Sulzer Pump Operating Manual PDF

OPERATING MANUAL
MC
Document No. OPM/MC-New/002.04
BA/e 4330 Wä
Sulzer Pumps India Ltd. 9, MIDC, Thane-Belapur Road, Digha,

Navi Mumbai, 400708. India.
1 Tel. 091-22-55904321.Fax. 091-22-55904306
Content
1. GENERAL REMARKS
1.1 About this manual
1.2 Guarantee
1.3 Type of operating manual
1.4 Service data - Service control
2. SAFETY
2.1 Marking of instructions in the operating manual
2.2 Qualification and training of personnel
2.3 Danger on non-observation of the safety regulations
2.4 Safety-guided working
2.5 Safety instructions for user / operator
2.6 Safety instructions for maintenance, inspection and assembly jobs
2.7 Prohibition of unauthorized rebuilding measures or alterations
2.8 Inadmissible operating modes
2.9 Explosion protection
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
3.2 Preservation and storage
4. DESCRIPTION
'escription of the pump
4. Bearing bracket and lubrication
4. Absorption of the axial thrust - balance drum
5. INSTALLATION
5.1 Mounting of the pump
5.2 Alignment of coupling
5.3 Suction and discharge pipework
5.4 Ancillary equipment
5.5 Minimum flow device
6. OPERATION
6.1 General
6.2 Commissioning
6.3 Pump start-up and operation
6.5 Shut-down
6.6 Restart procedure
6.7 Service control
6.8 Operating faults
7. MAINTENANCE
7.1 Pump general
7.2 Shaft seal
7.3 Bearing / Lubrication
8. OVERHAUL
8.1 Dismantling of the pump
8.2 Inspection of wearing parts
8.3 Assembly of the pump
8.4 Tools
8.5 Screw tightening torques
ENCLOSURES
Table of enclosures for operating manual
4000/e0-1-00-000 2
1. GENERAL REMARKS
1.1 About this manual
The operating manual contains important information on how to operate the pump safely, properly and most
efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to
increase the reliability and life of the pump.
How to use this manual
The operating manual must always be available wherever the pump is in use. These instructions must be
read an applied by any person in charge of carrying out work with and on the pump, such as transport,
storage, installation, operation and maintenance.
This manual should be used together with all other machine documentation in order to have accurate
information of your pump. Do not start or operate this pump unless you have complete understanding
of the pump system and all auxiliary systems (driver, cooling, seal flushing ...).
1.2 Guarantee
Guarantee is assumed according to the contractual agreements.
The normal Sulzer warranty covers manufacturing or material defect, it does not cover the damage caused
by improper storage conditions, incorrect installation, operation and using against designated use.
During the period of guarantee, repairs or modifications only can be made by our service personnel or with
our agreement.
1.3 Type of operating manual (Acc. to DIN 8418 and VDMA 24 292)
Documents no.: see cover sheet
Service address: see cover sheet
Issue: 20
We reserve all rights in this manual and in the information contained. Reproduction, use or disclosure to
third parties without our approval is strictly forbidden.
Revision history
0 20--25 First issue E. T.
Revision Date Description Sign

Remark
In the case of further questions, of spare part orders and other correspondence please mention always the
SULZER Serial No. and pump type. Both can be gathered from the rating plate of the pump.
0000/e1-0-00-000
3
01
1.4 SERVICE DATA - SERVICE CONTROL
02
1.4.1 Data
03
Sulzer Serial-No.:
Refer Documents and drawings of each pump item for details

04
Position-No.:
05 Medium delivered
3
06 Capacity m /h
3
07 Minimum capacity m /h
08 Differential head m FS
09 NPSH - R m
10 Differential pressure bar
11 Suction pressure norm./ max. bar
12 Discharge pressure norm./ max. bar
o
13 Pumping temperature (PT) C
3
14 Specif. grav. at PT kg/m
15 Pump input kW
16 Speed 1/min.
17
1.4.2 Lubrication
18 Oil (according to DIN 51 524) see also 7.3
o
19 Oil temperature C
20 Quantity of oil per bearing frame Liter
21
1.4.3 Cooling
3
22 Cooling water m /h
23 Pressure normal/max. bar
o
24 Temperature outlet max. C
25
1.4.4 Heating
26 Heat exchanging medium
27 Pressure normal/max. bar
o
28 Temperature entry max. C
29
1.4.5 Flushing (shaft seal)
30 Flushing / Sealing medium
3
31 Quantity min. m /h
32 Pressure bar
o
33 Temperature of flushing medium C
34
1.4.6 Flushing (wear ring)
35 Flushing / Sealing medium
3
37 Pressure bar
38
1.4.7 Quench
39 Quench medium
3
41 Pressure bar
42
1.4.8 Safety technical limit data
43 Max. allowable working pressure bar
o
44 Max. allowable working temperature C
4
0000/d1-4-02-000
2. SAFETY
This operating manual contains basic information, which has to be observed on the installation,
commissioning, operation and maintenance. Therefore this operating manual has to be available
constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or
assembly/disassembly of the pump.
Not only have the general safety instructions to be observed, which are given under this main point
"Safety", but also the special safety instructions given below in the operating manual.
2.1 Marking of instructions in the operating manual

The safety instructions contained in these operating instructions, which – if not observed - may result in harm
to persons,
are indicated with the general danger sign
or, in the case of warnings against electrical

voltage, with
and in terms of explosion protection with the

special sign
For safety instructions which – if not observed –
may cause risks for the machine and its
ATTENTION is inserted.
operation, the word
Indications which are directly attached at the machine itself such as
- arrow for rotational sense
- marking for fluid connections etc.
have to be kept in good, legible condition, as they have always to be observed.
2.2 Qualification and training of personnel

The personnel for service, maintenance, inspection and assembly has to hold the necessary qualifications for
this kind of jobs. Range of responsibility, competence and the monitoring of the personnel have to be fixed
clearly by the user. In case the personnel should not have the required knowledge, they have to be trained
and instructed. This may be undertaken by the manufacturer of the machine, if required, on user's request.
Further the user has to ensure that the personnel has a complete understanding of the contents of the
manufacturer's instruction manual.
2.3 Danger on non-observation of the safety regulations

By non-observation of the safety regulations danger may arise for persons as well as for environment and
machinery and may lead to a complete loss of any claims for damages.
- Non-observance may lead for example to the following dangers:
- Failure of important functions of machine/plant
- Failure of required procedures of maintenance and repair
- Endangering of people by electrical, mechanical and chemical impacts
- Endangering of environment by leakage of dangerous materials
2.4 Safety-guided working

The safety regulations given in this operating manual which consist of national regulations on accident
prevention, as well as company- internal job, operating and safety regulations issued by the user, have to be
observed.
0000/e2-0-00-000 Page 1 5
2.5 Safety instructions for user / operator
- In case hot or cold machine parts may lead to any danger, they have to be secured by user against
touching.
- Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.
- Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be
disposed of in such a way as to prevent any endangering of people and environment. Legal regulations
have to be observed.
- Endangering by electricity has to be excluded (details see for example in the regulations by the VDE and
local energy suppliers).
- The special safety instructions in the following paragraphs of this operating manual have to be observed.
2.6 Safety instructions for maintenance, inspection and assembly jobs

- The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by
authorized and skilled personnel only, who have been adequately informed by studying the operating
manual carefully.
- Basically any works on the machine may be carried out only during shut-down of the machine. The
procedure described in the operating manual for the shut-down of the machine has to be strictly adhered
to. The machine has to be locked against unauthorized or involuntary start-up.
- Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be worn.
There is a risk of injury as a result, for example, of such objects getting caught or pulled in.
- Pumps or aggregates delivering media hazardous to health have to be decontaminated.
- Immediately following the end of the works, all safety and protective devices have to be reassembled
respectively have to be put to work again.
- On a repeated start-up all points given in the paragraph initial commissioning have to be observed again.
2.7 Prohibition of unauthorized rebuilding measures or alterations

- Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer.
Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee safety.
The use of other parts may lead to a loss of the manufacturer's liability for the consequences.
- The operational safety of the delivered machine is only guaranteed by proper use acc. to the data under
item 1.4 of the operating manual.
- The limits given in the data sheet must not be exceeded in any case.
2.9 Explosion Protection

- Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g.
electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at
separately.
- Improper operating methods that result in the specified temperatures being exceeded (exceeding or falling
short of the operating data, falling short of the minimum delivery flow, reduction or failure of cooling water
or circulation delivery, etc.) should be avoided at all costs.
- Before starting the pump make sure that the pump system (suction pipe, pump casing and shaft seal) is
completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere in the
system.
- Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters,
ammeters, etc.).
- Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe
operation.
0000/e2-0-00-000 Page 2 6
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
A. General remarks
For all transport jobs the general rules of engineering and regulations on the prevention of accidents have
to be strictly observed.
These are especially
VBG 1 - General regulations
VBG 5 - Power-driven working devices
VBG 8 - Lifting devices
VBG 9 - Cranes
VBG 9a - Load suspension device with hoists and conveyors
The above regulations are applicable in the area of the Federal Republic of Germany, in other countries
the appropriate regulations have to be observed.
For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.
B. Transport
Transport devices (including vehicles) have to be checked for the admissible load weight. Total
weight of the delivered goods see dispatch documents. The load has to be secured during
transport against shifting.
C. Lifting
Check of the load suspension devices / ropes
It has to be assured that admissible, undamaged ropes and lifting
Sling rope as
devices will be used. The loading capacity of the lifting devices and market on
the ropes has to be suitable to take up the weight of the goods to be lifted. crate
Load weight indications of the delivered units are given in the installation
plan respectively the dispatch documents.
Never stay within the range of suspended loads.

Sketch 3.1-1
Fastening of the sling ropes on crates
The points for the fastening of sling ropes on closed crates are
marked. As the center of gravity (mass) cannot be recognized in
closed crates, the sling rope fastening has always to be done at the
marked spots. See sketch 3.1-1.
Fastening of the sling ropes on bar shaft pumps
The pump without packing can be lifted and transported by ropes witch are Sketch 3.1-2
laid around casing parts (shaft seal housings). See sketch 3.1-2.
Fastening spots for units
In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these
spots by shackling the rope. See sketch 3.1-3.
If required use traverse
Sketch 3.1-3
Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete
assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened
parts during assembly and disassembly
M000/e3-0-00-000 Page 1
7
3.2 Preservation and storage
A. General remarks
This information will enable you to store your pump effectively and safely. Should further information be
desired, or should particular problems arise which are not covered sufficiently please contact your nearest
Sulzer representative.
The following storage instructions apply only to the pump and may not be appropriate to furnished auxiliary
equipment. Follow manufacturer’s instructions for all other components of the pump system.
The preservation measures required for storage depend on the despatch preservation applied. The pump
unit can be stored in a dry warehouse without maintenance measures up to the time given by the dispatch
preservation.
B. Preservation for despatch

Standard packing
When the pumps are shipped, smooth outside faces are sprayed with “Tectyl 506” and pump internals with
“Mobilarma 524” (or equal product). Attention: this is not suitable as long-term preservation; 6 months are
max. allowed time for storing.
Seaworthy packing
The pump is despatched with PE-foil welding and with added moisture absorber. Sea-worthy packed pumps
can be stored up to one year without any special maintenance if the packing is not damaged.
Special packing
On special request the pump can be packed in aluminium foil (with moisture absorber). In this case the
preservation time amounts to 2 years without special maintenance.
If the seaworthy or other special package is removed, only the standard preservation is
ATTENTION effective, i.e. if no further measures are taken, the max. storage period will be 6 months.
C. Intermediate storage
Pumps which are not installed and commissioned immediately after delivery can be stored for the period
determined by the dispatch preservation.
ATTENTION To avoid the forming of condensate and consequently corrosion (especially in the gap
areas), bearing damage and contamination, a dry room, possibly with constant temperature
as well as a clean, shock- free storage space has to be selected.
In each case unfavourable climatic circumstances will have a negative influence on period of
ATTENTION proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed:
ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand,
etc.) the connection flanges of the pumps have to be plugged airtight.
D. Longterm storage - preservation

1. General
The pumps should always be stored in her functional position, that means that horizontal
ATTENTION
pumps should be stored horizontal and vertical pumps should be stored in vertical position.
Align and support the pump as required.
In case of long term storage a number of precautions must be observed to prevent pump damage. It is
recommended to enter all storage inspections and preservation measures in an log.
0000/e3-0-00-000 8
Long term storage may be required for:
1. New pumps witch are not commissioned.
The pump can be stored as described in Intermediate storage. After the dispatch preservation time
measures have to be taken to protect the equipment against corrosion damage.
2. Stand by pumps or pumps affected by a longer shut down of the plant.
The long term storage procedure depend on the material used in pump construction (cast iron, steel,
stainless steel, special alloys), medium delivered and environmental conditions (freeze damage) see
following table.
Material of Medium delivered
construction Neutral Aggressive
Hydrocarbon, ... Water, ... Seawater, ... Acids, ...
Cast iron B A - -
Steel B A - -
Stainless steel B B A
Special alloys B B A
A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium and
after draining (and drying) be protected with a preservative. For this purpose the disassembly of the
hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure
described below in section 2. to 4.
B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure for
the bearing housing as described in the sections below.
Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety
precautions specified by the manufacturers.
2. Protection of not painted outer parts of the pump
Pump outer parts: e.g. - raised faces of flanges
- pump shaft
- coupling
- connections for small conduits etc.
We would urgently advise against using normal lubricating oil as a rust preventative. For the preservation of
bright pump parts, the mineral-oil industry has developed special rust preventatives which at first are liquid
and are applied manually, by means of brushes, spray nozzles or aerographs. After the evaporation of the
solvent, a wax-type cover will remain.
This protective film can be removed by means of solvents or alkaline cleansing agents (see section V.).
We recommend rust preventatives
- Tectyl 506 from VALVOLINE
- Rust Ban 397 from ESSO
Other rust preventatives of the same quality may however be used as well. The average time of protection is
1-3 years. Rust preventatives are rust-preventing agents which however do not remove rust.
For this reason, it is a prerequisite for the application of rust preventatives that the parts to be protected are
clean and rustfree. The surface of the parts has to be cleaned carefully before the respective rust
preventative is applied.
3. Protection of the interior of the pump
If the hydraulic pump part (casing parts, impeller, wear rings…) are made of non-corrosive stainless or
special alloy, no protective measures (instead of flushing, case A) are required. Note: Bearing housing and
bearings have always to be protected.
Pump interior parts: e.g. - pump casings
- stuffing box chambers
- bearing housing, bearings, ...
For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm2/s
should be used.
0000/e3-0-00-000 9
We recommend the rust preventatives
ATTENTION The rust preventative for the pump interior have to be selected according to the gasket or
seal materials used.
Gasket or seal material: Rust preventative
Perbunan (NBR), Viton (FPM), Teflon (PTFE): - Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
Ethylene-propylene (EPDM): - Klüber Syntheso D 220

4. Proceeding in case of longterm preservation
General
Protect the pump and attachments with a vinyl-coated nylon tarpaulin.
Lash tarp evenly to provide drainage that does not form pools. Maintain sufficient air circulation with
minimum 10 cm clearance between tarp and pump parts.
Protect pump from blowing sand or dirt.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. The use of any
preventative is not recommended.
Soft packing
ATTENTION If the pump is supplied with a stuffing box packing installed, the packing has to be removed
and replaced by a special packing which is to remain in the stuffing box chamber during the
preservation time, only.
Preservation packing material recommended: Synth. fibres, with PTFE impregnation (e.g. Chetra 1711
GS or Hecker 1820). The packing chamber is filled completely with the separate packing rings.
Pump casing
At first the raised faces of the pump flanges have to be cleaned thoroughly and preserved with one of the
rust preventatives mentioned under I. On smooth flanges and those with annular tee-slots, flat gaskets
should be placed; in case of slotted flanges, 2 gaskets should be placed in the slot, and all the sockets have
to be closed tightly by means of metal covers. The connections for the cooling water/circulation lines etc.
should also be closed by means of normal steel plugs, using Molykote. Then fill (or spray) pump casing with
rust preventative (see 3.). While filling in this agent, turn pump shaft manually several times (observe sense
of rotation). Generally speaking in practical handling the casing interior of bigger pumps usually is only
sprayed, in this case the preservation has to be repeated every 6 months.
Bearing housing
If present: Drain lubrication oil thoroughly. Remove filler plug on the top of bearing housing and fill bearing
housing with rust preventative (see II.) up to the correct oil level. During filling rotate the pump shaft by hand
in the proper direction. If present: Fill also constant level oiler bottle with rust preventative.
E. Maintenance of the longterm stored pumps

Visual inspection
The exterior of the stored pump unit should be conducted every 30 days and inspected for surface damage,
dirt or animals in the pump area. If required initialise appropriate measures.
Maintain rust prevention coatings
If any rust is observed, measures should be taken to remove rust and protect against it.
Turn pump rotor manually
To avoid corrosion damage at bearings, drain the preservation oil every 3 month and refill if on the top of the
bearing housing. The pump rotor should manually be turned simultaneously, so that the preservation oil will
be distributed over the running surfaces of the bearings. Turn pump rotor at least 5 revolutions in the proper
direction of rotation.
0000/e3-0-00-000 10
Filled pump parts
At the parts which are filled with rust preventative (pump casing / bearing housing) the condensate should be
drained every 6 months; rust preventative should be added, if required.
According to manufacturers indications, the rust preventative has to be drained and refilled
ATTENTION
every 12 month. If the rust preventative is not renewed within this period the risk is to be
taken by the storage keeper. In order to have a guarantee for the proper execution of the maintenance
instructions, we recommend to establish maintenance sheets.
If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than after 6
months.
F. De-preservation procedure
Surface protected parts
In most cases the protection film must not be removed. If required remove rust preventative by the following
cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be used.
Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety
precautions specified by the manufacturers.
Note: Do not use nitro thinners!
Pump casing
Drain pump casing thoroughly, it may be required to lift the pump to fully drain the pump casing (see job
specific drawings). If required flush pump casing, turn pump rotor by hand in the proper direction of rotation.
For absolutely cleaning (pumping of clean product) the disassembly of the hydraulic part of the pump
becomes necessary in most cases.
Shaft seal
Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer seals
are subject to material specific and time-based alteration (aging) witch might reduce the efficiency of the
seal, therefore we recommend after a storage time for more than 3 years to change the seal rings.
Packing: Before commissioning, make sure that the preservation packing is removed and replaced by
packing rings of the quality provided for operation.
Bearing housing
Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the
preservation oil thoroughly. Flush bearing housing with lubrication oil and allow to drain. Mount constant
level oiler (if removed) and refill bearing housing with lubricating oil as given in the pump operating manual.
Dispose of rust preventive oil according to statutory regulations. Do not put into waste water
by any means.
G. Additional Information
When the pump is removed from storage special care have to be taken. Clean pump and equipment
surfaces (piping, coupling, driver,…) and inspect:
Minimum checks Additional recommended checks
Inspect for completeness Inspect bearings (if any sign of
Check all pressure case (plugged) openings and contamination be detected, replace brg.)
connections for tightness Inspect shaft seal and change all elastomer
Check for any sign of cracks or damage seal rings
Check pump rotation, check for correct gap Install additionally suction strainer
between stationary and rotating parts …
Check coupling alignment
Check all fasteners for tightness
Check service data (are the pump suitable)
ATTENTION If the pump has been stored for more than 3 years we recommend to open and inspect at
least bearings and shaft seal before start-up. If the pump has been stored for more than 5
years we recommend to disassemble the pump and change all gaskets and seal rings.
0000/e3-0-00-000 11
4. DESCRIPTION
4.1 Description of the pump
General: Pumps of the MC series are horizontal, multi-stage, ring section centrifugal pumps designed for
boiler feed and other high pressure applications.
ATTENTION The pumps are suitable for pumping clean liquids. The permissible operating pressures
and permissible operating temperatures depend upon the material specification. See
1.4.8 for safety limit data for the pump supplied.
ATTENTION The materials of construction have been selected for the liquid specified in your order.
Before the pump is operated with other liquids or at other temperatures it is essential that
the manufacturer be consulted.
Casing: The casing is radially split and consists of suction casing, stage casings as required and
discharge casing. The elements are sealed by O-rings and held together by external tie bolts.
Shaft: Accurate machining provides precision fits and clearances for assembly and operation. Machined
shoulders provide positive location of mounted parts.
Impellers: The impellers are key-driven, have closed channels and are sealed against the casing
elements by replaceable casing wear rings. The flow is guided from stage to stage by stationary diffusers.
Shaft seal: The inner chamber of the pump which is filled with liquid is sealed at the shaft by packed
glands or mechanical seals. See 7.2 or description of the seal manufacturer for further information.
ATTENTION The shaft seal housings are fitted with a cooling chamber as required. In order to prevent
evaporation in the vicinity of the shaft seal, the cooling water quantity given under 1.4.3
must be assured. Non-compliance can lead to total failure of the shaft seal.
Coupling: Flexible couplings must be used to connect the pump to the driver: these couplings must be
able to absorb small axial, radial and angular shaft misalignments.
4330/e4-1-01-000 Page 1 12
4.2 Bearing and lubrication
Bearing housings: The bearing housings flanged on both pump sides are equipped with ring oil
lubricated bearings. The lube oil quantity is given under 1.4.2 and 7.3.
ATTENTION Depending on the service conditions the bearing housings may require water cooling to
maintain acceptable bearing temperature. In this case the cooling water quantity is given
under 1.4.3.
Antifriction bearings: Roller bearings are used as bearings for the massive pump shaft in the bearing
bracket on the drive side, whereas paired taper roller bearings take up the axial forces at the non-drive
side.
Fan: A fan assembly is provided to enhance air cooling of the bearing bracket non-drive side.
Constant Level Oiler: An oiler is installed on each bearing housing. The oiler automatically maintains
bearing housing oil level and provides a means of monitoring and refill. See also 7.3
Sight glass: A sight glass is provided to allow visual monitoring of bearing housing oil level.
Lube oil system: Both bearing housings are provided with rotation-independent lube oil systems. The oil
ring rotates with the shaft and continuously distributes lube oil from the bearing housing sump into the
bearing cover whence it circulates through the antifriction bearings back into the oil sump. The lube oil
quantity is given under 1.4.2 and 7.3 .
Bearing bracket non-drive side Bearing bracket drive side
vent plug (oil fill connection)

tapered roller bearing
(or angular ball bearings) roller bearing
fan shaft
oil drain plug
4330/e4-1-01-000 Page 2 13
4.3 Absorption of the Axial Thrust - Balance drum
General
During operation of the pump an axial thrust is exerted on the rotor towards the suction side. This arises
because the area of the back shroud of the impeller is larger than that of the front shroud which is
interrupted by the impeller eye, both being subjected to the same liquid pressure. In multi-stage pumps
the forces per stage are cumulative and considerable axial loads result. These forces are absorbed by
the hydraulic balance device.
Working principle
The balance device consists of a balance drum
rotating with the shaft and a balance drum liner
c housed in the discharge casing. The pressure
difference between the pressure within the pump 'a'
(discharge pressure) and the pressure in the balance
605.01 chamber 'b' (suction pressure + frictional resistance
in the balance pipe) creates an axial force 'F' on the
b a balance drum. This axial force is opposite in
F direction to the pump axial thrust. The magnitude of
603.01 A the force 'F' depends on the area "A" of the balance
drum which is sized such that the axial thrust at the
operating point is almost completely compensated.
The residual axial thrust is absorbed by a thrust
bearing. The pressure difference between 'a' and 'b'
also sets up a flow through the throttling clearance 'c'
into the balance chamber. A perfect balance is only
axial thrust achieved if there is no build up of pressure in the
balance chamber as a result of the balance flow
being restricted.
Balance pipe
Severe damage to the pump will result, if the instructions for the laying of the balance
ATTENTION pipe are not strictly observed.
To prevent a pressure build-up in the balance chamber there must be a drain for the
ATTENTION
admitted liquid. A tapping for this purpose is provided in the pump balance chamber (the
position is indicated on the dimension drawing).
- The routing of the balance pipe depends on the operating conditions. It is either:
returned to the suction tank
or returned to the suction casing.
The data on the installation drawing is decisive for the pump supplied.
Note! With flow returning into the suction tank the following must be observed:
ATTENTION The frictional resistence of the balance pipe must not exceed 0,8 bar. Choose
corresponding nominal diameter.
A valve should be fitted in this pipe for maintenance purposes. Steps must be taken to
ATTENTION
ensure that this can be locked in the open position to prevent unauthorized and/or
accidental closure.
Damages on the balancing device may lead to a heating of the balancing liquid causing
inadmissible pressure in the balancing tube. A security valve has therefore to be built into this
tube. Adjust opening pressure at 5 bar over inlet pressure.
4330/e4-1-01-000 Page 3 14
5. INSTALLATION
5.1 Installation of the pump unit

A. General (refer to Job specific drawing(s), Installation plan …)
Machinery intended for use in potentially explosive areas must satisfy the “Ex” protection
requirements. Check the documentation relating to the machinery and accessories (and
nameplates).
Good planning and preparation result in fast, simple and correct installation. Safe running conditions with
maximum accessibility are assured. When preparing for installation of the machine, it is necessary to take
the following aspects into account:
The main dimensions, connections, position of fixing bolts etc., are shown on the dimension
drawing/installation plan.
Suitable lifting devices must be available for installation and repair work. Good lighting is important and
sockets for portable lights should be available. The pump should be readily accessible from all sides.
The pump foundations and type of installation should be designed so that vibration is kept to a minimum
both during operating and when the pump is at rest, otherwise the pump life will be reduced.
A drain must be provided so that gland leakage, cooling water (open system) and liquid drained from the
pump during overhaul can be led away.
The draining of the pump respectively the disposal of the leakage for pumps delivering toxic,
explosive, hot or in any other ways dangerous fluids, must not lead to any endangering of
operator(s) and environment.
Following manufacture the pump flanges and external tappings are protected by metal closures at least
5mm thick, with elastomer gaskets, which should not be removed before the pipework is ready to be
attached to the pump. The pump should be protected, if further site work is necessary nearby.
The foundation or any other necessary building work must be finished, set and dried. Roughen and clean
the foundation. All preliminary work for erection must be completed. With large units, suitable door and
wall openings are to be provided for transport to the installation site.
Grout selection
Select a non-shrinking grout that is compatible with the highest and lowest temperatures to which it may
be exposed. Use concrete from a concrete company with a final strength of 25 N/mm2 (B25) or better.
If the service of a concrete company is not available the figures given below may be taken as a guide.
- The concrete mixture suitable for grouting machine baseplate should contain 300 to 350 kg cement per
1 m3 (20 to 22 pound per cu. ft.) of concrete. The sand and gravel proportion for 1 m3 (1 cu. ft.) of
finished concrete (1.2 m3 (1.2 cu. ft.) mixture) is as follows:
For grouting 65% Fine sand grain size 1 - 5 mm (0.04 – 0.2 in.)
of the foundation bolts 35% Coarse sand grain size 5 - 10 mm (0.2 – 0.4 in.)
water as required
The use of so called „fast cement“ with short setting time is possible.
For grouting (filling) 40% Fine sand grain size 1 - 5 mm (0.04 – 0.2 in.)
of the baseplate 60% Coarse sand grain size 5 - 15 mm (0.2 – 0.6 in.)
100 - 140 liters (7 - 10 gallons) of water
Table 5.1.1
ATTENTION Only clean, washed sand may be used. The water-cement ratio has a decisive influence
on the final strength of the concrete.
A high concrete strength will be attained with high standard strength of the cement, low water-cement
ratio, and compacting by vibrating.
4330/e5-1-00-001 page 1
15
Tools and Equipment Required
The following tools will be required temporarily for the installation work:
- 2 Dial gauges
- 1 Spirit (machinist’s) level
- 1 Set of standard hand tools
- Suitable lifting devices for installation and repair work.
- Suitable lighting
B. Mechanical completion and installation sequence check list
REF. PAR. EVENT

5.1 A-G Instructions for site installation
5.1 C Installation of pump and driver
5.1 D Levelling, check leveling of baseplate
5.1 E Grout in foundation bolts
- Let the concret set
5.1 G / 5.1 D Snug-Up (tighten) foundation bolts and recheck levelling
- Mount driver (If field mounted)
5.2 A-H Align driver to pump
5.2 D Check for soft feet, pump and driver
5.1 F Grout baseplate
5.1 G Final tighten of foundation bolts after grout cures
5.3 A-H Install main piping
5.3. C Check stress free pipe connection
5.3 F Clean the pipework
5.4 A-H / 8. A-B Mount ancillary equipment
5.5 A-B Install Minimum flow device (if present)
- Fill and vent the pump system
5.2 A-I Final alignment (mount coupling guard)
Table 5.1.2
Check off when satisfactorily completed
C. Installation of pump and driver

Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work
immediately if any danger arises.
Note: With separate baseplates for pump and driver first erect the pump, then align the driver.
Precondition
- The location place must be sufficiently rigid to prevent pump vibration. The specific base design will
depend on location and external piping forces requirements.
Location place / surface check
- Check mounting surfaces. All location place surfaces used for mounting the pump unit must be clean.
Remove rust, dirt or other extraneous material.
- Roughen and clean the foundation. Walls of the grouting holes must have rough surfaces and must be
free from pollution. Remove any loose particles, dirt or oil-soaked concrete. All baseplate surfaces
which will be in contact with grout must be clean. Remove rust, paint or other extraneous material.
4330/e5-1-00-001 page 2
16
Installation
- Attach wire rope slings to the pump unit (see 3. Transport and lifting) and lift the pump unit carefully.
Insert foundation bolts into the holes in the baseplate and tighten the nuts a few turns.
- Lower the baseplate carefully into position on the foundation. The foundation bolts have to be lowered
into the foundation holes.
D. Levelling
Use mechanical installation report TC 0000/5-1-00-000.
- Place steel shims under the adjusting screws and align the pump unit horizontally with the aid of the
adjusting screws. Provide proper grouting clearance between foundation and baseplate (see installation
plan).
ATTENTION Check levelling in the direction of the pump axis and also at right angles along the
horizontal flange with a spirit (machinist’s) level. The flanges must be vertical on
horizontal branches. See sketch 5.1.1.
Preferred variance : 0.2 mm over 1 m (0.003 in./ft.).
Maximum allowable variance: 0.5 mm over 1m (0.006 in./ft.).
- Push steel shims into line to the right and left of the foundation bolts. The shims must be thick enough
so that there will be only minimal clearance between baseplate and shim. The space between
baseplate and shim must be filled with one or two thin parallel sheet metals which must be available in
different thickness. See sketch 5.1-2.
- Loosen adjusting screws and check levelling. If required correct levelling.
spirit level
pump flange adjusting screw foundation bolt baseplate
disc sheet metal
shim shim
concrete
shaft foundation
Sketch 5.1-1 Levelling the unit Sketch 5.1-2 Grouting foundation bolts
E. Grout in the foundation bolts

- Before grouting wet the foundation holes. Fill foundation holes with concrete. See sketch 5.1-2.
- After setting tighten the foundation bolts (see table 5.1.3) and check horizontal alignment again. If the
position of the pump has changed, correct alignment.
Do not bend the baseplate since this will cause development of vibration and noise
ATTENTION
during operation or the alignment of the coupling will not possible.
- Before grouting the baseplate align the coupling as described under 5.2 (alignment report).
4330/e5-1-00-001 page 3
17
F. Completion of grouting (when properly aligned)
Grouting of the machine into the foundation is a very important part of the installation.
ATTENTION
Problems can arise, if materials are of poor quality, which may show up early or after
several months of operation.
- Build a dam around the foundation. Forms must be strong baseplate

grout hole
enough to withstand the grout pressure. Attach a chamfer
strip on the form inside, at grout grade elevation, to provide
a neat beveled edge. See sketch 5.1-3. chamfer strip
- Finish grouting the baseplate in conformity with the grout
corresponding installation plan. Fill the baseplate with thin-
bodied concrete through grout holes. Take care that the
baseplate is completely filled with grout, vibrate as
necessary.
The concrete must neither dry out nor freeze
ATTENTION foundation
during the first 48 hours. During this time the
temperature of the foundation should not fall below 10 oC
(50oF). The optimum temperature for the setting process is
20oC +/-10 oC (65 +/-15 oF). 5.1-3 Grouting of baseplate
- If necessary: Seal the grout openings by covering with a

quality paint or with grout hole covers.
When the concrete has set, re-tighten foundation bolts (see table 5.1.3) and check coupling alignment
(alignment report).
G. Tightening torques for foundation bolts

Thread size M 12 M 16 M 20 M 24 M 30
(OD in.) (0.40) (0.60) (0.80) (0.95) (1.18)
before grouting of 15 (10) 30 (20) 70 (55) 140 (105) 280 (210)
Tightening torque baseplate
Nm (lbf.ft)
FINAL after grouting of 20 (15) 50 (40) 100 (75) 180 (135) 350 (260)
baseplate
Table 5.1.3
4330/e5-1-00-001 page 4
18
Title:
Test Certificate
Mechanical Installation
Plant / Location:.........................................................................................................................................
Aggregate Specification:...........................................................................................................................
Pump type:...................................................... Driver:..............................................................
Serial-No.:....................................................... Type / No.:.......................................................
Measures Confirmations
1. Foundation construction
Main dimensions and connections checked Yes No Date: Sign:
2. Level baseplate longitudial

crosswise
Date: Sign:
Levelling
Direction longitudial crosswise
Measured: ................. ................
X Prescribed: 0 ... 0.5 mm over 1 meter
Check distance between baseplate and foundation Dimension X Min: Max:
3. Foundation bolts
Foundation bolts grouted Yes No Date: Sign:
Foundation bolts tightened after setting Yes No Date: Sign:
4. Grouting baseplate
Levelling checked Direction longitudial crosswise
Measured: ................. ................
Baseplate completely filled with grout Yes No Date: Sign:
5. Piping connection
Coupling alignment checked Yes No Date: Sign:
Pump foot and driver tightened Yes No Date: Sign:
Stress control of main piping performed Yes No Date: Sign:
Piping cleaned and connected (main and auxiliary) Yes No Date: Sign:
6. Auxiliary checks and connections

Electrical connections (main and auxiliary) Yes No Date: Sign:
Lubrication check (pump, driver, ...) Yes No Date: Sign:
Driver test run, rotation check (pump uncoupled) Yes No Date: Sign:
7. System checks TEST DECLARATION

System cleaned Yes No Rework: Accepted:
System filled and vented Yes No Yes No Yes No
Pressure tested Yes No TC 0000 / 5-1-00-000
Date: Sign: Page … of …
4330/e5-1-00-001 page 5
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5.2. Alignment of coupling
A. General
If the Sulzer scope of supply does not include the coupling / coupling protection, ensure that only
approved materials and designs are used for applications in potentially explosive areas.
Driver “No Load” run

Before final aligning the coupling, and with the pump and driver uncoupled, check the direction of
rotation of the driver corresponding with the direction of rotation arrow on the pump.
The assembly of auxiliary equipment, and the electrical hook-up in the case of an electric motor, must be
completed in accordance with the manufacturer’s requirements. Refer to the driver manufacturer’s
manual for details.
"No-Load" driver testing will allow the driver rotation to be checked and provide an opportunity to make
final equipment adjustments before coupling to the pump.
Flexible couplings need very careful alignment of the shafts which can be achieved by
ATTENTION
placing thin shims under the machine feet. Negligence in alignment will destroy the
coupling and damage the pump and motor bearings, too.
ATTENTION When applicable, ensure that any rotor locking devices are removed before attempting to
turn rotors.
ATTENTION Bearings must be lubricated BEFORE attempting to turn rotors. Avoid any unnecessary
turning of machine rotors.
ATTENTION Whenever practical, the pump must be filled with product before turning by hand.
Stainless steel fitted pumps are particularly susceptible to “pick-up” and turning by hand
ATTENTION should be avoided whenever possible.
Scope
This section describes recommended procedures for aligning the motor (driving machine) to the pump
(driven machine) for the pumpset supplied.
1. Determine which machine is to be levelled and positioned correctly and then used as the reference
machine (normal pump). The position of this machine will then remain fixed, and the adjacent
machine(s) will be moved as necessary to align with it. See sketch 5.2-1.
2. Ensure that the reference machine (pump) is level and positioned correctly.
3. Work outwards from the reference machine, and position the next machine A in the train with the
correct gap between coupling flange faces or shaft ends (as applicable) and align the shaft to the shaft
of the reference machine.
4. Where a further machine B is included in the drive train, use machine A as the reference machine to
position and align B to A. In the same way, position and align C to B, etc.
Reference
B A A B
Machine
C Reference
D B A
Machine
Sketch 5.2-1 Reference machine – next machine
4330/e5-1-00-001 page 6
20
B. Misalignment types
There are three basic types of misalignments between the pump and driver shafts:
Sketch 5.2-2 Sketch 5.2-3 Sketch 5.2-4

Angular misalignment Parallel offset Axial distance
Shafts with axes that Shaft with axes parallel Shaft with axes parallel but
intersect at a point but offset wrong distance
C. Assembly
The assembly of the coupling must be carried out in accordance with the coupling manufacturer's
instructions. For mounting the coupling halves onto shaft ends see also maintenance manual.
D. Check for „soft machine feets”
Before coupling alignment the driver and pump fixation must be checked regarding “soft feet“ issue.
Loosen machine feet fasteners one after the other and check with feeler gauge if a gap between machine
feet and baseplate occur. If the gap is larger than 0.05 mm (0.002 in.), then the gap have to be
compensated by shimming.
If the base plate has not grouted yet, the “soft feet” may also be compensated by re-adjustment of the
baseplate.
If the pump or driver are not properly fixed to the base plate higher intermittent vibrations or excessive
misalignment due to nozzle loads can be expected .
E. Pump foot tightening torques
For the transport the tie bolts have to be tightened at the pump feet. To render possible a tension-free
thermal expansion of the pump during operation, the screws loosened again for the precision alignment of
the coupling must not be screwed so tight on the non-drive side as on the drive side. Essential values for
the tightening torque of tie bolts on drive side and non-drive side are shown in the table below.
Thread size Tightening torque
nominal diameter Drive side Non-drive side Non- drive end Drive end
mm in. Nm lbf.ft Nm lbf.ft
M 16 (0.6) 60 44 40 30
M 20 (0.8) 120 88 80 60
M 24 (0.95) 220 160 140 100
M 27 (1.05) 350 255 220 160
M 30 (1.18) 480 350 320 230
M 33 (1.30) 680 490 450 325
M 36 (1.42) 900 650 600 435
M 42 (1.66) 1500 1080 1000 725
M 48 (1.88) 2400 1740 1600 1160 Tightening torque Tightening torque
M 56 (2.20) 3900 2820 2600 1900 acc. to table acc. to table
M 64 (2.51) 5900 4270 3900 2800 Sketch 5.2-5 Pump foot tightening torques
Table 5.2.1
4330/e5-1-00-001 page 7
21
F. Compensation of thermal growth
Temperatures have a considerable influence and should therefore be considered during the alignment.
The shaft centreline of each pump and driver will rise when they reach operating temperature. Therefore,
the difference between the two anticipated growths should be incorporated into the cold alignment so that
the shafts will come into alignment when operating temperature is attained.
The unit with the greater thermal growth must be set lower than the other unit, by the difference between
their thermal growth.
Pump thermal growth
At pumps with feet bottom (not at axe level) and
ATTENTION operating temperatures above 80 oC the thermal
Shaft
growth should be considered according following table.
Pump size H Thermal growth H in mm
MC with operating temperature oC Thermal
growth H
> 80 > 100 > 130 > 150 > 170
40 – 180 160 0.10 0.13 0.18 0.22 0.25
50 – 220 185 0.11 0.15 0.21 0.25 0.29 Shaft
80 – 260 240 0.14 0.20 0.28 X X
100 – 300 275 0.17 0.23 0.32 X X
150 – 360 325 0.20 0.27 X X X Thermal growth X
negligible
200 – 400 360 0.22 0.30 X X X
X = Casing feet at axe level Sketch 5.2-6
Pump thermal growth
Driver thermal growth
ATTENTION The thermal growth of the driver equipment must be obtained from manufacturer
instructions.
Thermal growth varies with temperature, load and ambient conditions. With drive equipment by gear or
steam turbine an additional lateral and/or axial thermal growth have to be considered.
G. Axial shaft distance

The axial distance between the coupling halves must be observed. Please see installation drawing and
hints on coupling assembly. Refer also to manufacturer’s instruction.
The shaft of a driver without a thrust bearing must be set in proper running position before distance
between shafts is adjusted. Refer to driver manufacturer instructions.
Coupling Hub Spacing DBCFF or DBFF
Note: Where coupling flange faces do not align with shaft
ends, (see sketch 5.2-7) distance between coupling flange faces
(DBCFF or DBFF) is normally specified on the appropriate
drawings, and should be used as the reference dimension for
setting correct spacing between machines. The distance between
shaft ends (DBSE) may also be shown but is not to be used as a
reference dimension.
Where coupling flange faces do align with shaft ends, distance
DBSE
between coupling flange faces, DBSE is normally specified on the
appropriate drawings, and should be used as the reference
Sketch 5.2-7 Coupling hub spacing
dimension for setting correct spacing between machines.
4330/e5-1-00-001 page 8
22
H. Alignment
General
Any change in elevation can be accomplished by shimming between equipment feets and baseplate
pedestals. The maximum number of shims is four. After alignment tighten pump foot fasteners according
to the given torques (see pump foot tightening torques) and re-check alignment.
The coupling alignment certificate TC 0000 / 5-2-00-000 have to filled in during each alignment check /
procedure (see next pages).
Each alignment check / control has to be done only with pump in cold condition and under
ATTENTION
consider of the thermal growth of pump and driver. Hot alignment procedure after stop
from hot service are not allowed.
Alignment of coupling must also be monitored during pipework connection and re-checked after
pipework connection to ensure that pipework connection does not adversely affect alignment. If alignment
is affected, the pipe connections must be re-made until alignment remains correct.
Do not adjust driver OR driven machine positions to correct alignment errors caused by
ATTENTION
pipe connection.
Adjustment device
For axial and lateral moving of heavy equipment (motor) a device has normally been fitted at the
baseplate machine fastening pedestals. See sketch 5.2-8. Loosen equipment fastening screws and move
the machine by tightening the adjusting screw into appropriate direction. Note: Before moving the
machine be sure oposite adjusting screw are loosened.
ATTENTION After alignment and tightening the machine fasteners loosen all adjustment screws.
Adjustment devices Adjustment screws
Machine feet
Moving machine Baseplate

Baseplate
pedestals
pedestal
View "X"
X
Sketch 5.2-8 Adjustment device
Coupling alignment procedure

Every alignment check must be preceded by a run-out measurement. Record the results always in the
coupling alignment Test Certificate.
Vertical alignment is checked first, and any required adjustment is applied. Then, the horizontal alignment
is checked and any required adjustment is applied.
Loosen the hold-down bolts on the moveable machine, lift the machine and insert sufficient shims under
the mounting feet to approximately align the shaft with the shaft of the reference machine, taking into
account the cold-offset (thermal growth). Slotted shims of at least the same size as the mounting foot
must be used. The shim stock should ideally be stainless steel and be available in various thicknesses.
For horizontal alignment in most case positioning jack screws are provided. Tighten or loosen jack screws
as required to align the shaft with the shaft of the reference machine.
After shimming and horizontal aligning tighten down the reference and moveable machine hold-down
bolts to the correct torque value and recheck alignment. If required correct alignment.
4330/e5-1-00-001 page 9
23
Tolerances
The maximum admissible axial misalignment is 0.05 mm
(0.002 in.) on diameter, although ≤ 0.03 mm (0.0012 in.) is
preferrable.
The maximum admissible radial misalignment is 0.1 mm
(0.004 in.) on diameter, although ≤ 0.05 mm (0.002 in.) is
preferrable.
Clock gauge alignment
Alignment should be carried out with clock gauges in radial
and axial direction (see sketch 5.2-9). Ensure that the
supports for each indicator are sufficiently rigid to eliminate
any sag that may cause spurious readings. Sketch 5.2-9 Alignment of spacer couplings
All readings for radial and axial misalignment are
determined in the gauge positions: top, bottom, right and
left, i.e. every 90o, while both shafts are simultaneously
turned.
Optical Alignment
Instead of using a clock gauge assembly, optical (laser)
alignment equipment may be used. Laser optical alignment
is the most exact shaft aligning method. The transmitter is a
laser diode mounted on one side of the coupling and the
prism is mounted on the other side.
The laser beam emitted by the laser diode is reflected by the
prism to the localizer.
The offset can be detected by rotating the shafts.
Sketch 5.2-10 Optical Alignment
I. Coupling safety guard

The pump must only be operated with mounted coupling safety guard. After each alignment check
the coupling guard must be refitted immediately. Check for correct assembly, fastening and
distance to rotating coupling.
4330/e5-1-00-001 page 10
24
Title:
Test Certificate
Coupling alignment
Plant / Location:.........................................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Alignment before pipework connection: Remark:..............................................
Alignment after pipework connection: ...........................................................
Alignment before commissioning: ...........................................................
Alignment after commissioning (maintenance): ...........................................................
1. Axial distance check
Coupling gap (mm)
Specified gap:
Pump Driver Pump
Tolerance:
Driver
Spacer coupl. Non-spacer coupl. Actual gap:
Coupling type:.................................................... Spacer: ...............mm Yes No
2. Check of radial misalignment (see also 2.1)
Radial misalignment (mm)
Measuring p. Left Right Top Bottom
Measured:
Driver
Prescribed: 0 ... 0.1 (0.05 preferable)
Pump
2.1. Check of correct axis displacement

(only in case of defined displacement by different thermal growth between driver and driven machine)
Axis displacement (mm)
Displacement Horizontal Vertical
Measured:
Pump Driver
Prescribed: 0 ... 0.05
Driver is set ............... mm higher / lower
Driver is set ............... mm to right / left
3. Check of axial misalignment (parallelism)
Axial misalignment (mm)
Measuring p. Left Right Top Bottom
Measured:
Pump Driver
Prescribed: 0 ... 0.05 (0.03 preferable)
4. Bolt tightening check (after alignment) Test declaration

Pump foot checked: Yes No Rework: Accepted:
Driver foot checked: Yes No Yes No Yes No
Anchor bolt checked: Yes No TC 0000 / 5-2-00-000
Date: Sign: Page … of …
4330/e5-1-00-001 page 11
25
5.3. Suction and discharge pipework
A. General
Welding, burning and grinding work should only be carried out on the pump where specifically
authorised, e.g. there may be a risk of fire and explosion.
Pipe diameters will have already been determined at the planning stage and many factors unknown to the
pump manufacturer will have been taken into account. As a general rule the liquid velocity should not
exceed 2 m/sec (6.5 ft./sec) in the suction pipework and 3 m/sec (10 ft. sec) in the discharge pipework.
It is also good engineering practice to increase the size of both suction and discharge pipes at the pump
nozzles in order to decrease the head loss from friction. For the same reason piping should be arranged
with as few bends as possible and even then should be made with a long radius wherever possible.
A few useful hints are given below which should be observed when the pipework is installed.
In case the possibility of dangerous recirculation may occur after shut-down of pump,
ATTENTION especially with "emergency trip out", back-flow preventors (check valve) have to built in.
B. Assembly
The pipework must be supported in an adequate manner to ensure that no inadmissible
ATTENTION
bending moments or stresses caused by the weight of the pipework or thermal expansion
are transmitted to the pump flanges (install an expansion piece).
All supports and expansion equipment must be installed before making connections to pump flanges.
Ensure that the correct gasket is used at all flanged joints and that the gasket is mounted concentric with
the bore of the pipe.
C. Stress free pipe connection

The stress free pipe connection is to be checked (cold condition, pump empty) in the following way:
• The pipe has to be suspended over the pump flange and there must be space enough to easily build
in the sealing.
• The supports have to be designed in such a way that the weights of the pipe and the fluid are
compensated and will not put inadmissible high pressure on the pump branch (observe nozzle loads in
the installation plan).
Higher than the given max. admissible nozzle loads may lead to a sudden leakage of medium
delivered, life danger occurs.
• If the pipe supports (especially fixed points) are not near to the pump with 1 or 2 elbow
( 45 or 90° direction change ) the pipe can be considered as flexible.
In such cases following tolerances can be used for “stress free connections” :
A
Pipe Pipe
Pump case Pump case
Sketch 5.3-1 Radial misalignment Sketch 5.3-2 Angular displacement
4330/e5-1-00-001 page 12
26
Stress free connection for flexible suction and discharge pipes (cold condition)
Pipe nominal diameter up to 200 (8 in.) over 200 (8 in.)
Radial misalignment A max. 0.5 mm (0.02 in.)
Angular displacement S max. 0.2 mm (0.008 in) max. 0.4 mm (0.016 in.)
• If the pipe is considered as not flexible, so 50 % of the tolerances of flexible piping can de used. Be
sure the max. admissible nozzle loads ( see installation plan) are not exceeded.
Adjustments must be made to the piping, if these limits are exceeded or serious damage
ATTENTION
to the pump may result.
D. Pipe fittings
Discharge line A check valve and a shut-off valve should be installed in the discharge line. The check
valve, placed between the pump and the shut-off valve, is to protect the pump from reverse flow and
excessive back pressure. The shut-off valve is used in priming, starting and when shutting down the
pump.
Suction line In the suction line a shut-off valve should be installed for extended shut downs, repairs and
for pump draining. It must be fully open during operation, and must not be used for pump regulating.
Fittings having the same nominal bore of the pipework should be used. If the pump
ATTENTION
branches have a smaller nominal bore than the fittings suitable taper pieces should be
installed.
E. Suction pipe
On flooded suction applications, the horizontal sections of the pipework should descend towards the
pump and on suction lift applications they should steadily rise towards the pump to prevent air locking.
Sketch 5.3-3 Flooded suction (Suction head) Sketch 5.3-4 Suction lift
The pieces should be designed and constructed so as not to obstruct the free flow of the liquid. The
transition from small to large pipe diameters must be gradual. As a general guide the length of a
concentric taper piece must be 5-7 times the difference in pipe diameters.
Sudden reductions in pipe cross sectional area and sharp bends should be avoided especially in the
suction or inlet pipework, as these greatly increase the frictional resistance within the pipework. A high
frictional resistance within the suction or inlet pipework leads to reduced pressure available at the suction
branch. Too low pressure leads to cavitation at the impeller inlet.
To prevent turbulent flow into the pump, do not position the shut-off valve in the suction piping adjucent to
the pump suction nozzle. The suction valve should be positioned with the handwheel horizontally or
vertically downwards to prevent air pockets forming. Install between flow disturbances as fittings or
elbows a straight pipe with length of 5 to 8 time pipe diameter.
Multi-pump installations should have separate suction pipes to each pump. Excepted are
ATTENTION
duty and standby pumps which may have common suction pipework since only one pump
operates at any time.
4330/e5-1-00-001 page 13
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F. Cleaning the Pipework
Before a pumpset is commissioned, all traces of foreign bodies and impurities must be carefully flushed
out of the supply tank and pipework. Where pipework has been welded, all welding slag etc. must be
removed.
G. Suction strainer
In order to prevent any of the above impurities entering the pump, we
recommend to install a suction strainer made of stainless steel in the inlet
pipework. The strainer insert should consists of a supporting strainer (plate
with round holes 5 to 8 mm, (0.2 to 0.32 in.) to which a wire screen (wire
cloth 0.315 x 0.2 mm, (0.0125 x 0.008 in.) is fixed by welding. The effective
area of passage of this strainer must be at least 1.5 to 2 times the pipe
ø 0.2 mm 0.315 mm
diameter. (0.008 in.) (0.015 in.)
Monitor the pressure drop across the strainer by a differential pressure
Sketch 5.3-5 Wire cloth
gauge. If at any time, a reduction in pump suction pressure is observed, the
strainer should be removed and cleaned.
The differential pressure ≥0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5
ATTENTION
bar (7 psi.) the pump is SHUT OFF; higher differential pressures may lead to the damage
of the strainer result in serious damage to the pump.
ATTENTION The given values are limits for the load on the strainer. As NPSHavailable at the suction
branch is reduced by the max. admissible differential pressure at the strainer whereas
NPSHavailable has always to exceed NPSHrequired , lower regulation limits for ALARM / SHUT OFF may have
to be set accordingly.
H. Pressure test
ATTENTION The pipework should be pressure tested in accordance with the statutory regulations.
4330/e5-1-00-001 page 14
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5.4. Ancillary equipment
A. General
Ancillary equipment is used to monitor the pump (measuring equipment for pressure, temperature etc.)
and to maintain operation (cooling, flushing, sealing etc.). The extent depends on the application and
installation requirements. For type, position and dimensions of the ancillary connections please see
installation drawing.
In case the failure of any auxiliary devices (e.g. cooling, circulation) may lead to an inadmissible
pressure build-up in the pump suitable safety devices have to be installed by user (e.g. alarm,
emergency shut-down or similar).
ATTENTION Do not mix up connections. After laying the pipes (and also after repairs), check the pipe
runs.
The following instructions may be used as a guide insofar as they apply to the pump as delivered.
B. Electrical connections
Electrical connections for motors and controlling devices may only be implemented by skilled
personnel. The instructions of the electrical equipment manufacturers have to be observed as well
as the valid national regulations on electrical installations and the legal regulations of the local
power suppliers.
The applicable standards and guidelines in respect of terminal connections should be observed. If
provided on baseplate the earthing lug must be connected.
C. Pressure measuring equipment

- The start-up and monitoring of the operating point of the pump is made easier with pressure gauges.
See also 6. and 6.7. Pressure gauges should be mounted on a common gauge panel and connected to
the tappings in the pump branches or adjacent pipework using a hydraulic tube with an expansion loop.
Isolating and vent valves should be installed in the pipework for ease of maintenance.
- If case of external flushing of the shaft seal, pressure gauges are installed in this pipes for monitoring
the pressure (see 1.4.5).
D. Temperature measuring instruments

- If pump operates near the vaporization point of liquid, thermometers are recommended for control of
liquid temperature. See also point 5.4 "Minimum flow device". At installation of thermometers in the
pipework let submerse the temperature gauge at least 40 mm into the fluid. At pressures over 16 bar
use protection tube (DIN 43763).
- If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid
vaporization in the sealing range (see 1.4.5).
- At heating the max. temperature of heat carrier has to be controlled (see 1.4.4).
- A measuring possibility of cooling water outlet temperature is favourable, as the adjustment of outlet
temperature smaller than 40 oC avoids deposits in the cooling water pipings.
- At pumps with high loaded bearings numerous controls of bearing- or oil temperature are required. If
necessary control by means of contact thermometer. Execution and measuring points see pipework
scheme or installation plan. Limit values see 7.3 and 1.4.2.
- It's useful to control temperature under sound insulation covers with tele-indication. Align such a way,
that oil- or bearing temperature respectively of pump and driver cannot exceed the permitted limit.
E. Bearing monitoring (Vibration measurement)

By means of impact impulse measurement (possible with antifriction bearings), by bearing housing
vibration or by shaft vibration measurement.
- Advancing bearing damage and other machine failure can be recognised and deteced by means of
electronic sensor measurement. This electronic (computerized) vibration system can be used to
continuously measure and monitor a variety of supervisory parameters for preventing unexpected
machine failure. For further information refer to the manufacturer’s description.
4330/e5-1-00-001 page 15
29
F. Flow indication or flowmeters
- According to technical requirements flow indicators are installed in the reflux of supply pipework. Don't
start-up pump before auxiliary pipings are open and the liquid stream can be determined on flow
indicator.
- If there is danger for mechanical seal in case of too low circulation, a flowmeter is installed in the
circulation piping, which causes alarm when circulation quantity decreases or which shuts the pump
down.
G. Filter / strainer / cyclone separator

are absolutely necessary at rinsing of mechanical seal with spoiled rinsing liquid.
Attention in case of operation with strainer or filter (is not valid in case of cyclone
ATTENTION
separator). If the pump may not be shut-down for change of filter, switchable, parallel
arranged filters are installed. Rising temperature at cover of mechanical seal or inadmissible high
differential pressure between measuring points in front of and behind the filter indicate dirty filter.
Exchange or clean filter immediately. For operation safety reasons it is recommended to carry out the
surveillance of filter not only locally, but also by tele-indicator in the central switch office.
H. Ancillary pipework
- Drainage of the pump casing can be effected by leading a pipe into the drip tray of the baseplate or into
a collection pipe. Isolating valves must be installed in the pipe and must have a pressure rating at least
equal to the rating of the casing.
The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to
any endangering of operator(s) and environment.
- Gland leakage from the shaft seal can also be led into the drip tray or collection pipe.
The leakage of dangerous fluids has to be drained or quenched in such a way as to prevent any
dangers to persons and environment.
- Cooling through cooling liquid: Connections and scope see installation plan or separate drawing
respectively. Don't confuse inlet and outlet connection. (Inlet lowest, outlet highest point of cooling
chamber). For the adjustment of cooling water quantity regulating valves are installed in the supply
pipings. At open system lead the drain pipings over a funnel.
- Heating: Connections and scope see installation plan or separate drawing respectively. Don't confuse
inlet and outlet connection. (Inlet highest, outlet lowest point of heating chamber). In the supply pipings
regulating valves are installed. Lead reflux in a collecting piping, if necessary via steam trap.
- Flushing and / or sealing of the shaft seal: Connections and scope see installation plan or separate
drawing respectively. For pipings which lead to a heat exchanger, pressure transmitter or supply
reservoir, a vent possibility is provided at the highest point. In case of thermosyphon revolution the
biggest pipework diameter possible will be used. Supply piping is layed evenly ascending and without
sharp bend.
- Quench: In case the necessity arises to quench any leakage from the mechanical seal see 1.4.7 for
information on quench media and quantity.
4330/e5-1-00-001 page 16
30
5.5. Minimum flow device
Note: In accordance local-safety standards these instructions must form part of every operating manual. Safety
instructions for pumps which operate in the partial load region. The following information may be disregarded, if the
pump supplied never runs in the partial load region.
-------------------------------------------------------------------------------------------------------------------------------------------
General
In the partial load region (when operating the pump near zero flow) almost the total pump
ATTENTION
power is imparted to the flow as thermal energy. If this flow is less than a certain
minimum (see 1.4.1), heating will occur and continue until the liquid boils, causing severe damage to the
balance device, impellers and casing wear rings leading to eventual breakdown of the pump. To avoid
this there must always be a certain flow of liquid through the pump.
If the shut-off device in the delivery pipe is tightly throttled or closed during pump operation, the
delivery fluid inside the pump will heat up after just a short time. This may cause the surface
temperature on the pump casing to rise above the permissible temperature class. If necessary,
provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with
emergency switch-off).
The following two situations arise for multi-stage pumps with hydraulic balance of the axial thrust:
1. The balance quantity is sufficient
This means that in cases of relatively low driver power and favourable suction conditions the balance
flow is sufficient as the leak-off to be piped away. If this condition applies to the pump supplied, it is
noted expressly on the data sheet under 1.4.1 that the minimum flow is equal to the balance flow. The
balance pipe must not be connected to the suction casing, but must lead to the suction tank.
2. The balance quantity is insufficient
A device must be fitted in the discharge pipe immediately after the pump, which guarantees minimum
flow even with closed discharge valve. The following devices have proved successful in use:
a) Automatic leak-off non-return valves operate such that as the flow decreases the minimum
flow line automatically opens and an integral throttle element controls the minimum flow. The
contrary happens on increasing the capacity. The minimum flow line is directly flanged to the
automatic leak-off non-return valve and leads back to the suction tank.
b) Constant by-pass. A by-pass line is fitted between the pump and the discharge valve, which
also leads back to the suction tank. A throttle is built into the pipe which determines the flow
rate. With this type it should be remembered that the by-pass quantity also flows with the
discharge valve open, which reduces the efficiency of the pump. It must be considered
carefully whether it is worth buying an automatic leak-off non-return valve.
Minimum flow line or by-pass
ATTENTION The minimum flow line is not supplied by the pump manufacturer. It must be provided by
the operator. The pipe must always lead from the pump to the suction tank. For shut-
down and disconnection for maintenance, a shut-off valve must be fitted in the minimum flow line, but
must be locked open before commissioning. If several pumps are installed to operate in parallel and the
minimum flow pipework connects into a common header, it is necessary to install a non-return valve in
each feed piping.
ATTENTION Separate pipes must be laid for minimum flow pipe and balance pipe if both are required
to be led back to the suction tank.
minimum flow line
Never operate below pump
ATTENTION
minimum flow. Minimum flow
operation causes in higher internal wear
therefore operation at minimum flow should be Suction tank
maintained for no longer than 2 hours in any 24 Minimum
flow valve
hours of operation.
4330/e5-1-00-001 page 17
Sketch 5.4-1 Typical piping layout for minimum flow line
31
6. OPERATION
6.1 General
The following recommended start-up and operating procedures apply to the pump only. For information on
any equipment (driver, shaft coupling, shaft sealing system ...) refer to manufacturer’s instructions.
Safety information
Do not start or operate the pump,
- unless the installation has been verified to be correct and all safety and control functions have
been checked.
- unless you have a complete understanding of the location and function of all components of the
pump aggregate including valves and any upstream and downstream equipment that my effect
the flow of medium to or from the pump.
- unless you have a complete understanding of the all auxiliary mechanical, electrical, and
hydraulic systems as well as the function of all monitoring gages and warning devices.
When starting the pump, be prepared to execute an emergency shutdown in case of failure of the
pump or auxiliary system.
6.2 Commissioning
ATTENTION The items described individually have to be carried out, as far as applicable, step by step
during commissioning.
With electric drive it has to be assured by qualified personnel that the necessary protection measures
work. Earthing, reset, residual current failure operated device etc. have to be ready for service acc. to
approval by skilled personnel.
Before commissioning
a. Connections Check bolted connections and plugs. Inspect ancillary pipework for correct installation.
b. Lube Rinse bearing housing with light oil and allow to drain. Fill with lubricating oil, see also 1.4.2 / 7.3
and table recommended lubricants.
c. Alignment Check alignment of coupling (see 5.2)
d. Shaft seal Check shaft seal (see 7.2). In case of double acting mechanical seal fill and vent sealing
system (refer to manufacturer’s instruction). ).
e. Filling the pump
ATTENTION In case of hot (or cold) product: extreme caution must be exercised when filling a pump that is
at ambient temperature. To prevent thermal shock the pump should slowly and controlled
3
filled up with small fill up rate 0.3 to 0.5 m /h (1.2 to 2 gpm) so that the pump case and internals can be
warmed up (or cooled down) uniformly.
Filling the pump - feeding operation Filling the Pump - suction lift
• Slowly open shut-off valve in inlet line • Fully open shut-off valve in suction pipe
• If existing (see installation plan) Open vent • If existing (see installation plan): Open vent (not
(not valid for self-venting casing) valid for self-venting casing)
• In case of mechanical seal: Shaft sealing • In case of mechanical seal: Shaft sealing
chamber has to be vented (see also 5.4 chamber has to be vented (see also 5.4
Flushing and Sealing) Flushing and Sealing)
• As far as existing: Close vent when pumped • Fill pump (suction pipe must have foot valve)
medium flows without bubbles • As far as existing: Close vent when pumped
• Fully open shut-off valve in inlet line medium flows without bubbles
ATTENTION Before starting the pump, the suction piping, pump case and shaft seal chamber must be
completely filled with liquid.
If there is danger of frost, protect the pump casing, bearing housing and cooling chambers
ATTENTION
against freezing.
f. Minimum flow line (if fitted) Open and lock the valve in the minimum flow line (see also 5.4 - para.
Minimum flow device).
M000/e6-1-00-000 Page 1 32
g. Balance line If the balance line is returned to the suction tank, also open and lock the valve in this line.
(see Installation Plan or P & I Diagram).
6.3 Pump start-up and Operation

Pump operation is based on the assumption that the pump system is always completely full of delivery
fluid. This prevents the existence of any potentially explosive mixture in the pump. If this is not
guaranteed, appropriate safety systems (e.g. liquid detectors or motor load controllers) must be provided on
the equipment.
a. Ancillary equipment If available, put ancillary equipment into operation (e.g. cooling, heating, sealant
pressure...), open the valves in the ancillary pipework (open Quench after pump start-up), vent pressure
gauge (see also 5.4).
b. Start-up with non-pressurized system Start-up with pressurised system
• Close shut-off valve in the discharge pipe (precondition is non-return valve in discharge
(minimum flow must be guaranteed). pipe)
• Start driver and bring the pump rotor • Start driver with open discharge valve and
immediately to operating speed. bring the pump rotor immediately to
• Open discharge valve slowly, until the operating speed
differential pressure drops to the value given
on the data sheet.
Operation below min speed e.g. by variable speed drive or turbine drive, causes serious
ATTENTION
damage to the pump.
ATTENTION Pump should produce pressure at discharge as soon as rated operating speed is reached. If
not, shut down immediately and vent pump system.
Warning: The differential pressure must not fall below the design point even with plants with fluctuating
system pressure. Note: The pressure gauge on the discharge side shows the differential pressure plus the
suction pressure.
c. Observe ammeter reading The full load amps given on the rating plate of the motor must not be
exceeded.
d. Adjustments The pump capacity can be adjusted by the discharge valve.
Do not operate pump below minimum flow (see 1.4 and 5.4 Minimum flow). During pump
ATTENTION
operation the valve in the suction line must be fully open.
Non-observance may result in an unacceptable temperature increase and cause the pump to run dry.
In extreme cases the pump casing may burst.
Starting of a Stand-by pump or starting a Parallel working pump

Note: If a stand-by pump should replaces the function of another one (operating pump), both pumps have to
run parallel for a short time.
a. Proceed preliminary work for the stand-by or parallel working pump as given in section 6.1 General and
6.2 Commissioning.
b. Start-up pump as given in 6.3, check discharge pressure. Operate both pumps parallel.
c. Stand by pump After running in full operation the first operating pump can be shut down. Refer to 6.5
shut down.
Parallel working pumps Both pumps remain
in operation. Each (identical) pump deliver only
half of capacity delivered, see pump curves
Head in (m)
below. Non-identical pumps can also operate in

parallel but selection must be done very single pump curve two identical pumps
carefully. working parallel
3
Capacity in (m /h)
4000/e6-0-00-000 page 2
33
Overloads have to be avoided by all means as they may lead to a failure of parts due to too stringent
mechanical requirements. Overloads occur, if the pump is run beyond its original application range,
i.e.
z exceeding of the max. admissible speed
z remaining of the min. speed (low speed rotation e.g. by turbine drive, high velocity flushing through the
pump, damage of discharge non-return valve causes serious damage to the pump)
z exceeding or remaining of the medium viscosity
z exceeding of the max. admissible inlet pressure
z exceeding of the max. admissible temperature
z exceeding or remaining under the operating range of the pump
z running of the pump without proper venting of pump interior
z running of the pump without required safety devices ( safety valves, electrical overload protection etc.)
z operation of the pump with closed or strongly throttled shut-off device in the discharge line without
having a minimum flow device (exception: during start-up).
z operation of the pump with closed or throttled shut-off device in the inlet line (dry running)
z operation of the pump for the delivery of fluids, for which the pump are not suitable (chemical, solids,
gas content ...)
z operation of the pump with wrong sense of rotation
z operation of the pump with inadmissible bearing lubrication or with wrong lubricant
Operating modes like that and other inadmissible operating modes may lead to heavy damage on
the pumps and other parts of the plant. Danger may arise by the bursting of pressure-holding parts
and people within the range of danger may be hit by pieces or fluid, which may be hot, aggressive or
toxic, as the case may be. There may be mortal danger.
6.5 Shut-down (observe sequence)

Remark: If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shut-
down is for a short time only. For lengthy shut-downs, for repairs and where there is no non-return valve, the
discharge valve must be closed.
a. Close discharge valve slowly and top the driver, when doing this pay attention to whether the rotor runs
down smoothly.
Standby service
Ancillary systems as cooling- , sealing- and quench systems are operational. Standby pumps should be
started at regular intervals to ensure their readiness for immediate service. We recommend to start-up the
pump unit once every month and run for 30 minutes.
Extended shut down
b. If the pump works on a suction lift and is not to be left ready for start-up, the suction valve should also be
closed.
c. If existing, close quench piping.
d. If fitted, close the valves in the ancillary pipes with the exception of the cooling water, which should only be
switched off when the pump has cooled down.
Freeze damage, preservation
e. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including
external heat exchangers and pipings.
Emergency shut down of the pump
a. In case of failure of the pump or any auxiliary system shut down the driver immediately.
b. Before restarting the unit once again follow 6.6 Restart procedure
6.6 Restart procedure

If the pump is switched off by emergency shut down or trip, do not restart before the causes of the
emergency has been found and removed.
a. Before restarting, check that the pump shaft is at a standstill. If the non-return valve in the discharge pipe
is leaky, the pump shaft may rotate in reverse direction due to the backflow of the medium delivered.
The pump must not be switched on when the pump shaft is rotating in reverse direction, as
ATTENTION
this may damage the pump.
b. Proceed restart as given in section 6.3 Start-up and operation.
4000/e6-0-00-000 page 3
34
6.7 Service Control
General
A pump must be looked after and carefully supervised to ensure trouble free running.
During the first period of operation (24 hours) supervision should be intensive. Read and check the operating
parameters every hour. During the next period of operation (first week) supervision should be done every 24
hours. During normal use checking should be done together with the regular inspections at least ones a
week.
If any vibrations, unusual noises or faults are observed stop the pump unit at once.
ATTENTION
Refer to section “Operating faults”.
Number of starts
The pumps are designed for continuous operation. Too many and too frequent starts can accelerate ageing
and result in abnormally high wear and short life time. In case of many starts we recommend an intensive
supervision and maintenance intervals should be shortened. The recommended number of start-ups are as
following:
- Commissioning phase: up to 200 start / stops (max. 6 starts / day)
- Commercial operation: up to 3 starts / day
Cumulated number of starts max. 600 starts / year
Remark: In case of many start / stop cycles we recommend to perform a general overhaul of the pump after 6
years running time.
Checking the duty point (design point) of the pump
Particularly important at the initial start-up:
• Check the speed.
• Read the discharge pressure and subtract the suction pressure.
Convert this pressure (generated pressure) to a head and compare it with the generated head shown on the
pump duty plate at the corresponding speed.
generated pressure (bar) x 10 200

generated head (m) = 3
density of liquid (kg/m )
Metric units 3
generated head (m) x density of liquid (kg/m )
generated pressure (bar)
= 10 200
The generated pressure must not fall below the value given in the pump data sheet, otherwise
ATTENTION
the maximum allowable capacity could be exceeded, the driver could be overloaded or the
suction pressure could fall below the minimum required by the pump.
Checking the capacity
pump characteristic curve
The capacity is determined from the pump performance
curve and the generated head (m) as calculated above.
Operating range
Find the calculated value of the generated head on the
vertical axis of the performance curve.* Draw a horizontal
line through this point until it intersects the curve. The
corresponding capacity is read on the horizontal axis
vertically below the point of intersection.
Maximum capacity
Head in (m)
Minimum capacity
* If the characteristic curve sheet only includes the

pressure of one stage divide head by number of stages
of the pump supplied.
3
Capacity in (m /h)
4000/e6-0-00-000 page 4
35
6.8 Operating faults
Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable
operating faults in the plant.
There is usually a certain connection between the different types of faults. It is, therefore, expedient to list and
compare the symptoms as well as the possible causes. Assistance can be found for individual operating faults
in virtually all cases.
Symptoms / Possible causes of faults / Remedies
Symptoms Possible causes of faults Remedies
1 Pump does not work. Driver out of service, speed too low Check - refer to manufacturer‘s
No discharge manual
pressure. Rotor blocked Check and correct
(Failure at start-up) Wrong direction of rotation Check-refer to pump rotation arrow
Pump not primed Vent pump
Suction valve/line blocked Inspect and correct
Foot valve blocked or damaged Inspect foot valve
Impeller passages blocked Inspect pump internals
2 Loss of discharge Suction pipe not completely full Fill the system
pressure after start-up Too much air or gas in the pumped Check operating data (1.4)
liquid
Leakage of air into pump suction Check and correct (seal)
3 Pump flow too small. Suction or Discharge valve not fully Check valve position and correct as
Differential pressure open required
too low. Suction strainer blocked Disassemble and clean strainer
Efficiency loss Minimum flow line open, minimum Check minimum flow line, minimum
flow valve damaged or bypass orifice flow valve, bypass orifice (5.4)
worn
Furring of the pump internals and/or Clean and flush pipework.
pipework Disassemble and clean pump
internals.
Impeller passages blocked Disassemble and inspect pump
internals
Pump internals worn (gap clearances) Disassemble and inspect pump
clearances (8.)
4 Pump vibrates or Coupling alignment faults Check coupling alignment (5.2)
causes too much Worn shaft coupling Check coupling condition and replace
noise Suction valve not fully open Check and correct (open fully)
Suction strainer blocked Disassemble and clean strainer
Pump runs with cavitation Check operation data (1.4). Create
more pressure at the pump suction.
Piping strain, excessive high nozzle Piping should be properly supported
forces and moments to prevent strains from being
imposed on the pump
Foundation too weak, base not or not Inspect foundation bolt tightening and
correctly grouted baseplate grouting (5.1)
Impeller damaged or blocked Inspect pump internals
Bearings damaged Disassemble and replace bearings
(8.)
Unbalanced rotor – causes vibration Check balance of coupling, driver
and pump rotating parts
Shaft bent Disassemble and check shaft runout
(8.)
4000/e6-0-00-000 page 5 36
Symptoms Possible causes of faults Remedies
5 High shaft seal Seal flush insufficient (flow rate) or Check flow requirements
temperature. missing
High leakage of Wrong orifice size or worn orifice Check size, flow requirements
mechanical seal. Solids block seal rings/springs Disassemble and remove solids,
Short shaft seal life review application
Vaporisation in the seal ring area Check circulation flow or cooling
requirements (1.4, 7.2)
Seal fluid not suitable (abrasive) Review application, install filter or
separator
Seal rings, auxiliary gaskets (O-rings) Disassemble and replace damaged
or springs damaged seal parts (8.)
Dry operation of seal. Seal system not Fill and vent shaft seal
correctly filled or vented chamber/system
Seal face material inadequate Review application with seal
manufacturer
Pump shaft bent Check shaft runout at seal area
6 High bearing Pump not running at operating point Review operating parameters (1.4)
temperature. Coupling alignment faults Check coupling alignment (5.2)
Short bearing life. Too much grease or oil in the bearing Check and correct (7.3)
Oil level too low or high Check and correct oil level (7.3)
Wrong lube oil quality Verify that recommended lubricant is
used (7.3, T 3). Change lube oil.
Bearings loaded during assembly Examine assembly and condition of
bearing and associated parts (8.)
Insufficient bearing cooling (air / Check air intake (environmental
water) temperatures under noise hoods).
Check cooling water requirement
(1.4)
Bearings damaged Disassemble and replace bearings
(8.)
Excessive pump thrust Check hydraulic balance device,
balance pipe. Disassemble and
inspect pump internal clearances (8.)
Shaft bent Disassemble pump and check shaft
runout (8.)
7 Lube oil leakage Oil level too high Check and correct oil level (7.3)
Labyrinth seal or shaft seal ring Examine assembly (labyrinth leakage
improperly installed bore downwards)
Bearing cover gasket or seal Disassemble and replace
damaged gaskets/seal (8.)
Vent blocked Check and clean vent connection
8 Excessive wear of Pump not running at operating point Review pump operating parameters
pump internals Insufficient suction pressure. with a Sulzer representative, make
- Corrosion Operating fluid differs from specified necessary correction to unit design.
- Erosion value (temperature, specif. gravity...) Refurbish pump with correct parts,
- Loss of material Materials of construction not clean system. Assemble filter or
compatible with medium delivered separator.
9 Pump Operating below minimum flow Review hints for minimum flow. (1.4,
overheating/seizure (pump dry running) 5.4) In case of seizure disassemble
and repair unit.
4000/e6-0-00-000 page 6 37
7. MAINTENANCE
7.1 Pump general
The operating personnel shall inspect the machine frequently. The purpose of the inspection is to thoroughly
familiarize personnel with the equipment. This is imperative if abnormal occurrences are to be detected and
remedied in time. It is vital that the inspections cover the following points:
1. Leakage > Check main connections on pump suction and discharge
> Check leakage on shaft sealing, auxiliary connections
> Check for oil leakage on bearing housing
2. Gauges > Check pressure gauges (pump suction, discharge, ...)
> Check temperature (fluid, bearings, driver, ...)
> Check ammeter (motor)
3. Bearings > Check the bearing temperature
> Feel the bearing vibrations (measure the SPM- values)
> Check the oil level, refill constant level oiler
4. Vibration, Noise > Feel the machine
> Check for undue vibration
> Check for unusual noises
5. Fastening elements > Check that all screw fasteners are correctly tightened
Safe operation can only be guaranteed if the pump unit is kept in perfect technical condition. This, in
turn, can only be achieved through constant monitoring and proper maintenance.
If any vibrations, unusual noises or faults are observed stop the pumpunit at once.
ATTENTION
Ascertain the cause and rectify (see Operating faults).
Monitor ancillary equipment during operation (if fitted)
Gauges: pressure, temperature, ammeter at regular intervals
Cooling: flow and temperature
Flushing/Sealing: pressure, temperature, (quantity)
Any deterioration in pump performance not caused by alteration or furring of the pipework is probably due
to wear of the pump internals. The pump should be taken out of service and overhauled. See section 8. for
details on overhauling the pump.
The pressure in the balance chamber should always remain constant. If the balance
ATTENTION
pressure increases by 2-3 bar over the pressure when the equipment is new, the balance
device must be checked for damage. In most cases it will be necessary to change the balance parts. The
increase in balance pressure can, however, also be attributed to the increase in resistance in the balance line
due to furring.
Bearings
For information about lubrication see chapter 7.3.
Bearing housings has to be kept clean on the outside, since the radiation of heat is reduced by deposits of
dust or dirt.
Bearing monitoring: Check the bearing vibration during running.
In case of antifriction bearing, by means of shock impulse method. Carry out checks according to the
operating instructions of the measuring gauge in fixed intervals. During first start-up the initial values
must be recorded to find out deviations of later measurement. After measuring put coloured caps on
measuring nipples distinguishing,
> green cap = everything o.k
> yellow cap = increased attention
> red cap = beginning bearing damage
With correct maintenance and unhindered heat dissipation, it is possible – in the area of the rolling
o
bearings - to maintain temperature class T4 (135 C) at the surface for ambient temperatures up to
o
+40 C. Special measures (cooling) must be taken for higher ambient temperatures, or for
o o
temperature classes T5 (max. 100 C) and T6 (max. 85 C).
0000/e7-1-01-000 page 1 38
Vibrations
These can be detected by hand or with electronic equipment (frequency or amplitude analyser).
Horizontal pumps, which are fastened to the foundation with anchors should not exceed a vibration speed
given in the following table.
Bearing vibration level unfiltered RMS / 10-1000 Hz
-1 -1
Operating speed up to 3000 min up to 3600 min
Continuous operation 4.5 mm/s (0.18 In/s) 5.6 mm/s (0.22 In/s)
Alarm at 7.1 mm/s (0.28 In/s) 9.0 mm/s (0.35 In/s)
Shut off aggregate 11.0 mm/s (0.43 In/s) 11.0 mm/s (0.43 In/s)
This values are valid for operation at rated point / preferred operating range (from >70% Flow
ATTENTION
to <120% BEP) only.
Flow < 70% BEP - part load operation acceptance criteria: +1.5 mm/s (0.06 In/s) RMS compared to the value
for preferred operating range.
Measured values which are too high can also be caused by the plant (pipings/accessories) or by other
vibration sources (machines). In order to determine the reason for high vibration values a vibration
analysis is necessary.
Noise
Some abnormal noises can be heard immediately, such as those due to rolling element indentations because
of improper mounting; others are progressive. Noise is usually an indication of incipient failure and varies in
intensity and frequency with the extent of damage.
Alignment
During shut-down (according to operating requirements) check the alignment of the coupling (at least
once a year). Re-align if necessary (see 5.2).
Operating log
It is recommended to enter operating data and data on lubrication, repairs etc. in an operating log. An
ongoing operating record will assist troubleshooting and machine service decisions. Analyse machine
performance regularly.
Spare parts
It is recommended that spare parts listed below are always kept in stock. This modest investment can often
prevent minor faults from developing into serious trouble. The following parts should be stocked:
> Antifriction bearings, in case of plain bearing (set bearing shells, pads)
> Balance drum and liner (set balance discs)
> Wear rings and setscrews
> Gaskets and O-rings
> Mechanical seals
For pumps used in extremely important service or if several identical machines are operating in the same
plant, it is recommended that a complete machine be stocked at job site.
Orders for spare parts should always include the following information:
> Type of pump (rating plate or operating manual)
> Order number (rating plate or operating manual)
> Quantity and designation of parts / article-number (parts list)
> Part number (parts list or sectional drawing)
Pump safety can only be ensured if repairs are carried out by expert specialist personnel using original
replacement parts.
0000/e7-1-01-000 page 2 39
Inspection and check list
The intervals between the necessary overhauls may vary extraordinary, as the differing operating conditions
can have substantial influence on the service life of machine parts.
Under normal operating conditions and with pumps which are not neglected in maintenance and care, the
check and overhaul works are recommended in the following intervals.
Further
recomm.
see
6 monthly
Overhaul
Monthly
Weekly
Measuring devices
During
Yearly
Daily
(Pressure gauges, thermometers ammeters as far a existing and not
monitored by automatic switches alarm/emergency out)
Pressure > Delivery pump (suction and 1.4.1 / 6.7 X ➊

discharge)
> Balance chamber 4.2 / 7.1 ➊
Temperature > Medium delivered 1.4.1 X

> Pump bearing / oil sump 7.3 ➊
Further checks and inspections
Oil level > Oil sight glass / Constant level oiler 7.3 X
Leakage > Shaft seal / Mechanical seal cover 7.2 ➊
> Flange sealings (main connections) - X

> Lubricating oil from bearing housing - X
Vibration > Vibration measurement 7.1 ➊
> Bearing shock impulse 5.4 / 7.1 ➊
Maintenance works
Oil change > Bearing housings 1.4.2 / 7.3 ➊
Coupling > Check alignment 5.2 ➊
General > Bearings, balance drum and liner, 8. ➋

overhaul / wear shaft seal, impellers, wear rings ...
check
➊ These parameters should be recorded in an operating log and used as a basis for maintenance works.
➋ Overhaul allows supervision of wear, early recognition of any sign of damage and replacement of
defective parts in time. All signs of wear and spare parts used should be recorded in the operating log.
0000/e7-1-01-000 page 3 40
Title:
Report Supervision check list
Plant / Location:.........................................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Start-up normal abnormal Remark:...........................................................
Run ........................................................................
Noise ........................................................................
Vibration ........................................................................
........................................................................
Comments:.................................................................................................................................................
...................................................................................................................................................................
...................................................................................................................................................................
TIME Gauges Bearings
o
Pump Temp. C Oil level
Start up Shut down Suction Discharge Balance D-side ND-side D-side ND-side
Remark:
R 0000 / 7-0-00-001
Date: Sign: Page ... of ...
0000/e7-1-01-000 page 4 41
Title:
Report Inspection check list
Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
1. Leakage normal abnormal Remark:.....................................................
Pump suction ..................................................................

Pump discharge ..................................................................
Shaft seal ..................................................................
2. Gauges Remark:.....................................................
Pump suction .............. bar ..................................................................

Pump discharge .............. bar ..................................................................
Balance chamber .............. bar ..................................................................
3. Bearings normal abnormal
o
Temperature .................................. C D-side / ND-side
Oil level ................................... O.K. Yes / No
Oil refilled ................................... Refill QTY. liters
Oil leakage ................................... Yes / No
4. Vibration / Noise normal abnormal

Remark:.....................................................
Bearing hous. D-side ..................................................................
ND-side ..................................................................
Pump casing .................................................................
Noise .................................................................
..................................................................
Comments:............................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
Remark:
R 0000 / 7-0-00-002
Date: Sign: Page ... of ...
0000/e7-1-01-000 page 5 42
Title:
Report Maintenance list
Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................
Maintenance interval No.: ....... Operating hours: .........h Number of starts: ........
Bearings:
Lubricating oil change Lubricant type : .........................................
Leakage checked Quantity: ...................................................
Bearing monitoring: Green Yellow Red

Drive side:
Non-drive side:
by impact impulse measurement everything o.k. attention damage
Comments: ......................................................................................................................
Mechanical part:
Coupling alignment checked (reported)
Bearings opened and checked
Mechanical seal checked
Balance device opened and checked
General overhaul with pump hydraulic part opened and checked
Rotor newly adjusted (axial / radial center position)
Parts changed:
Mechanical seal - Drive side / Non-drive side
Balance device
Bearings - drive side / non-drive side
Shaft
Wear rings
others: ..........................................
Comments:..............................................................................................................................................
................................................................................................................................................................
................................................................................................................................................................
Remark:
R 0000 / 7-0-00-003
Date: Sign: Page 1 of 1
0000/e7-1-01-000 page 6 43
7.2 Shaft seal
Single-acting mechanical seal
General remarks
Mechanical seals intended for use in potentially explosive areas must satisfy the “Ex” protection
requirements.
In the case of mechanical shaft seals the exit of the medium delivered is prevented by two plane parallel
lapped ring surfaces which are pressed together with the help of spring force and liquid pressure. Seal rings
(stationary and rotating) are sealed against adjacent pump parts with the help of adjoining sealings (as for
example O-rings) serving simultaneously as elastic bearing.
Conditions
ATTENTION In order to have trouble-free operation a liquid film has to form between the slide faces and
therefore the following conditions have to be fulfilled by the medium delivered:
- sufficient lubricating properties
- evaporation temperature considerably higher than operating temperature
- no impurities in the slide ring region
If auxiliary facilities like
- flushing
- blocking
- heating
- cyclone separator/filter (in case of an impure medium delivered)
are necessary for arriving at the operating conditions required the details given in paragraph 1.4.3 / 1.4.4 /
1.4.5 / 5.4 and in the installation plan of the pump have to be observed.
Failure of an auxiliary device (cooling, circulation, etc.) may cause the temperature of the casing
surface to rise to an unacceptable level. If necessary, provide the equipment with appropriate safety
systems (e.g. remote temperature monitoring with emergency switch-off).
Maintenance
The maintenance of the mechanical seal can be limited to the control of the auxiliary facilities, leakage and
temperature at the mechanical seal cover. In the case of normal flushing by circulation the seal cover must
not reach any higher temperature than the adjacent pump casing. In the case of cooling or heating the data
mentioned in paragraph 1.4 have to be observed.
A slight leakage of the mechanical seal is normal. It is impossible, however, to make special
ATTENTION
statements with regard to the leakage of the mechanical seal, as the quantity of leakage
depends on a lot of different factors (e.g. size, material, liquid pumped, temperature etc.). In case of high
leakage seal ring pairs may also leak. In this case defective parts have to be replaced. Auxiliary seals (such
as O-rings) have to be renewed during each assembly. Mechanical seal rings (stationary and rotating) have
always to be replaced as a unit.
0000/e7-2-01-002 44
7.3 MAINTENANCE - BEARING / LUBRICATION
Anti-friction bearing with ring oil lubrication
General
ATTENTION Centrifugal pumps are often exposed to heavy stress caused by continuous operation and
heavy forces (radial, axial). Therefore a proper oil quality is a prerequisite for a long bearing
life and trouble-free operation. The oil must not contain any foreign substances, acids or resins. Minimum
requirements of suitable lubrication oils are given in DIN 51 511, API-SF/CC, MIL-L-46152 B.
All lubricating oil suppliers are therefore in a position to classify their products accordingly and to propose a
product which satisfies these standards.
Oil viscosity
Since, with anti-friction bearings, the self-heating of the bearing due to filling plays an important role, and
since, on the other hand an oil viscosity of at least 12 mm2/s at operating temperature of the bearing is
required for a sufficient lubrication film, the oil viscosity has to be selected as follows:
ATTENTION Multigrade Engine Oil SAE 15W-40 should be used. The max. allowable temperature values
are given in the table below. In case of deviations contact the service. If the temperatures
after overhaul rises over the given values for continues operation (> 90 oC in the oil sump), as a first
measure check thrust bearing axial clearance (see 7.6).
Change intervals and oil quantity

In case of first commissioning or of an overhaul, change the oil after 10-15 hours of operation. If further
pollution by foreign substances and water is low, change intervals of 6 months or 4000 operating hours
can be adhered to.
Pump size 40-180 50-220 80-260 100-300 150-360 200-400
Oil filling in liters 0.6 0.9 1.6

per bearing housing
Check regularly the oil level in the bearing housings (oil sight glass).
In the case of automatic constant–level-oilers pay attention to refill the reservoir (oiler tank).
Max. allowable temperatures
Measuring spot
Mode externally at bearing at external bearing in the oil sump

housing near bearing race
Continuous operation < 100 oC < 110 oC < 90 oC
Alarm at > 110 oC > 120 oC > 100 oC
Switch off aggregate > 120 oC > 130 oC > 110 oC
Check temperature at the measuring spots regularly
Suitable lubricators of different brands see lubrication recommendation T3 annex
4330/e7-3-01-000 Page 1 45
SAE 15W-40
Recommended Lubricants T3
Proper lubrication is particularly important for the operational safety of centrifugal pumps.
If suitable lubricants are correctly applied, an optimum performance is obtained and trouble and its
consequences are avoided. Supplementing the operating instructions, the table gives the lubricants which
are recommended for the lubrication of centrifugal pumps which are suitable for an ambient temperature
between -10oC and +40oC.
The lubricants have been listed in alphabetical order which does not say anything about their quality.
Supplier Multigrade Engine Oil
SAE 15W-40
AGIP F1 SUPER MOTOR OIL, SINT 2000
ARAL SUPER ELASTIC MOTOROIL 1540
BP BP SB MOTOROIL, VISCO 2000
Castrol GTX 2, GTX 3, TXT SOFTEX CASTOLITE
DEA REGIS MULTIGRADE, TORUS 15W40
ELF PRESTIGRADE, SPORTI T, MULTIPERFOR. 3C
ESSO ESSOLUBE MHC 1540, MHX 1540
MOBIL OIL SUPER FORMULA, DELVAC SUPER 15W40
SHELL HELIX STANDARD, ROTELLA MX 1540, RIMULA TX
TEXACO HAVOLINE, URATEX MULTIGRADE 15W40
WINTERSHALL TFE 10W40, MAGNUM SL, MULTI RECORD 15W40
4330/e7-3-01-000 Page 2 46
SAE 15W-40
Oil level
The center of the sight glass (if present) indicates the minimum oil level required in the bearing housing. During
standstill of the pump the oil level is to settle higher; during operation the oil level sinks towards the centre of
the sight glas s.
Monitoring oil level. A sudden oil level drop can indicate a leak. Stop operation and inspect unit.
ATTENTION
Oil replacement
Warning: Lubeoil can cause skin irritation and eye inflammation. Follow all safety precautions specified
by the manufacturer.
For oil replacement proceed as follows:
1. Shut down pump.

2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage bores and
size see installation plan or dimension sheet.)
3. Remove screw plug, drain oil thoroughly. Tighten screw plug again securely.
4. Fill bearing bracket with fresh oil as described.
Dispose of used oil according to statutory regulations. Do not put into wastewater by any
means.
Filling-in of oil with constant level oiler (Non Adjustable Type))

Remove oil filling plug at the top of the bearing housing. Fill oil through the bearing-housing fill opening until the
casing of the constant level oiler begins to fill up (swing back oiler bottle to check oiler case filling). Then fill the
bottle with the same oil and swing it back to its working position. Repeat this procedure until a minimum of 2/3
of the bottle remains filled up. Screw in and tighten filling plug.
Maintenance: Check the supply in the bottle at times and refill, if neces sary.
Constant level oiler working principle

When the oil level within the bearing housing drops, the opening to the supply bottle gets free. Oil flows from
the supply bottle until the former oil level is reached and the opening to the supply bottle is covered by the oil
level.
Oil bottle swinged back Oil bottle in working position
refill here
Oil level
casing
gasket
Make sure that the glass bottle is tightly closed, if necessary replace gasket. Turn bottle
ATTENTION
handtight into threaded cover.
0000/e7-3-01-002 47
8.1 OVERHAUL - DISMANTLING OF THE PUMP
When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts) well
beforehand to minimise the down time. When ordering spare parts it is essential to give an exact description
of the part, its part number, the pump type and serial number (see the duty plate).
References Refer to specific drawings (section drawing(s), parts lists, installation plan).
Note: A pump should only be disassembled by qualified specialists with suitable tools and by strictly
observing the instructions.
Preliminary work
- Close the suction and discharge valves and secure them against unauthorised opening.
- Let hot pumps cool down to ambient temperature before disassembly.
- Isolate the driver to prevent start-up.
With electrical driver: Remove residual current (take away safety fuses). Have electrical connections
disconnected by an electrician.
- Drain the pump (position of drain screw see installation plan)
The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to
any endangering of operator(s) and environment. Observe legal provisions for disposal.
In case the pump delivered aggressive, toxic or otherwise dangerous media, it has to be flushed carefully, to
be cleaned on the outside and to be decontaminated in the case of radioactivity.
If the pump is sent to the manufacturer to be repaired, the cleaning / decontamination has to be
carried out before transport.
The service personnel will have to be careful however inspite of this, as even in the case of a thorough
flushing and cleaning, residues of the fluid may leak out.
- Remove the coupling guard and separate the coupling halves.
- Remove any instruments and ancillary pipes.
- Drain off oil from bearing brackets.
Dispose of used oil acc. to legal regulations. Never put it into the sewage system.
- Disassemble pump and take it to assembly site.
Pay attention to hazardous situations during disassembly, i.e. take care to stand firm, secure
assembly parts against dropping, support or prop loose parts etc.
- Remove coupling half on pump side (see sketch 8.1-1), take off key (940...)
To avoid damage to the bearings or to the shaft

ATTENTION
centering thread use a suitable puller and
protect the shaft centering thread by a disc. The bearings
must by no means be subjected to any pressure or shock.
Sketch 8.1-1
4330/e8-1-01-003 Page 1 48
Dismantling of bearing - non-drive side
- Remove screws (900.01) for the fastening of the fan cover (832.01) and take off fan cover. Take circlip
(932.01) out of shaft groove by means of spring ring pliers, push fan (831.01) off the shaft and remove
key (940...).
- Loosen setscrew (904.06) of thrower (507.05) and push thrower off the shaft. Remove carefully any burrs
caused by setscrew.
- Remove hexagon socket screws (914.02) from bearing cover (360.02) and take off bearing cover.
- Remove shaft nut (920.16 or 920.15 depending on model).

Shaft nut (920.16): Locking pins pressed against the shaft by the adjusting screws, are in the bearing
fastening nut KMT (920.16). As the locking pins were fitted into the bearing nut by pressure fit, the
bearing nut will still rest tightly on the shaft thread after loosening the adjusting screws. Light tapping on
the shaft nut near the screw holes will loosen the locking pins a little so that the shaft nut can be screwed
off easily.
Shaft nut (920.15): Bend lockwasher tang out of bearing nut (920.15) and screw off bearing nut. Take off
lockwasher (931.01) and distance disc (551...).
- Take off lockwasher (931.01) and oil ring (644.01). Push spacer sleeve (525...) off the shaft.
- To dismantle the bearing bracket, remove dowelling (tapered pins, 560...) on bearing bracket. Screw in
(tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws
901...) on the bearing bracket flange.
Arrest the shaft before drawing off the bearing bracket on non-drive side to avoid damage to the
ATTENTION mechanical seals. To do so mount a holding device on the drive side to fasten the rotor to it by
means of the shaft bore, see sketch 7.1-2.
Draw off bearing bracket with puller: Arresting the rotor on drive (turbine) side:
Push bearing bracket together with Replace 2 fastening screws from bearing
antifriction bearings evenly off the shaft. cover opposite to each other by the holding
device and secure the rotor by the shaft
puller centering thread.
holding device
shaft
shaft Bearing bracket Bearing bracket
drive side non-drive side
Sketch 8.1-2
- Screw off hexagon socket screws (914...) of the bearing bracket fastening, mount puller (see sketch) and
draw off bearing bracket together with antifriction bearings (320.02). Dismantle antifriction bearings.
- Push inboard thrower (507.06) off the shaft.

-
- Screw off hexagon nuts (920.02) and loosen and remove bearing bracket lantern (344.01). If present (see
sectional drawing).
4330/e8-1-01-003 Page 2 49
Removal of bearing - drive side
- To disassemble the bearing bracket drive side remove holding device again (mounted for dismantling the
bearing on the non-drive side).
- Unscrew hexagon socket screws (914.02) from bearing cover (360.01) and take off bearing cover.
- Loosen grub screw (904.06) and pull outboard thrower (507.04) off the shaft.
- Unscrew hexagon socket screws (914.02) from bearing cover (360.01) and take off bearing cover.
- Bend lockwasher tang out of bearing nut (920.17) and screw off bearing nut. Take off lockwasher
(931.02) and oil ring (644.01). Push spacer sleeve (525...) off the shaft.
- To dismantle the bearing bracket, remove dowelling (tapered pins, 560...) on bearing bracket. Screw in
(tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws
901...) on the bearing bracket flange.
- Screw off hexagon socket screws (914.05) of the bearing bracket fastening. Loosen and remove bearing
bracket together with bearing. Press out antifriction bearing outer race with rolling elements.
- Draw inboard thrower (507.01) off the shaft, the antifriction bearing inner race will be taken along as well.
If required use suitable puller.
Removal of shaft seal - drive side

Single-acting mechanical seal:
- Loosen external parts of shaft seal (mechanical seal cover) from shaft seal housing (441.02) and remove
them, draw shaft sleeve off the shaft (mechanical seal with rotating parts)
- Loosen and remove shaft seal housing (441...) by removing the hexagon socket screws (914.01) from
suction casing. Be careful: Remaining medium will flow out.
Removal of shaft seal and balance device

Single-acting mechanical seal:
- Loosen external parts of shaft seal (mechanical seal cover) from shaft seal housing (441.02) and remove
them, draw shaft sleeve off the shaft (mechanical seal with rotating parts)
- Unscrew hexagon socket screws (914.01) fastening shaft seal housing (441.02), loosen shaft seal
housing and pull it off. Be careful: Remaining medium will flow out.
- Draw sleeve (520.01) off the shaft and remove split ring (501.01) from the shaft groove. Take off key
(940.04).
- Mount device and draw balance drum (603.01) and balance drum liner (605.01) off the shaft. See sketch
8.1-3. Take off keys (940.02).
Sketch 8.1-3
Removal of balance drum
and balance drum liner
4330/e8-1-01-003 Page 3 50
Dismantling of the hydraulic pump part
Mark the stage casings, diffusers and impellers with the stage number during dismantling, as they must be
refitted in the same place.
- Remove nuts (920.01) from the tie bolts (905.01) and withdraw the tie bolts.
- Loosen and remove the delivery casing (107...) by carefully tapping with a rubber hammer and levering
between the release pins. Be careful: Remaining medium will flow out.
- Remove last diffuser (177.01) from delivery casing
- Slide the impeller (230...) off the shaft, remove key (940.01)
- Loosen and remove stage casing (108...) together with diffuser (171...). Be careful: Remaining medium
will flow out.
- Slide next impeller (230...) off the shaft, remove key (940.01)
- Dismantle stage by stage in the same way. Support shaft adequately to prevent bending.
- Withdraw carefully shaft with first stage impeller out of suction casing, slide impeller off the shaft and
remove key.
- Press diffusers (171...) out of the stage casings (108...)
- If required (in case of wear, see 7.5): The wear rings (502...) in the suction casing / stage casings and the
interstage bushes (541...) in the diffusers can be replaced.
After disassembly
All pump parts should be cleaned and prepared for short term storage by applying a rust preventive to all
machined surfaces which are not made of stainless steel. Recommended rust preventives are given under
3.2.3 part II. Protection of the interior of the pump.
Handle the pump shaft with care and whereever possible store shaft by hanging vertically to maintain
staightness.
Inspect all parts for wear or damage, see ..
4330/e8-1-01-003 Page 4 51
8.2 Overhaul - Inspection of wearing parts
Carry out all checks with the greatest possible care. Examine all parts for wear and re-machine or replace as
the case may be. Negligence leads to a premature failure of the pump.
Impellers
Inspect impellers for wear or damadge. Look for cavitation marks (pits) in the suction area, erosion of vanes
and cracks in the ahroud. Smooth minor irregularities with a fine file or emery paper.
Wear rings and clearances

Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum diametrical
clearances between impeller and wear ring is given in the table below.
Replace impeller and wear ring when pump performance drops below acceptable system standards or the
maximum clearances have been reached or exceeded.
The permissible clearance between impeller and stage casing/wear ring can be taken from the following
table.
REMARK: Each clearance enlargement causes efficiency loss in pump.
Pump size 100-300 150-360 200-400 Material index
Min. clearance 0.4 0.45 cast iron or soft nitrided steel
(with new parts) 0.55 0.6 stainless steel
Max. clearance 0.8 0.9 cast iron or soft nitrided steel
(with worn parts) 1.1 1.2 stainless steel
* clearance in relation to diameter
Measure the clearance between corresponding sets of rotating and stationary

parts. Use several measurement locations, then calculate the clearance as
described below.
Largest casing wear ring ID – smallest impeller OD = diametrical clearance
Wear ring replacement

Case wear rings: Remove setscrews and press stationary wear rings out of their
seats. Suction casing: Insert a pulling tool or pry bar between wear ring and seat
and apply pressure. Stage casings: Note that bushing is shouldered on one side.
Use a suitable press. Installation: Be sure rings and seats are clean and free of
burrs. Install rings, chamfered towards inside, with a press. Fit and secure
setscrews by peeling.
Inter stage bush: Remove inter stage bushes by removing setscrews and tapping
them out of their seats. A press can be used. Inspect seat and remove any burrs.
Assemble new bushing. Drill and tap for setscrews. Fit and secure setscrews by
peeling.
4330/e7-5-01-009 Page 1 52
Balance drum / Balance drum liner
Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size.
Replace balance drum/balance drum liner as a unit when the maximum clearances given in the table have
been reached or exceeded.
Pump size 100-300 150-360 200-400 Material index
Max. permissible 0.4 0.6 cast iron or soft nitrided steel
clearance (worn parts) 0.5 0.7 stainless steel
*clearance in relation to diameter
Balancing
It is recommended that impellers are individually balanced on a balancing machine. Dynamic balance to VDI
2060, ISO 1940, Q = < 2,5.
The assembled rotor is not balanced as a unit, since the deflection of the rotor is different during balancing in
air to the deflection under the influence of hydraulic axial and radial forces in the close clearances within the
pump.
Shaft
Handle the shaft with care and support it evenly to maintain straightness. Avoid bumping, hitting or springing
the shaft.
True running of the shaft: Support shaft at bearing area (use V-blocks or rollers) and check for
concentricity (max. permissible run-out 0.025 mm). If the run-out is outside the permissible value replace the
shaft.
Mechanical seal
The front sides of the sealing rings (running faces) should show no sign of scoring. Renew stationary and
rotating seal rings which are scored or crazed, as a unit, never replace only one ring. Check shaft sleeve for
perfect surface quality, especially at the seat of the rotating unit; renew if necessary.
Assembly: In case of re-assembly use new gaskets and O-ring seals. We recommend the use of new
rotating and stationary seal rings.
Assembly must be done very carefully and under conditions of extreme cleanliness. The seal
ATTENTION parts must by no means be subjected to any pressure or shock (danger of break). Seal faces
should not be lubricated with oil or grease as this may prevent introduction of the sealed fluid in operation,
leading to overheating and failures. Remove protective films from new parts direct before assembly.
Antifriction bearings
Rinse bearings in light oil. In case of major overhaul or damaged, replace it.
In case of renewed taper roller bearings: Use only paired bearings with reinforced
ATTENTION
intermediate ring (without groove on the outside diameter) market by SKF through addition 03
to the bearing design number on the original packing. Never replace only one bearing of a unit. The bearing
design number is given in the pump parts list.
4330/e7-5-01-009 Page 2 53
Rotor concentricity check (shaft with rotating parts)
Concentricity should be checked with the shaft in unloaded and loaded condition. Assemble the complete
rotor. Instead of the last impeller insert a thread sleeve with SKF hydraulic nut HMV screwed on and a
spacer sleeve according to sketch. The additional parts required can be supplied by the manufacturer (upon
request).
Do not fully tighten the hydraulic nut. Support shaft at bearing area (use V-blocks or rollers).
Make run out check in unloaded condition. The measuring points are: diameter of impeller clearances,
the extension of the hub on the rear of the impellers, the shaft (protection) sleeves, balance drum and the
coupling shaft end (see sketch). The max. permissible run out is given in the following table.
Operating speed  3000 1/min > 3000 to 5000 1/min > 5000 1/min
max. permissible runout 0.04 0.03 0.02
Hydraulic nut
If the run out test has been satisfactory, the same check is carried out with the loaded rotor. Connect
SKF hand lever oil pump to the hydraulic nut (fill oil reservoir) and by manual operation of the pump, axially
load the parts rotating with the shaft. Oil pressure required see table hydraulic nut.
High pressure hydraulic equipment can be dangerous if misused. Use heavy gloves and eye
protection. Make sure that the high pressure pump and high pressure pipes are not damaged. Use all
equipment strictly in accordance with the instructions of the equipment manufacturer. When mounting,
make sure that there is no leaking of oil at the connections. Jets of liquid escaping from high pressure
equipment have sufficient power to penetrate the skin, which can cause blood poisoning. In case of such an
accident, immediate medical attention must be sought.
With rotor in loaded condition Repeat runout check on the same spots. If the gauge indicates an
inadmissible runout all surfaces which are at right angles to the axis of the shaft and which are used to
absorb or transmit axial forces, such as shaft shoulder, impeller hubs, balance drum and sleeves have to be
checked for squareness.
The max. permissible variance in the vicinity of the shaft outer diameter (shaft shoulders, hubs, sleeves etc.)
should not be more than 0,01 mm. If this value is exceeded, re-machine: e.g. turn on mandrel (without
clamping) or grind with the minimum possible reduction in the hub and/or sleeve length.
Repeat concentricity check as described above. Upon satisfactory completion of concentricity check,
dismantle rotor. Mark impellers in sequence so that they can be refitted in the same order when assembling
the pump. Remove the special components used for the concentricity and keep to use in future overhauls.
4330/e7-5-01-009 Page 3 54
Components of the hydraulic clamping device for true running test of rotor
Hydraulic clamping nut Size d D e h Oil Part 008 Part 009

for Pump size pressure Drawing No. Drawing No.
100-300 19 A M 95 x 2 162 43 5 360 4-061 420 4-088 974
150-360 24 A M102 x 2 188 44 5 430 3-086 836 4-089 060
200-400 26 A M130 x 2 198 44 5 420 3-086 835 4-089 058
000 Hydraulic clamping nut, make SKF type HMV

001 Union K-GEV 8L - G ¼ 1.0718
002 Pipe 8 x 1,5 DIN 2391 130 long 1.0308 GBK
003 Union K-GEV 8L - G ¼ 1.0718
004 Reducing socket ¾ x ¼ 1.0718
005 Pump support SKF 101 352 3
006 Wika-pressure gauge 211.100.600 bar
007 Oil pump SKF 226 400
008 Sleeve 1.0503.05
009 Sleeve 1.0503.05
* The additional parts required for the concentricity check can be supplied by the manufacturer upon request.
4330/e8-2-01-009 page 4 55
8.3 OVERHAUL - ASSEMBLY OF THE PUMP
References Refer to specific drawings (section drawing(s), parts lists, installation plan).
A pump should only be assembled by qualified specialists with suitable tools and by strictly observing the
instructions.
All assembly works have to be carried out with the greatest possible care. Negligence leads to
ATTENTION premature failure of the pump.
Preliminary work
- Clean pump parts
- Prepare lubricants (e.g. oil, Molykote, Never Seez)
- Only use glycerine or "Klüber PROBA 270" paste for O-ring seals
- Always renew seal rings and gaskets
Pay attention to possibly hazardous situations during assembly, i. e. take care of a firm stand, secure
assembly parts against dropping, support or prop loose parts etc.
Assembly of the hydraulic pump part (Refer to matchmarks during reassembly)

Note with pump sizes: 100-300 from 7 stages; 150-360 and 200-400 from 6 stages:
With pumps having a large number of stages, the pump casing must be adjusted to the deflection line of the
shaft. In such cases the correction is obtained by obliquely turning one or more of the stage casings. The
oblique stage casing carries the mark “OBEN" and the number of the stage in which it must be mounted
(counting from the suction end). See sketch 8.3-1.
oben
Sketch 8.3-1
If the pump is assembled horizontally, the stage casings should not be supported underneath before the tie
bolts are tightened, so that the stage casings can be “suspended".
- Clean shaft, impeller bores and coat the contact surfaces slightly with lubricant.
- Insert key (940.01) for the first impeller, and push impeller (231...) onto shaft stop (210...)
- Insert diffuser (171...) in the first stage casing (108...) and place O-ring seal (412.01) on the spigot of the
stage casing.
- Slide shaft with impeller into the stage casing from the drive side.
- Insert key (940.01) and push on next impeller (230...) from the non-drive side.
- Fit another pre-assembled stage casing (with diffuser and O-ring seal).
- Assemble remaining stages in the same way.
- Slide delivery casing (107...) with inserted last diffuser (177.01) and O-ring seal (412.12) on the spigot of
the last stage casing (108...).
- Place O-ring seal (412.01) on the spigot of the suction casing (106...) and mount suction casing.
4330/e7-6-01-002 Page 1 56
ATTENTION Adjust and support pump suction and discharge casing feet on a smooth steel plate.
- Fit tie bolts (905.01), discs (550.01) and nuts (920.01). Clamp the whole hydraulic assembly together
evenly and crosswise.
- see table 8.5 for tightening torques-
Assembly of the balance device

- Insert key (940.02) for balance drum (603.01) and slide on balance drum with inserted O-ring seal
(412.08).
- Push balance drum liner (605.01) with O-ring seal (412.07) into delivery casing and allow the cylindrical
dowel pin (561.02) preventing rotation to engage in the hole.
- Insert key (940.04) and split ring (501.01) into shaft and slide on sleeve (520.01).
Measurement of theoretical axial position of rotor

Measurement is not necessary, if the installation length of the pump parts have not changed through re-
machining during repair, but it is essential, if new parts (shaft, impellers, stage casings) have been
fitted, otherwise continue with paragraph "Rotor centering procedure".
In order to achieve the most favourable hydraulic efficiency of the pump, the impellers and diffusers must be
placed in the optimum position to each other. For this purpose and in order to avoid lateral distortion of the
rotor, the theoretical axial position of the rotor is to be measured and set. The construction tolerances make
it possible to keep the correction of the axial rotor position within very low limits.
Remark: Mount all parts required for the measurement without o-ring seals.
- Mount shaft seal housings on delivery casing (107...) and suction casing (106...) using hexagon socket
screws (914.01). Note: Be sure venting bores of seal chambers are on top.
- If present (see sectional drawing): Fit intermediate pieces (132...) on the shaft seal housings.
- On both sides: Assemble bearing bracket lanterns (344.01) and bearing brackets (330...) and fasten
with nuts evenly and crosswise.
- Push rotor until stop in the direction of the non-drive side.
- On the non- drive side: Determine measurement „A" (see sketch 8.3-2) from the support shoulder of
the thrust bearing in the bearing bracket bore to the face of the shaft shoulder with depth gauge.
- The (non-drive side) inboard thrower sleeve (507...) must be longer than the measurement "A" by the
value "B" given in the following table
Pump size 100-300 150-360 200-400 Dimension in mm
Dimension B= 6.5 ± 0.1 7 ± 0.1 8 ± 0.1
- New thrower sleeves are supplied with oversize, they must be machined to the calculated dimension.
When repair work is done the nominal dimension can also be gained by applying supplementary discs.
ATTENTION The max. permissible variance in the vincinity of the thrower sleeve shoulders is 0.01 mm.
4330/e7-6-01-002 Page 2 57
Measurement of the axial position of rotor
Rotor pushed up to top in

direction of non-drive side
A+B
Sketch 8.3-2
- On the drive-side: Check the length dimension of the thrower sleeve (507.01) while the rotor is moved to
the non-drive side. To do so measure with depth gauge from the circlip in the bearing bracket (stop anti-
friction bearing outer race) to the front face of the shaft shoulder. The measuring result should
correspond to the dimensions given in the following table.
Pump size 100-300 150-360 200-400 Dimensions in mm
measuring result 4 ±1 5 ±1
Remark: Because of the big tolerance the spacer sleeve on the drive side has very rarely to be re-machined.
Rotor centering procedure

The disassembly of the hydraulic pump part requires that the rotating element radial center position be
determined and adjusted, otherwise continue with paragraph „Assembly of shaft seal non-drive side“
ATTENTION Serious damage can be caused if the pump is started with off-center rotor
- On the drive side: Loosen all adjusting screws and put bearing bracket in the lowest position possible.
- Tighten fastening of bearing bracket and loosen them once again, so that the bearing bracket can be
shifted by the adjusting screws (901.03) which are at the bearing bracket flange.
- Adjust bearing bracket by the lateral adjusting screws. Measure between shaft and bearing bracket bore
by means of an inside spring caliper until shaft is in the horizontal center. See sketch 8.3-3. Tighten and
secure lateral adjustment screws in such a way as to fix the bearing bracket in horizontal position and
allow vertical movement.
4330/e7-6-01-002 Page 3 58
Execute the lateral adjustment of the Inside spring caliper =
=
bearing bracket by turning the adjusting
screws until shaft is set in horizontal center
position of bearing bracket bore
Adjusting screw Adjusting screw
Sketch 8.3-3
Shaft Bearing bracket
- Attach a measuring gauge vertically near the bearing (the measuring pin has to be positioned at right
angle to the shaft) to ascertain at the bearing area by what dimension the shaft can be lifted. Divide the
result by two and note. See sketch 8.3-4.
ATTENTION Do not bend the shaft!
- Mount roller bearing: Heat inner race of roller bearing (320.01) in oil bath up to 80 oC and push onto shaft.
Build in outer race with rollers into bearing bracket bore.
- Fit measuring gauge again, screw in lower adjustment screw (901.03) until shaft is lifted by the dimension
noted before. Fasten bearing bracket tightly. Observe measuring gauge, the shaft position must not
change. Secure adjustment screws with nuts (920.03).
- On the non-drive side: Measure shaft vertical movement in the same way as on the drive side. Fit
another available roller bearing or an ancilliary bush with the corresponding dimensions instead of the
taper roller bearing unit. Adjust bearing bracket in the same way as described for the drive side.
Check of free running state of the rotor

Due to manufacturing of the turbinepump parts within given tolerances the rotor theoretically
ATTENTION should be in center position, i.e. could usally be turned by hand. To do so, attach lathe carrier at
coupling shaft end and check free running.
- Turn-on rotor and look for touching during running down.
Causese and measures in case of touching of the rotor
1. Center position of the rotor not correctly adjusted, adjust once again.
2. Tightening the screws in practice may, however, cause a different prestress in each screw by differing
friction values in the thread and the nut support. Due to the differing prestress a deformation (bending) of
the stage casing package, which is clamped together, may occur. This may cause a touching of the rotor
parts at the stationary casing parts. With increasing stage number this will be more and more likely.
If it is found that the rotor can only be turned under difficulty or not at all, the bending of the
ATTENTION stage casing package needs correction by tightening the tie bolts with differing torques. As
there is no proper way of predicting how the bending of the stage casing package will work out,
the tie bolts to be tightened more strongly will have to be found by trying.
Note: The torques given in the table 8.5 may be exceeded in these cases by max. 50 %. It may be
necessary to adjust center position again!
After check of free running
If check of free –running is satisfactory dowel bearing housings in new position. Existing taper pin
holes can be reaimed to the next size taper pin or, if required, drill new holes.
- After measurement remove bearing brackets, bearings and bearing bracket lanterns on both sides again.
Also remove thrower sleeves, dummy sleeves and shaft seal housings. Refer to 8.1.
4330/e7-6-01-002 Page 4 59
Assembly of the shaft seal housings
- Drive side: Insert key (940.04) for shaft sleeve.
- Insert O-ring seal (412.02) in groove of the shaft seal housings (441...). Locate shaft seal housings on
delivery casing (107...) and suction casing (106...) using hexagon socket screws (914.01). Note: Be sure
venting bores of seal chambers are on top.
- In case of shaft seal housing cooling: Place O-ring seal (412.02 or 412.03) on the spigot of the seal
housing and O-ring seal (412.04) into the shaft seal housing groove. If present (see sectional drawing):
Fit intermediate pieces (132...) on the shaft seal housings.
Assembly of shaft seal - non-drive side
- Mount rotating parts of the shaft seal on the shaft sleeve (523.01). Insert O-ring (412.10) in the groove of
the shaft sleeve bore and push shaft sleeve onto shaft.
- Build stationary elements of the mechanical seal into mechanical seal cover. Fit o-ring seal and slide on
seal cover with the pre-assembled stationary parts of the shaft seal, but do not fasten yet.
Assembly of bearing - non-drive side

- Lubricate the shaft and push inboard thrower (507.06) with nominal dimension into position on the shaft.
- Mount bearing bracket lantern (344...). Lube threads and support surfaces of nuts (920.02) and tighten
evenly and crosswise (tightening torque see 8.5).
- Lift bearing bracket (330...) into position and screw on fasteners (914.05) finger tight. Insert taper pins
(560...) through bearing bracket flange into bearing bracket lantern (344...). Support bearing bracket and
seat taper pins, then properly tighten bearing bracket fasteners evenly and crosswise.
- Assemble thrust bearing: Build in thrust ball bearing (320.02). Warm bearing in an oil bath to approx.
o
80-100 C and push them up to shaft stop.
ATTENTION In case of renewed thrust ball bearings:
Use only paired thrust ball bearings, never replace only one bearing of a unit. The bearing design number is
given in the pump parts list.
- Install spacer sleeve (525.05), screw on shaft nut (920.16 or 920.15 depending on model).
Shaft nut (920.16): Screw on and tighten shaft nut (920.16). Secure shaft nut by tightening the adjusting
screws.
Shaft nut (920.15): Install spacer ring (551...), lock washer (931.01) and shaft nut (920.15). Apply
lubricant to the contact faces of the lock washer and shaft nut. Tighten bearing nut and bend lock washer
tang into one of the shaft nut slots.
ATTENTION Do not over tighten bearing nut.
- Fit lubricating ring (644.01) in the spacer sleeve groove. Insert O-ring (412.05) into the bearing bracket
groove. Install bearing cover and tighten bearing cover fasteners evenly and crosswise. Tightening torque
see table 8.5. During tightening the rotor reaches the final axial position.
4330/e7-6-01-002 Page 5 60
Assembly of shaft seal and bearing - drive side
- Mount rotating parts of the shaft seal on the shaft sleeve (523.01). Insert O-ring (412.10) in the groove of
the shaft sleeve bore and push shaft sleeve onto shaft.
- Build stationary elements of the mechanical seal into mechanical seal cover. Fit o-ring seal and slide on
seal cover with the pre-assembled stationary parts of the shaft seal, but do not fasten yet.
- Lubricate the shaft and push inboard thrower (507.01) with nominal dimension into position on the shaft.
- Mount bearing bracket lantern (344...). Lube threads and support surfaces of nuts (920.02) and tighten
evenly and crosswise (tightening torque see 8.5).
- Lift bearing bracket (330...) into position and screw on fasteners (914.05) finger tight. Insert taper pins
(560...) through bearing bracket flange into bearing bracket lantern (344...). Support bearing bracket and
seat taper pins, then properly tighten bearing bracket fasteners evenly and crosswise.
o
- Assemble radial bearing: Heat inner race of roller bearing (320.01) in an oil bath to approx. 80-100 C
and push up to shaft stop. Build in anti-friction bearing (320.01) outer race with rolling elements into
bearing bracket bore.
- Install spacer sleeve (525.04) and lock washer (931...), screw on bearing nut (920...). Apply lubricant to
the contact face of bearing nut and lock washer.
- Tighten bearing nut and bend the lock washer tang into one of the bearing nut slots.
ATTENTION Do not over tighten bearing nut.
Check and correct the thrust bearing axial clearance (end play)
ATTENTION To allow the forming oil films between bearing parts and for heat expansion, it is necessary to
provide a correct bearing end play. The bearing end play must be checked after every
disassembly of the thrust ball bearings.
- Place clock gauge axially on the front of the shaft on the non-drive side; check axial clearance of the
taper roller bearing unit by axially moving the rotor into its final positions. See sketch 8.3-4. Tap lightly on
the bearing bracket (non-drive side) with a rubber hammer to straighten twisted rolling elements.
Move rotor into its final axial positions, use device as shown. Tighten hexagonal nut  (not
too strongly),  loosen, read clock gauge, loosen , tighten  and read nominal end play.
1 2
Nominal end play
0.04 to 0.06 mm
Sketch 8.3-4
- If there is no noticeable clearance the bearing elements may be twisted, turn rotor slowly in both
directions and measure once again. If the measure axial clearance is smaller than 0.04 mm, the fault may
be corrected by tightening the thrust bearing shaft nut (920.15) more strongly. Correct mistake.
4330/e7-6-01-002 Page 6 61
- Remove device for bearing end play measurement.
If the taper roller bearing temperature after overhaul rises >90 oC, as a first measure check
ATTENTION
bearing end play.
Final assembly
- On the drive side bearing bracket: Fit lubricating ring into the spacer sleeve groove. Insert O-ring
(412.05) into the bearing bracket groove. Install bearing cover and tighten bearing cover fasteners evenly
and crosswise. Tightening torque see table 8.5. Push outboard thrower (507.04) onto shaft, adjust gap
between bearing cover and thrower to 1 mm and tighten setscrew (904...).
- On the non-drive side bearing bracket: Push thrower (507.05) onto shaft, adjust gap between bearing
cover and thrower to 1mm and tighten setscrew. Insert key (940.03) for fan (831.01) into shaft, slide on
fan and place circlip (932.01) in shaft groove. Place fan cover (832.01) and fasten with cylindrical screws
(900.06).
coupling half nut
- Mount coupling half: Insert key that drives the coupling into
shaft. To assemble coupling half remove parts suspectible to
heat (e.g. rubber buffer elements, sealing rings ...) and heat
coupling half by homogeneous dry heating (e.g. oven, oil bath...)
to about 80oC. Push coupling half onto shaft using shaft
centering thread (see sketch 8.3-5). When cooled down remount
the disassembled parts. Couplings with bores up to 50 mm
diameter may also be assembled in cold condition.
pump shaft bar stud
The bearings must by no means be subjected to any
ATTENTION pressure or shock. Sketch 8.3-5
- Assemble pump onto baseplate. Couple driver, check alignment of coupling and tighten foot fasteners
with torque wrench (see 5.2). Connect ancilliary equipment and instruments.
ATTENTION Do not mix up connections. Carefully check piping system.
Electrical installations/connections for motors and controlling devices may only be carried out by
qualified electricians.
- Fit coupling guard. Rinse bearing housing with light oil and fill with lubricating oil, see 7.3 and lubricant
table T3.
ATTENTION For recommissioning repeat all steps from paragraph 6.1.
4330/e7-6-01-002 Page 7 62
8.4 Tools
A. Disassembly equipment for the balance piston and thrust bearing housing
Part Part Pump size 40-180 50-220 80-260
No.
1 1 Flange 200 x 25 x 165
Drawing No. 2-104 084 159
Article No. (tool set complete) 104 998 809 362
2 4 Stud (bearing hous. removal) M 10 x 165 M 12 x 200
3 2 Stud (balance piston removal) M 10 x 440 M 12 x 620
4 4 Disc A 10.5 A 13
5 4 Nut M 10 M 12
6 1 Hexagon screw M 20 x 1,5 (140 or 180 length)
7 1 Ball 12 mm diameter
Sketch 8.4-1 Thrust bearing housing removal

1 2
1
6 7
5
Sketch 8.4-2 Balance drum (drum liner) removal
1 3
1
6 7
B. Rotor concentricity check (see also 8.2)

Qty. Between balance drum and last stage impeller
1 Disc Dimension in mm, inner dia. x outer dia. x thickness

Pump size 40-180 50-220 80-260
Dimension S 50x62x3 S 65x85x3.5 S 70x90x3.5
Qty. Instead of thrust bearing
1 Sleeve Dimension in mm, inner dia. x outer dia. x length

Pump size 40-180 50-220 80-260
Dimension 40x52x46 60x75x62 55x68x58
4330/e8-0-01-001 page 14 63
8.5 Screw tightening torques
Tightening torques (Nm)
Casing seal
part no.: 905.01

Pump size Working pressure (bar)
< 80 > 80 to 120 > 120 to 150
40 – 180 710 1030 1260
50 – 220 1090 1580 1940
O-ring
80 – 260 650 940 1160

100 – 300 1000 1450 1780
150 – 360 1550 2250 2770
200 – 400 2100 3110 3850
Tightening torques (Nm) for

Pump size bearing bracket fastening bearing cover screws
part no.: 920.02 part no.: 914.02 / 03
40 – 180 20
105
50 – 220
80 – 260
30
100 – 300 205
150 – 360
200 – 400
Note: Tightening torques are only valid, if thread and support surface for nuts
(respectively screw head supports) are lubricated. Bolting sequence
A. Even loading
Suggested torque values are recommended to produce properly stressed
joints with a minimum probability of nuts, bolts or studs breaking or ➅ ➁
loosening. ➃ ➆
Avoid possible distortion by using correct tightening sequence during torque
development.
B. Thread lubes
Lubricate threads and support surface for nuts with graphite and oil, ➇ ➂
molybdenum disulfide, or another anti-seize lubricant of comparable quality, ➀ ➄
except in instances where the lubricant is incompatible with fasteners
application.
C. Torque development
Tighten opposing fasteners in an alternating sequence when developing
required torque.
Lubricate and install fasteners finger-tight. Develop the required fastener ➃ ➁
torque in a minimum of three steps with a maximum of 33 % torque value on
the initial pass.
tie bolt 905.01 nuts 920.02

➀ ➂
nuts 920.02
screws 914.02
➀ ➃ ➅
➃ ➆ ➀
➁ ➂ ➁ ➇
➄ ➂
screws 914.03
Note: Refer also to 5.2 for tightening torques for pump feets
4330/e8-0-01-001 page 15 64
ENCLOSURES
Table of enclosures for operating instruction
PUMP
Performance data-diagram
Performance curve
Dimension drawings
Installation plan
Plant drawings
P + I Diagram
Device list
Sectional drawing
Centrifugal pump
Parts list - pump
SHAFT SEAL
Shaft seal system

Shaft seal drawing
Instruction
Barrier system
Instruction
ACCESSORIES
Drive
Coupling
Driver
Valves
Minimum flow regulation
65

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OPERATING MANUAL

Document No. OPM/MC-New/002.04

Sulzer Pumps India Ltd. 9, MIDC, Thane-Belapur Road, Digha,

0 20--25 First issue E. T.

Revision Date Description Sign

Refer Documents and drawings of each pump item for details

2.1 Marking of instructions in the operating manual

are indicated with the general danger sign

or, in the case of warnings against electrical

and in terms of explosion protection with the

2.2 Qualification and training of personnel

2.3 Danger on non-observation of the safety regulations

2.4 Safety-guided working

2.6 Safety instructions for maintenance, inspection and assembly jobs

2.7 Prohibition of unauthorized rebuilding measures or alterations

2.9 Explosion Protection

Never stay within the range of suspended loads.

If required use traverse

B. Preservation for despatch

D. Longterm storage - preservation

Ethylene-propylene (EPDM): - Klüber Syntheso D 220

E. Maintenance of the longterm stored pumps

4.1 Description of the pump

Bearing bracket non-drive side Bearing bracket drive side

vent plug (oil fill connection)

5.1 Installation of the pump unit

B. Mechanical completion and installation sequence check list

REF. PAR. EVENT

C. Installation of pump and driver

disc sheet metal

E. Grout in the foundation bolts

- Build a dam around the foundation. Forms must be strong baseplate

- If necessary: Seal the grout openings by covering with a

G. Tightening torques for foundation bolts

2. Level baseplate longitudial

6. Auxiliary checks and connections

7. System checks TEST DECLARATION

Driver “No Load” run

Sketch 5.2-1 Reference machine – next machine

Sketch 5.2-2 Sketch 5.2-3 Sketch 5.2-4

G. Axial shaft distance

Adjustment devices Adjustment screws

Moving machine Baseplate

Coupling alignment procedure

I. Coupling safety guard

2.1. Check of correct axis displacement

4. Bolt tightening check (after alignment) Test declaration

Date: Sign: Page … of …

C. Stress free pipe connection

Pump case Pump case

Sketch 5.3-1 Radial misalignment Sketch 5.3-2 Angular displacement

C. Pressure measuring equipment

D. Temperature measuring instruments

E. Bearing monitoring (Vibration measurement)

G. Filter / strainer / cyclone separator

6.3 Pump start-up and Operation

Starting of a Stand-by pump or starting a Parallel working pump

below. Non-identical pumps can also operate in

6.5 Shut-down (observe sequence)

6.6 Restart procedure

generated pressure (bar) x 10 200

* If the characteristic curve sheet only includes the

Pressure > Delivery pump (suction and 1.4.1 / 6.7 X ➊

0 20--25 First issue E. T.

Pump suction ..................................................................

Inspect all parts for wear or damage, see ..