperature
allows to respect the temperature class required in the installation area.
Declaration of Conformity and/or the Declaration of Incorporation are included in

the Inspection Book, as applicable to the specific Purchase Order.
1
PED applies only to pump components (reservoirs, etc.)

01 - Safety Precautions
1. SAFETY PRECAUTIONS
1.1 General
This pump has been designed to provide safe and reliable service within the
designated specifications. It is a pressure containing, rotating machine; therefore,
good judgment and proper safety practices must be exercised by responsible and
qualified personnel to avoid damage to the equipment and surroundings or possible
serious injuries.
It is assumed that the operators safety department has an established safety

program based on a thorough analysis of industrial hazards. Before installing and
operating or performing maintenance on this pump, it is suggested to the operator to
review the safety program and ascertain that it covers the hazards arising from
rotating machinery and pressure vessels.
For a safe pump operation be careful of the proper installation and continued
maintenance of protective guards and safety devices.
It is important that due consideration is given to all hazards resulting from the
presence of:
electrical power
hot liquids
hot surfaces
rotating parts
toxic gases
flammable liquids and gases
explosive atmospheres
environmental noise
Noise levels of the pump unit are given in the Data Sheet supplied in the
Documentation that goes along with this manual.
This manual contains four types of hazard seriousness messages. They are as
follows:
Immediate hazards that will cause, in presence of explosive atmospheres,

ignition with consequent explosions.

Hazards that could result in serious injury to the pump and others,
or extensive damage to the pump unit or surroundings
Hazards that could result in damage or malfunction to the pump or its parts,
leading to subsequent downtime and expense.
A message to clarify or simplify an operation or technique,

or to avoid a common mistake.
1.2 Major warnings
DO NOT START OR OPERATE this pump unless the installation has been verified
to be correct and all pre-startup safety and control functions have been checked.
DO NOT START OR OPERATE this pump unless you have a complete
understanding of the location and function of all upstream and downstream
equipment that may affect the flow of liquid to or from the pump.
NEVER WEAR NECKTIES or other loose clothing while in the proximity
of the pump or auxiliary equipment.
NEVER DISCONNECT THE SUCTION OR THE DISCHARGE FLANGES
of the pump, without first isolating the pump from the inlet and outlet
systems by closing and tagging block valves. Open connections
not protected with block valves should be covered with blind
flanges, rated for the pressure conditions that may prevail.
Both ALL PUMP DRAINS and ALL HEATING JAKED DRAINS
must be opened to depressurize the pump.
DO NOT REMOVE any covers, guards, gland housings,
drain covers, plugs etc, while the unit is operating.
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS
that are not described in this manual.

1.3 Components and auxiliaries
Regarding proper operation and residual risks of components (motors, seals,

lubrication systems, etc.), supplied by constructors different from Weir Gabbioneta
srl, Buyer shall refer to each relevant use and maintenance manuals enclosed with
pump Documentation.
This manual does not replace manuals of enclosed components

supplied by other manufacturers.
USER SHALL KEEP TO WHAT IS PRESCRIBED
IN THE RESPECTIVE MANUALS.
1.4 Pump to be scrapped
The user must to be sure that product will be disposed in accordance with the
regulations in force, so as to prevent any potential negative consequences to the
environment and human health.
EngMan01.doc - rev. 3 - jul 03 9

02 - General description
of VI pumps
2. GENERAL DESCRIPTION OF VI PUMPS
Weir Gabbioneta srl VI pumps are vertical single stage pumps, with a side discharge
column, typically used as sump pumps.
Discharge column, line shaft and support column may consist of multiple sections,
depending upon the pump setting, specified on the Data Sheet.
The discharge column is mounted with a sliding fit through the sole plate, to account
for thermal expansions, if any.
As a standard, VI pumps do not require mechanical shaft seals, since the sump and
the support column are at atmospheric pressure.
A soft packing is normally fitted in the stuffing box to prevent inlet of dirt into the
sump or outlet of vapours or odours.
When the sump is under vacuum or under pressure, or in hazardous areas, the
Purchase Order and the pump Data Sheet specify the use of mechanical seals
(special VI applications).
These special applications are not covered by the present instruction manual.
VI pumps are also applied at high temperatures for molten salts. In these
applications, support column and pump discharge column are jacketed and heated
to prevent crystallization.
2.1 Casings and impellers
Impellers of VI pumps can be closed or semi-open, depending upon the

requirements of the Purchase Order.
When the impeller if of the semi-open type, the thrust bearing holder is mounted in
the bearing housing through adequate shims that permit axial adjustment of the
rotor.
On semi-open impeller pumps the suction casing can be fitted with wear plates, if so
required by the Data Sheet.
2.2 Rotating Assembly and Bearings
As a standard, the rotating assembly is supported by an oil-lubricated, antifriction-

bearing.
Intermediate bushings, lubricated from an external source, or by the same pumped
liquid are located in each column section.
The span between the bushings is a function of the rotational speed, to avoid
resonance, as specified by applicable standards.
EngMan02.doc - rev02 - feb02 10

02 - General description
of VI pumps
Bearing housings can be air-cooled or water cooled, depending upon the conditions
of service, specified on Data Sheet and Purchase Order.
As a standard, bearing housings are equipped with replaceable labyrinth end seals
and deflectors.
If specified by the Purchase Order, the end seals (or bearing isolators) can be of the
Inproseal type (non contacting oil seals of the labyrinth type) or magnetic type.
2.3 Technical Data
This VI pump has been specifically built for the application mentioned in the data
sheet. Information about the main characteristics of this pump is recorded :
on the pump nameplate

on the pump data sheet ( refer to the Documentation enclosed with this
manual).
on the test certificates.
2.4 Pump serial number
Pump nameplate and certified drawing specify the pump serial number. This
number is a unique identifier of the pump; it must be specified when ordering
replacement parts and in all correspondence with the factory.
The serial number is also stamped on the discharge flange O.D., for identification
and reference purposes. It is an alphanumeric code of 5 digits and 1 letter (item).

03 - Vertical pumps:
transport &
intermediate
storage
3. TRANSPORT AND INTERMEDIATE STORAGE (1)
3.1 Shipping preparation / Crating
After testing, the pump is prepared for shipment according to procedures G.08.01.01
or G.08.01.02 depending on which type of storage is chosen: the standard or long
term one.
Prior to crating, the pump unit is given a final inspection from a quality inspector,
who checks for completeness and appearance.
3.2 Lifting
Lifting and handling operations must be carried out by specialized personnel.

Weir Gabbioneta srl refuses all responsibility for any damage to
persons or property caused by failure to comply with the safety provisions
governing lifting and handling operations inside or outside the factory.
Skid mounted units should remain on their respective skids until placement on their
permanent foundations. When a pump unit is on its skid, the skid should be used for
lifting. Pump units shipped on baseplates can be lifted using lifting provisions on the
baseplate.
For correct sling selection, refer to the unit gross weight specified outside the
crating.
Lift slowly and carefully to ensure stability and safety.
NEVER attempt to lift the unit USING pump or driver eyebolts. These
eyebolts are intended for lifting the individual components only. Using any
of the eyebolts to lift the entire unit presents a SERIOUS SAFETY HAZARD.
1
Refer to API Practice 686 - 1996
EngMan03.doc - rev05 - apr05 12

transport &
intermediate
storage
3.3 Short term storage
Weir Gabbioneta srl pumps are normally prepared for short term storage up to 6
months.
The pump should remain in its container, with all covering left intact. Indoor storage
is preferred. The unit should be stored in a clean non-corrosive atmosphere and
protected against damage, loss, bad weather and foreign material, such as dust or
sand, where temperature and humidity values should be maintained at levels
preventing condensation (T = -1050C, R.H. < 90%).
Crates shall be placed on solid flooring but shall not be placed straight on floor.
Temperature control is not necessary.
3.4 Long term optional storage
Long term storage means a period of more than 6 months.

If Long Term Storage was specified in the Purchase Order, the units have been so
prepared at the factory and can be stored for a maximum of 18 months.
The pump should remain in its container, with all covering left intact. Indoor storage
is preferred. The unit should be stored in a clean non-corrosive atmosphere and
protected against damage, loss, bad weather and foreign material, such as dust or
sand, where temperature and humidity values should be maintained at levels
preventing condensation (T = -1050C, R.H. < 90%).
Crates shall be placed on solid flooring but shall not be placed straight on floor.
Temperature control is not necessary.
When it is necessary to store equipment outdoor, it is recommended to put them on

solid floor or on concrete with the interposition of joists and to cover them completely
with tarpaulin.
3.5 Preservation
When the storage period (standard or long term) has expired,

it shall be extended 18 months more by specialized technician.
3.6 Uncrating and Inspection
Remove the packing material and check all items are in accord with the packing list.
Ensure that parts are not missing or damaged. Handle all parts with care.
If any parts are missing from the shipment, contact Weir Gabbioneta srl.
Ensure that loose parts are not discarded with the packing material.

transport &
intermediate
storage
3.7 Installation and stops
Before to put it into service, the pump must be checked in order to assure its
functionality. A Weir Gabbioneta specialist should carry out this check.
If the equipment has been stored for more than 6 months (if standard storage is
applicable) or more than 18 months from last long term storage preparation, the
equipment shall be put into service by a Weir Gabbioneta technician,
otherwise the warranty expires.
When the equipment is installed on the plant but not yet put into service it is
recommended to fill in the bearing bracket and, if applicable, the seal reservoir.
At least once a month, it is advisable to turn by hand all the rotating systems to keep
free the internal parts with reduced clearance and the mechanical seal. Verify that
the external metallic parts made of non-inox material are correctly protected against
corrosion (with product equivalent to Valvoline Tectiyl) and restore the protection if
necessary.
Two different situations may occur, they request different means of conservation:
a) the equipment is installed on the plant, it is completely empty and never started:
. internal and external surfaces protections are still operating and it is enough that
the equipment is installed in a clean non-corrosive atmosphere and protected
against damage, loss, bad weather and foreign material, such as dust or sand.
Temperature and humidity values shall be maintained at levels preventing
condensation (T = -1050C, R.H. < 90%).
. If equipment is not put into service within the foreseen storage period, a Weir
Gabbioneta technician shall check it before to start it, otherwise the warranty
expires.
b) the equipment was installed on the plant and started for a period to check it in
rated conditions, than it was stopped waiting for the real starting of the plant:
surfaces protections are not operating. Once stopped, the pump shall remain filled
with pumped fluid. Otherwise protections must be restored according to paragraph 5
of procedure G.08.01.04 possibly by a Weir Gabbioneta technician.

installation
4. INSTALLATION (1)
4.1 General
Proper installation of pump and driver is vital for successful operation of the system.
It is for this reason that competent and experienced personnel should be employed
during installation.
Refer to the Certified Drawing in the Document enclosed with this manual, prior to
installation.
The following recommendations and instructions are provided to assist the

purchaser and/or his contractor. Fully qualified labour, including qualified
supervision is required for proper installation, start-up and subsequent operation.
The services of a Weir Gabbioneta srl serviceman or authorized personnel are
recommended for supervision of installation and start-up of the pump.
To achieve satisfactory operation, the following steps must be carried out in

sequence:
Refer to the certified outline drawing and carefully read all installation notes,
piping connection details, dimensions and any other special data.
Remove all protective coatings and foreign matter from the unit.
Provide a proper and adequate foundation for the pump sole plate or suction
barrel (if any).
Insert shims around each anchor bolt and level suction barrel flange.
Grout the suction barrel to the foundation as required.
4.2 Pump installation and foundation
A foundation or frame must maintain alignment under all normal and abnormal
conditions. This includes the way a foundation or frame is supported on the soil
and/or superstructure, soil settling, soil resonance, thermal distortion and piping
forces.
Sufficient space should be provided around and above the foundation to allow for
proper installation and maintenance.
If required by the Purchase Order, vertical pumps can be mounted on a frame

across a sump or mounted on a can.
On vertically suspended can pumps, the foundation shall be designed so that the
pump can is directly attached to the mounting plate and is removable without
damaging the grout. The foundation must be water tight.
A minimum clearance of 50 mm (2") should be maintained between the outside of
the can and the inner liner surface.
1
Refer to API Practice 686-1996
EngMan04.doc - rev07 - jun06 15

installation
An axial clearance of 300 mm (1 foot) should be maintained between the bottom

surface of the cavity and the bottom of the pump can, to prevent distortions due to
thermal growth.
The foundation (or the support structure) must minimize vibration by being non-
resonant within the operating range of the pump unit.
Normal excitation frequencies (i.e.: 1- and 2-times running frequencies or blade-
passing frequencies) can cause abnormal vibrations.
Upon request, Weir Gabbioneta srl engineers can provide assistance in the design
and dynamic analysis of tuned foundations.
A certified outline drawing is furnished with each pump unit and is included in the
Documentation enclosed with this manual. This drawing includes dimensions for
locating anchor bolts, unit overall weight and single component weights, as well as
general information required to determine foundation dimensions and design.
A generous safety factor should be used when determining foundation thickness.

Anchor bolts must be positioned accurately, while the foundation is cast. Skilled
craftsmen should be able to set anchor bolts to a tolerance of 3 mm by locating and
drilling holes in the template after they have been secured to the brace forms.
Templates must be rigid enough to prevent bolts from shifting while concrete is
being poured. After concrete has been poured and before it has hardened,
recheck positions of anchor bolts.
Mounting plates, if required by the Purchase Order, are designed in accordance to

the guidelines given in Chapter 4 - Section 2.6 of API Practice 686, i.e.:
- mounting plate diameter is at least 50 mm (2") bigger than the pump/can

flange diameter;
- anchor bolt holes have a minimum 3 mm annular clearance with the anchor
bolt, for field alignment;
- mounting plates are provided with vertical leveling screws.
The mounting plate or the frame shall be installed in accordance with the
construction drawing and leveled with a master level or a precision machinist's level.
Mounting plate level is to be set to within 40 m per meter (0.0005 in/ft) by adjusting
the jacking screws and inserting shims.

installation
4.3 Pump - motor alignment
After the installation of the motor, motor to pump alignment must be checked, prior
to inserting the bolts on the coupling halves.
Generally no operation is required, because alignment between motor and pump
shaft is ensured by the rabbet joint provided on motor to pump mounting surface.
It is however advisable to check concentricity of the motor fit and perpendicularity of
its mounting surface, by turning the motor shaft by hand, after installing on this one
a bracket carrying a dial gauge. Both readings shall not exceed respectively 0.05
and 0.025 mm per each 100 mm of DBSE.

Start-up and
Operation
5. START- UP AND OPERATION
5.1 Warnings
The operator should read Section 2 and the Documentation enclosed with this
manual to become familiar with the pump, before attempting to start and operate it.
DO NOT START OR OPERATE this pump unless the INSTALLATION has been
verified to be CORRECT and all SAFETY FUNCTIONS have been checked.
DO NOT START OR OPERATE this pump unless you have a COMPLETE

UNDERSTANDING of the location and function of all components on suction and
discharge pipings and ancillaries, including valves, bypasses, vents and drains
and any equipment that may affect pump and seal operation
DO NOT START OR OPERATE this pump unless you have a COMPLETE

UNDERSTANDING of the lubrication system and all auxiliary mechanical, electrical,
hydraulic and pneumatic system, as well as the meaning of all monitoring gauges,
meters, digital readouts and warning devices.
Maximum temperature of pump open surfaces is similar to the pumped fluid one.
If the pumped fluid temperature is too high, pump surface could burn if touched.

Start-up and
Operation
For pumps operating IN PARALLEL be sure that relative

performance curves are strictly similar
5.2 General
The following recommended start-up and operation procedures apply to the basic
pump configuration. For information on any optional equipment refer to the
Documentation enclosed with this manual.
None of the recommended start-up and operating procedures contained in this

manual shall be interpreted in any way as relieving the user of his responsibility
for compliance with the requirements of any regulatory body, or for the exercise
of normal good judgment in the start-up, operation and care of the pump unit.
To ensure trouble-free operation, the pump must be:
cleaned accurately prior to start-up, and kept clean at all times;

properly lubricated at regular intervals, as recommended in Section 6;
regularly inspected and maintained according to a scheduled preventive
maintenance program;
operated according to the procedures specified in the present instruction
manual.
The following is a recommended list of items that should be checked before start-up:
examine suction and discharge piping for manually operated check valves
and recirculation line. All check valves must be fully open, before start-up;
identify the pipe section fitted with the temporary suction strainer (if any). The
installation of this strainer (refer to fig. 1) is a recommended practice to
prevent dirt or welding slags from entering the pump, which may damage the
impeller and other internal components. The strainer must be made in
stainless steel, with an open area from 3 to 5 times the cross section of the
suction piping (60 mesh is a recommended practice);
check that strainer is not clogged;
identify the differential pressure gauge, installed on the strainer. This gauge
must be monitored to detect clogging and need for cleaning or replacement.
visually inspect the unit, the grouting and the anchor bolts for any missing or
improperly fitted component;

Start-up and
Operation
check the correct installation of the recirculation valve, if included in the

scope of supply;
check oil levels;
check water cooling lines, if installed;
check flushing lines to seal(s) against pump and seal manufacturers
instructions;
on motor driven units, check electrical connections and motor auxiliaries
against motor manufacturers instructions;
on turbine driven units, check steam piping and turbine auxiliaries against
turbine manufacturers instructions
5.3 Start-up procedure
5.3.1 Lubrication requirements
Several lubrication options are available; the selected option, installed on this pump,
has been specified in the Purchase Order.
Unless otherwise specified, bearing housings are arranged for oil lubrication. The
bearing adapter sleeve, running on the pump shaft picks up oil from the reservoir in
the bearing housing and conveys it to the bearing.
The oil level within the bearing housing must be sufficiently high to allow the sleeve
to run in the oil. However, an oil level that is too high may result in oil leakage past
the shaft seals or in excessive friction.
Check oil level in the glass level gauge installed on the bearing housing.
For details on the recommended type of oil refer to the Lubricant List, in the
Documentation enclosed with this manual.
In many applications, the bearing housings may be water-cooled. Refer to the

Certified Drawing for the location of the cooling water connections.
All unused bearing housing connections should remain plugged.
Use only clean, fresh (non corrosive) water. Maximum allowable cooling water
pressure is indicated on the pump data sheet.

Start-up and
Operation
Cooling water flow should be adjusted to maintain oil temperatures in the sump
between a minimum of 40 C ( 100 F) and a maximum specified by applicable
standards (e.g.: max 82 C / 180 F for a maximum ambient temperature of 43 C or
110 F).
Do not allow COOLING WATER to COOL bearing oil to below 40 C,

as this may interfere with the action of the oil rings or cause
ATMOSPHERIC MOISTURE to CONDENSE in the oil reservoir.
5.3.2 Flushing and filling of bearing housings
Before starting the pump for the first time, open all bearing housing drains and allow
any residual oil to drain. Then close the drains and fill the bearing housings with a
light, warm oil. Rotate the shaft and then drain this oil.
The oil recommended for permanent operation (see below) should now be added to
the bearing housing through the vent plug hole, after removing the vent plug and the
constant level oiler, until oil comes out from the oiler hole.
Re-install the oiler and add oil as necessary through the constant level oiler, until the
oil level in the level gauge is correct.
The constant level oiler maintains a constant level of oil in the bearing housing as
long as there is oil in the bottle and the oiler operates properly.
The presence of oil in the constant level oiler does not necessarily
mean that oil in the bearing housing is at the proper level.
CLEANLINESS is essential for long and trouble-free service of the bearings.

Care must be taken to ensure that NO FOREIGN MATERIAL enters bearing
housings or constant level oilers when performing maintenance operations.

Start-up and
Operation
The Lubricant List, given in the Final Documentation, indicates:
the type of oil suggested;

the quantity of oil required;
the estimated consumption under normal operating conditions;
the recommended frequency of oil changes.
for oil mist or pressurized lube oil systems refer to the documents supplied in
the Documentation enclosed with this manual, namely: P&I, Instrumentation
List, Instrumentation Data Sheet and Logic Diagram.
5.3.3 Initial start-up procedure
Before starting the pump the following precautions should be taken:
review the warnings in Section 5.1;

check that suction and discharge pipes are properly connected and that all
bolts are tight;
remove coupling guard and coupling spacer;
disengage mechanical seals locking tabs, if installed;
check that pump and driver rotate freely;
check the direction of rotation of the driver, as per installation drawing (see
the rotation arrow attached to the pump casing);
re-install coupling spacer and coupling guard;
check oil levels in bearing housings;
admit cooling water to bearings, if required, and check circulation;
check circulation of the auxiliary seal liquid to the seal(s), if an auxiliary
system is installed;
check the forced feed lube oil system, if installed;
check proper axial clearance between deflector and bearing cover;
check that either the electrical tracing or the pump heating jacket are
activated, obviously if they are provided;
open hand valves on the vent line(s), if installed, or temporarily remove vent
plug(s), so as to fill completely the pump;
close the valve(s) on the vent line(s) or re-install the vent plug(s); Note: the
pumps vent, if any, shall be kept open when pumping volatile fluids and in
cryogenic services;
open the valves of the warm-up system, if any;
close the gate valve on the discharge pipe, keeping open the recirculation
line, if any. Otherwise, partially open the gate valve on the discharge pipe.
open the valve on the suction pipe;
check proper connection of ground wires;
start-up the driver according to manufacturers instructions. Check mechanical
running. When the driver has reached its normal operating speed, check
pump discharge pressure against the shutoff pressure indicated on the data
sheet.
slowly open the discharge gate valve until the required flow and pressure are
reached.

Start-up and
Operation
Pump operation at SHUT-OFF (discharge valve closed) is allowed

for a max of 10 seconds, after which the valve must be opened.
Failure to comply with this practice may result in dangerous
OVERHEATING of the pump and SEIZURE OF THE ROTOR.
5.4 Pump operation
TEMPERATURE CLASS marked on pump nameplate shall be consistent

with temperature required on installation area.
Pump surface temperature shall comply with

TEMPERATURE CLASS marked on pump nameplate.
Incidental OVERHEATING can cause, in presence of explosive atmospheres,
ignition source with consequent explosions.
Pump flow shall be in the Allowable region

as specified in the Performance Test Certificate.
Monitor the trend of the discharge pressure:

a sharp change may indicate that the pump is working with no fluid.
During pump operation, regularly check oil levels, bearing temperatures and
vibration levels.

Start-up and
Operation
Bearing temperatures may vary depending on type and size. Continuously rising
bearing temperatures or abrupt temperature rises are indicative of premature wear
of bearings and short-term failure.
Recommended TEMPERATURE SETTINGS are listed in the table in the following

page:
TYPE TEMPERATURE ALARM TRIP

of GAUGE
BEARINGS LOCATION C C
antifriction bearing
87 95
bearings outer race
thrust bearing
93 115
shoe
hydrodynamic
bearings
line bearing 93 115
shoe
Oil must be regularly changed according to a schedule that is influenced by the

pump duty. On normal duties, it is recommended to change the oil every 4000
working hours or at least every 6 months.
VIBRATION LEVELS should be checked and recorded regularly. Continuously rising
vibration levels are indicative of internal wear, incipient damage or other
irregularities. The following table should be adopted, unless otherwise specified in
the Purchase Order.
TYPE OF ALARM SETTING TRIP

VIBRATION SENSOR
proximity probe
65 100
(m peak to peak)
velocimeter
5.4 8.5
(mm/s RMS)
These limits apply to the broad band r.m.s. values of vibration velocity and
displacement, in the frequency range from 10 Hz to 1000 Hz, and are valid for
operation at the rated flow rate of the pump.
The vibration levels indicated on the table are applicable only for the vibration
produced by the machine itself and not for the vibration that is transmitted to the
machine from external sources.

Start-up and
Operation
When an excessive background vibration is suspected, measurements should be

made with the machine shut down, to determine the degree of external influence.
If the vibration with the machine stationary exceeds 25 % of the value measured
when the machine is running, corrective action is recommended, to reduce the effect
of background vibration.
For all cryogenic services venting connection in discharge head must be always
opened during both operation and stand-by conditions.
5.4.1 Standby operation
Pumps that are not running continuously are in standby operation, where they
must be ready to operate at any time with little or no advance notice.
Pumps on high or low temperature duties are very sensitive to temperature

gradients that may affect internal clearances, due to differential thermal expansion
of rotating and stationary components, resulting in rubbing or seizure at the wear
rings or bushings.
Therefore, a circulation system (heating jacket) must be foreseen by the plant

operator to keep high temperature pumps at a specified and uniform temperature
during standby operation.
No attempts should be made to rotate the shaft of a HOT STANDBY PUMP,

unless the pump has been accurately and uniformly warmed-up.

Start-up and
Operation
5.4.2 Re-rating and Upgrades
Weir Gabbioneta srl pumps can eventually be re-rated to different conditions of

service. Contact Weir Gabbioneta srl factory to determine if a re-rating or upgrading
can meet your needs.
Materials used in pump construction vary with the characteristics of the pumped
liquid. These materials were selected according to the original rating of the pump.
NEVER attempt to RE-RATE a pump without the assistance of the
manufacturers representative misapplication of materials COULD
result in serious equipment damage and/or personal injury.
5.5 Pump shutdown
Shutting down operations must be accomplished in the following order:
1. shut down the driver;

2. immediately close the discharge gate valve;
3. close the suction gate valve and the valves of the auxiliary systems.
In some applications, both the seal flushing and the heating pump system must be
maintained open during pump shutdown, to prevent the formation of crystals.
WATER COOLED JACKETS must be DRAINED

if there is a possibility of freezing temperatures

06 - Maintenance
& Servicing
6. MAINTENANCE AND SERVICING
6.1 Introduction
This pump is a high quality machine that has been carefully assembled and
thoroughly tested at the factory. It requires periodic maintenance and service. This
section describes periodic maintenance requirements.
Refer to Section 8 for major service and overhaul instructions.
BEFORE DISCONNECTING SUCTION OR DISCHARGE FLANGES

BE SURE THAT THE INCIDENTAL FLUID LEAKING IN THE ATMOSPHERE
DOES NOT REPRESENT AN IGNITION SOURCE,
WITH CONSEQUENT DANGER OF EXPLOSIONS.
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR MODIFY

ANY PART of this pump unit WHILE IT IS IN OPERATION, unless
such action is expressly described in this instruction manual
NEVER DISCONNECT SUCTION OR DISCHARGE FLANGES

of the pump without first isolating the pump from the system
by CLOSING AND TAGGING BLOCK VALVES.
Open connections not protected by block valves
must be covered with blind flanges.
Both ALL PUMP DRAINS and ALL HEATING JACKED DRAINS
must be opened to depressurize the pump.
MAINTENANCE PERSONNEL should be thoroughly FAMILIAR with

the pump and accessories, before attempting any maintenance
or service. A complete reading of this manual is recommended.
When RESTARTING a pump after repair or maintenance,

always treat the pump as if it were A NEW PUMP being
started for the first time. Refer to Section 5.

06 - Maintenance
& Servicing
6.2 Maintenance and Inspection schedule
Maintenance requirements may vary with the application and the service conditions.
The following guidelines are recommended for pumps operated under normal
conditions. It is also recommended to establish a Maintenance Program.
Suggested Maintenance and Inspection Schedule:
Frequency Maintenance or Inspection Procedure
Check for smoothness of operation, unusual noises or other

changes in operating conditions.
Check oil level in bearing housing(s).

Add oil, if required.
Daily Check oil temperature
Carefully inspect baseplate to detect signs of leakage from

mechanical seal or from pump.
Check that pump surface temperature complies with temperature

class marked on pump nameplate.
Check connection of ground wires.

Weekly
Check electrical continuity of pump and auxiliaries connected to it.
Sample the lubricating oil and replace it, if necessary.

Monthly
Check and record vibration levels.

06 - Maintenance
& Servicing
Replace the lubricating oil
Every 6 months
Check cooling jacket on bearing housings for sludge or
sediments.
Every 2 years Replace bearings.
6.3 Major Inspection checklist
Weir Gabbioneta srl recommends that the pump be periodically shutdown and
subjected to a major inspection. The frequency of this inspection will depend on the
service conditions, the convenience of scheduling the shutdown and the users
experience with similar machines.
Parts to be Inspect for Action required

inspected
Wear Rings Wear, signs of foreign matters Treat with fine emery cloth
Sleeve Wear, signs of foreign matters Treat with fine emery cloth
Antifriction bearings Excessive radial play Replace bearings
Mechanical seal Scratches on mating surfaces Relap the surfaces.
Gaskets ---------------------------------- Replace all gaskets.

06 - Maintenance
& Servicing
6.4 Factory replacement parts
Weir Gabbioneta srl recommends that only original parts be used in their pumps.
The use of Weir Gabbioneta srl parts ensures that the replacement components are
manufactured from the highest quality materials, exacting tolerances and
specifications, thereby ensuring efficient and long-lasting operation, under service
conditions that the pump was built for.
The use of non- original repair parts shall be considered

IMPROPER MAINTENANCE and shall VOID ALL guarantee clauses.
When required, Weir Gabbioneta srl can supply the most frequently requested spare
parts on an emergency basis, for shipment worldwide.
The following is a list of recommended spare parts that should be kept in inventory
at the users plant to handle all repairs, excepted the most extensive ones:
one set of casing wear rings

one set of impeller wear rings
one shaft sleeve
one complete mechanical seal
one set of bearings
one set of gaskets
one set of O rings
The serial number, identifying the pump, should be used in all inquiries and parts
orders. The serial number is an alphanumeric code, consisting of 5 digits and 1
letter (item).
This number appears on the nameplate and is stamped on the discharge flange
O.D. of the pump casing.

07 - Faults : causes
and remedies
7. FAULTS: CAUSES AND REMEDIES
This Section should be consulted when the pump is not operating satisfactorily.
The following table lists the most common symptoms, probable causes and
corrective actions that should be taken.
If the problem cannot be completely remedied using the table, refer your questions
to:
Weir Gabbioneta srl

Viale Casiraghi, 68
20099 SESTO SAN GIOVANNI (MI) - ITALY
Tel: +39 02 24 1001 ; Fax: +39 02 24 24550
E-mail: after.sales@weirgabbioneta.com
When contacting the factory, it is of the greatest importance to provide suction and
discharge pressures, power input, rotational speed as well as electric motor data or
steam pressures, in the case of turbine driven equipment.
Symptom Probable Cause Corrective Action
Pump does not Pump and suction pipe have Thoroughly vent suction pipe and pump
deliver liquid not been filled completely with casing.
liquid
Pump does not 1. Air leaks into suction pipe Check and tighten bolts on suction flange.
deliver enough Replace gasket on suction flange.
liquid 2. Suction lift too high Check installation against drawings
3. Speed too low Check driver electrical or steam
connections
4. Wrong direction of Change power input cables to motor.
rotation Check rotation arrows on turbine and
pump. If incompatible, review terms of
Purchase order.
5. Impeller(s) damaged Replace impeller(s)
6. Worn wear rings Replace wear rings
Pump loses 7. Air or gas in liquid - see Tighten bolts on suction piping or replace
prime after start- n 2 & 3 gaskets on suction line.
up
Insufficient 8. Viscosity too high or see Check actual liquid against pump data
discharge n 4 & 7 sheet
pressure

07 - Faults : causes
and remedies
Pump overloads 9. Specific gravity or Check pump and motor data sheet.
driver viscosity of the pumped
liquid different from the
rated ones
10. Head and capacity Adjust discharge valve
different from the rated
ones
11. Wrong alignment Re-align the unit - see Section 4
12. Mechanical defects : bent Disconnect coupling and check shaft
shaft ; internal rubbing runout. Replace shaft if runout exceeds
0.025 mm at shaft end - Refer to Section
8.
13. Packing or mech. seal Loosen packing gland bolts.
spring too tight, causing Check setting of mechanical seal.
excessive friction
Pump vibrations 14. Pump operates at too low Open valve on discharge piping
capacity
15. Misalignment Disconnect coupling and check alignment
as per Section 4.
16. Worn bearings Replace bearings Refer to Section 8.
17. Unbalanced coupling Remove coupling halves and check for
unbalance.
18. Piping strain Check piping supports. Refer to Section 4.
Bearing failure 19. Improper lubrication Verify that the proper lubricant is being
used. Check oil for sediments and
condensate.
20. Improper water cooling Adjust water-cooling to maintain oil
temperature as recommended by Section
5.
21. Misalignment See Vibrations n 16
22. Excessive thrust See Mechanical defects n 13
23. Rust Rust may develop during improper
storage of the unit. Refer to Section 3.
Seal failure 24. Improper flushing of seal Check flushing line(s) for circulation of the
cavity flushing liquid
25. Wear of the shaft sleeve See Mechanical Defects n 13

08 - Disassembling &
Parts replacement
VI Pumps
Bearings & seals
8. DISASSEMBLING AND PARTS REPLACEMENT: Bearings & Seals
8.1 Warnings / Cautions
BEFORE DISCONNECTING ANY COMPONENTS

BE SURE THAT THE INCIDENTAL FLUID LEAKING IN THE ATMOSPHERE
DOES NOT REPRESENT AN IGNITION SOURCE,
WITH CONSEQUENT DANGER OF EXPLOSIONS.
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR MODIFY

this pump unit WHILE IT IS IN OPERATION, unless such action
is expressly described in this instruction manual
NEVER DISCONNECT SUCTION OR DISCHARGE FLANGES of the

pump without first isolating the pump from the system by CLOSING
AND TAGGING BLOCK VALVES. Open connections not protected
by block valves must be covered with blind flanges.
ALL PUMP DRAINS and ALL HEATING JACKET DRAINS must be opened to
depressurize the pump.
DO NOT remove any COVERS, GUARDS, GLAND HOUSINGS etc.

while the UNIT IS IN OPERATION.
EngMan08.doc - rev06 - jan06 33

Parts replacement
VI Pumps
Bearings & seals
NEVER SUBSTITUTE A BOLT of unknown or lesser grade

for an original bolt supplied with the pump. DO NOT MIX BOLTS
during disassembly. Failure to use the proper grade bolt could
result in serious FAILURE of pressure containing components.
MAINTENANCE PERSONNEL should be thoroughly FAMILIAR with the pump

and accessories, before attempting any maintenance or service.
A complete reading of this manual is recommended.
Maintenance personnel must be aware that the USE OF NON-GENUINE

Weir Gabbioneta parts shall VOID ALL WARRANTY clauses.
When RESTARTING a pump after repair or maintenance, always treat the pump
as if it were A NEW PUMP being started for the first time. Refer to section 5.
CLEANLINESS is ESSENTIAL for long, trouble-free service of

bearings and rotating components in general. Take care to ensure
that no foreign material enters bearing housings or constant level oilers,
when performing maintenance operations.

Parts replacement
VI Pumps
Bearings & seals
Before proceeding to pump disassembling, disconnect auxiliary piping,

remove instrumentation and, in general, all ancillary equipment.

Parts replacement
VI Pumps
Bearings & seals
8.2 General
Any pump part can be replaced in the field using instructions presented in this
section, if qualified personnel and facilities are available. If not, it is recommended
that a service representative from Weir Gabbioneta srl be employed to make the
field repairs.
Before disassembling VI pumps, it is important to understand that shims (65/5)

control the axial adjustment of the complete rotating assembly, whose total end
float, without shims, is approximately 8 10 mm.
For correct operation of the pump, the rotor is normally lifted 2 3 mm from its
lowest setting, when fitted with a closed impeller, and 0.5 mm when fitted with a
semi open impeller.
Prior to pump disassembly, it is recommended to ensure that the pump has been
depressurized and drained.
8.3 Bearings removal and replacement
VI pumps are fitted with antifriction bearings mounted inside a bearing housing that
can be air- or water-cooled, as specified by Purchase Order and Data Sheet.
8.3.1 Bearings - removal
To remove the bearing proceed as follows referring to Cross Sections:

Remove plug (57/2) and drain the oil from the bearing housing.
Unscrew the screws on the upper flexible coupling.
Remove the motor from its baseframe (26).
Using a suitable puller, remove coupling half and key (14/1) from the pump
shaft.
Lift the tab on lockwasher (64/6) and unscrew locknut (42/2).
Remove locknut (42/2) and lockwasher from the pump shaft.
Remove screws (28/4) and bearing cover (38/5) with seal ring (39/9).
Using a suitable puller remove the bearing adapter sleeve (43) with the
bearing (25/8) from the pump shaft.
To remove the bearing (25/8) from the adapter sleeve, unscrew oil ring (75).
Using a suitable puller remove the bearing from the adapter sleeve.
When removing or replacing antifriction bearings mounted on the adapter,

NEVER PRESS or apply force on THE OUTER RACE, as this may
damage the internal components of the bearing.
NEVER HAMMER on either the inner or outer races.

Parts replacement
VI Pumps
Bearings & seals
If the bearing BINDS during installation or removal, DETERMINE THE CAUSE

AND CORRECT it, rather than apply more force.
8.3.2 Bearing housing - removal
Remove nipple (59/2) from bearing housing.

Unscrew screws (28/2) and separate lower bearing cover (38/2) from bearing
housing (174).
Unscrew the nuts on stud bolts (36/33), hoist the complete bearing housing
(174) and remove it from the pump. Lift slowly and carefully.
Bearing housing seals and oil deflectors - Options
Lip-seals may be provided on request. In this case the oil deflector is press-fitted
onto a shaft sleeve that runs under the lip seal. Unscrew set screws and remove oil
deflector and shaft sleeve.
Inproseals are optional, non-contacting oil seals that replace standard labyrinth type
bearing housing seals. Refer to the Documentation enclosed with this manual for
removal and installation of Inproseals.
8.3.3 Bearings - replacement
Install shims (65/5) and the new bearing (25/8) on the adapter sleeve (43).
HEAT THE BEARINGS prior to assembly. Bearings must be heated slowly

and evenly to a temperature NOT EXCEEDING 120 C (250 F),
using electrical heaters or an oil bath.
Tighten oil ring (75) according to torque values given on Table 1 (page 43).
Install adapter sleeve (43) with bearing and oil ring on the shaft (5/3).
8.3.4 Bearing housing - replacement
Insert the lower bearing cover (38/2) on the shaft (5/3).

Proceed with the antifriction bearing replacement as described on par 8.3.2
Install the complete bearing housing (174) on the pump.
Insert upper bearing cover (38/5) with seal ring.
Install lockwasher (64/6) and locknut (42/2) on the shaft.

Parts replacement
VI Pumps
Bearings & seals
Tighten locknut according to torque values given in Table 1 (page 43) and
check pump for free rotation.
Bend one tab of the lockwasher and complete the installation of the upper
(38/5) and lower (38/2) bearing housing covers.
Re-install oil nipple (59/2) with plug, shaft key (14/1) and upper coupling half.
8.4 Mechanical seal - removal and replacement
Lock the setting tabs into the slot on the mechanical seal sleeve.
Unscrew the set screws on the mechanical seal cartridge, according to the
instruction given in the Documentation enclosed with this manual so as to
loosen the seal cartridge from the shaft.
Unscrew screws (28/27) on upper coupling half and allow the rotor to
gradually reach its lowest setting.
Unscrew screws (28/41) of the split ring (20/19) and remove this one.
Slide the upper coupling half (410/5) sufficiently upwards to allow removal of
the coupling spacer (410/3).
Unscrew screws (28/27) on lower coupling half and remove the coupling
spacer (410/3).
Unscrew screw (28/16) of the lower coupling half (410/4).
Using a suitable puller, remove the half coupling (410/4) and the key (14/7)
from the pump shaft
The mechanical seal cartridge can now be removed according to the
instructions contained in the Mechanical seal Instruction manual - Refer to
the Documentation enclosed with this manual.
All SHARP edges must be REMOVED before mounting the mechanical seal.
Care should be taken during mounting of the O rings to

prevent damages with spanners, pins etc.
The shaft or the shaft sleeve should be lightly lubricated

before installing the mechanical seal.
NO LUBRICATION is required on the FACES of the seal.
NEVER OPERATE a mechanical seal DRY, unless so required

by the mechanical seal instruction manual.

Parts replacement
VI Pumps
Bearings & seals
To replace the mechanical seal, follow the instructions given in the Documentation
enclosed with this manual and reassemble the pump in reverse sequence, i.e.:
check the concentricity and perpendicularity of seal chamber with pump shaft
axis (se points 2.7.3.11 2.7.3.13 of API 610 8 Ed.). The eventual required
corrections can be done acting on bearing housing centering.
tighten the screws on the seal gland;
Install coupling halves and spacer. By tightening screws (28/27) on upper
coupling half the complete rotor is lifted to reach its original setting.
tighten the set screws on the seal sleeve;
disengage setting tabs.
reinstall the split ring (20/19) against the hub of the coupling half and tighten
the screws (28/41)

09 - Inner Parts
replacement
VI Pumps
9. VI PUMPS: INNER PARTS REPLACEMENT
Weir Gabbioneta srl VI pumps are vertical single stage pumps, with a side discharge
column, typically used as sump pumps.
Discharge column, line shaft and support column may consist of multiple sections,
depending upon the pump setting, specified on the Data Sheet.
The discharge column is mounted with a sliding fit through the sole plate, to account
for thermal expansions, if any.
Impellers of VI pumps can be closed or semi-open, depending upon the

requirements of the Purchase Order.
On semi-open impeller pumps the suction casing can be fitted with wear plates, if so
required by the Data Sheet.
9.1 Pump disassembly
To disassemble the pump, perform the operations outlined in Section 8, disconnect

discharge flange and proceed as follows:
Remove hold down bolts on pump soleplate.
Hoist pump bracket (26) and lift the complete pump out of the sump. Proceed
slowly and carefully.
Lay the pump horizontally and start disassembly from the suction end.
Remove the suction strainer (11), if any, by unscrewing the nuts on stud bolts
(36/4).
Unscrew nuts on stud bolts (36) and remove suction casing (3).
Lift tab on lockwasher (64/2) and unscrew impeller locknut (94).
Remove impeller (6) and key (14) from the shaft.
The impeller is secured to the shaft with a sliding fit and a key.
Separation of the impeller from the shaft may require a puller,
due to the presence of crusts or scales.
DO NOT apply HEAT to ease removal of impeller or sleeve.
Unscrew nuts on stud bolts (36/7), (36/10) and screws (28/22) and remove
casing (1) from discharge and support column.
Remove bearing bushing (147) from pump casing (1) after unscrewing nuts
on stud bolts (36/48) with a suitable puller.
Unscrew nuts on screws (54/34) and remove column (151/1).
As a standard, intermediate bearing bushings (147/1) can be removed from
their seats with a puller. In special VI versions bearing bushings are mounted
with screws on the intermediate bearing, to facilitate replacement. Remove
screws (28/12) to remove the bushing.

09 - Inner Parts
replacement
VI Pumps
Remove all columns in sequence. During pump disassembly, the shaft must
be accurately supported to prevent bending.
Before removing the upper column (151/3), unscrew nuts on gland (88), remove the
gland and the packing (89) from the stuffing box.
Remove column (151/3) from soleplate after unscrewing nuts on studs (36/8).
Remove discharge elbow (180) by unscrewing nuts on stud bolts (36/9).
Remove O-ring (89/1) or packing (89/5) and remove discharge column from
soleplate.
Remove sleeve (87/2) from the shaft, using a suitable puller. Remove key
(14/2).
Multiple section shafts can be disassembled by removing the intermediate shaft

couplings as follows:
Unscrew set screw (185/6) on shaft coupling (410/6) and slide the coupling
along the shaft until split rings (20/4) can be removed.
Remove keys (14/21).
Remove shaft sleeves (87/3), keys (14/5) and circlips (20).
Remove circlip (20/5) and upper shaft sleeve (87) with "O" ring (19).
Inspect impeller wear rings for wear or scoring (closed impeller version).
Inspect the casing wear rings for wear or scoring (closed impeller version).
Inspect the suction casing or the wear plate for wear or scoring (open
impeller version).
Replace wear rings when the clearance between stationary and rotating parts
has doubled with respect to the value indicated on the data sheet.
Replace the suction casing when the wear is in excess of 2 mm.
Replace the wear plate when the hardened surface has been worn out.
Inspect the pump shaft for scoring or corrosion. Shaft and shaft sleeves
should not be corroded nor oxidized. In case of corrosion, replace the part.
9.2 Wear rings - removal and replacement (closed impeller version)
Impeller and casing wear rings can be removed using a suitable puller, after removal
of the set screws.
Replacement of wear rings requires drilling and tapping of new holes for the set
screws.
After replacement of the wear rings,

impeller re-balancing is required. Refer to section 9.3

09 - Inner Parts
replacement
VI Pumps
9.3 Balancing
Impellers of VI pumps shall be dynamically balanced to the unbalance limit specified

by the applicable standard, i.e. ISO 1940 Grade 1.0.
Before proceeding to the balancing, calculate the residual admissible weight with the
formula:
where:
p = residual admissible weight grams
Pe P = impeller weight
p kg
r r = impeller radius where material is removed mm
e = residual admissible eccentricity of the
center of gravity (C.G.) m
The value of e is given by a diagram and can be found in the following table for the
most commonly used rotational speeds.
rotational speed (rpm) 1450 1750 2950 3550

e = residual admissible eccentricity of C.G. (m) 17.2 14.3 8.5 7
Balance each impeller by removing some material from the discs, at radius r, by
milling or grinding.
9.4 Rotor replacement
From the upper end of the pump, reinstall discharge column, shaft sections with
sleeves and columns as previously described, in reverse sequence.
Install pump casing (1) after coating sleeve (87/2) with light oil.
Tighten nuts on stud bolts (36/7), (36/10) and screws (28/22). Torque as
per Table 1 (page 43).
Install key (14), impeller (6), lockwasher (64/2) and impeller nut (94).
Tighten the impeller nut and bend the lockwasher tab.
Install the suction casing (3) and tighten nuts on stud bolts (36). Torque as
per Table 1 (page 43).
Install the suction strainer (11).
Install packings and gland (88) in the stuffing box. Do not tighten nuts on
stud bolts (90), until the pump is in operation.
Lift the pump and install it into the sump.
Complete pump reassembling as per Section 8, in reverse sequence.

09 - Inner Parts
replacement
VI Pumps
Table 1: Recommended Bolt Torque

(Nm)
Bolt size Bolt material

A 307 A
Nitronic 50 XM-19
(mm) (inch) A 193 B8 A 193 B7
A 453 660B
A 193 B8M
M6x1 1/4 x 20 UNC 5 6 7
M8x1.25 5/16 x 18 UNC 10 13 15
M10x1.5 3/8 x 16 UNC 20 25 30
M12x1.75 1/2 x 13 UNC 35 50 70
M16x2 5/8 x 11 UNC 70 110 150
M20x2.5 3/4 x 10 UNC 125 200 250
M24x3 1 x 8 UNC 290 490 600
M30x3 1 x 8 UN 600 1000 1300
M36x3 1 x 8 UN 1050 1800 2100
M42x3 1 x 8 UN 1700 2900 3500
M48x3 2 x 8 UN 2700 4500 5500
M48x2 2 x 12 UN 2800 4700 6000
Table 2: Minimum Running Clearances
Diameter of Rotating Member at Clearances Minimum Diametral Clearance

(mm) (mm)
< 50 0.25
50 to 64.99 0.28
65 to 79.99 0.30
80 to 89.99 0.33
90 to 99.99 0.35
100 to 114.99 0.38
115 to 124.99 0.40
125 to 149.99 0.43
150 to 174.99 0.45
175 to 199.99 0.48
200 to 224.99 0.50
225 to 249.99 0.53
250 to 274.99 0.55
275 to 299.99 0.58
300 to 324.99 0.60
325 to 349.99 0.63
350 to 374.99 0.65
375 to 399.99 0.68
400 to 424.99 0.70
425 to 449.99 0.73

09 - Inner Parts
replacement
VI Pumps
Attachment 1: VI Cross Section

09 - Inner Parts
replacement
VI Pumps

09 - Inner Parts
replacement
VI Pumps

VI Rev07 PDF

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TABLE OF CONTENTS

2. GENERAL DESCRIPTION OF VI PUMPS......................................................... 10

3. TRANSPORT AND INTERMEDIATE STORAGE .............................................. 12

5. START- UP AND OPERATION.......................................................................... 18

6. MAINTENANCE AND SERVICING .................................................................... 27

9. VI PUMPS: INNER PARTS REPLACEMENT .................................................... 40

equipment subjected to misuse, neglect, accident;

EngMan00.doc - rev04 - jul04 3

HOW TO USE THIS MANUAL

This instruction manual contains installation, operation and maintenance instructions

A complete reading of this manual by personnel

This Instruction Manual consists of several sections, as listed in the table of

Weir Gabbioneta srl

EngMan00.doc - rev04 - jul04 4

A typical pump nameplate is given below.

SESTO S. GIOVANNI - ITALIA

EngMan00.doc - rev04 - jul04 5

Note about temperature class: (EN 13463-1:2001 - par 14.2)

Pump temperature class:

Pump temperature class Pumped fluid maximum temperature:

Declaration of Conformity and/or the Declaration of Incorporation are included in

EngMan00.doc - rev04 - jul04 6

It is assumed that the operators safety department has an established safety

Immediate hazards that will cause, in presence of explosive atmospheres,

EngMan01.doc - rev03 - jul03 7

A message to clarify or simplify an operation or technique,

1.2 Major warnings

EngMan01.doc - rev03 - jul03 8

1.3 Components and auxiliaries

Regarding proper operation and residual risks of components (motors, seals,

This manual does not replace manuals of enclosed components

1.4 Pump to be scrapped

EngMan01.doc - rev. 3 - jul 03 9

2. GENERAL DESCRIPTION OF VI PUMPS

2.1 Casings and impellers

Impellers of VI pumps can be closed or semi-open, depending upon the

2.2 Rotating Assembly and Bearings

As a standard, the rotating assembly is supported by an oil-lubricated, antifriction-

EngMan02.doc - rev02 - feb02 10

2.3 Technical Data

on the pump nameplate

2.4 Pump serial number

EngMan02.doc - rev02 - feb02 11

3. TRANSPORT AND INTERMEDIATE STORAGE (1)

3.1 Shipping preparation / Crating

Lifting and handling operations must be carried out by specialized personnel.

EngMan03.doc - rev05 - apr05 12

3.3 Short term storage

3.4 Long term optional storage

Long term storage means a period of more than 6 months.

When it is necessary to store equipment outdoor, it is recommended to put them on

When the storage period (standard or long term) has expired,

3.6 Uncrating and Inspection

EngMan03.doc - rev05 - apr05 13

3.7 Installation and stops

EngMan03.doc - rev05 - apr05 14

The following recommendations and instructions are provided to assist the

To achieve satisfactory operation, the following steps must be carried out in

4.2 Pump installation and foundation

If required by the Purchase Order, vertical pumps can be mounted on a frame

EngMan04.doc - rev07 - jun06 15

An axial clearance of 300 mm (1 foot) should be maintained between the bottom