General Manual DB

Dalian Deep Blue Pump Co.
,Ltd
37 Pump Installation And Operation Manual
ƺ1.GENERAL
1.1Introduction
This manual contains all the basal information for installation, trial run, operation, and
maintenance of EAPˈEAPGˈANSˈXLˈZXˈESHˈESHKˈEHGˈSCSˈDCSˈEDSˈHDDˈ
LYAˈLGˈLCˈLDBˈHZWˈPP series manufactured by Dalian Deep Blue Pump Company. With
regard to each specification, consult appropriative manual for the feature structure, parameter,
assembly and disassembly. It is necessary to read this entire manual for all the maintenance
engineers and jobsite service workers before installation or trial run.
Ordering spare parts and any other business, please pay attention to series number, model of
the pump and factory serial number of productions indicated in the nameplate. Dalian Deep Blue
Pump has the legal copyright.
1.2 Quality Warranty
Quality Warranty shall be according to the contractual agreement.
1.3 Safety Rules
1.3.1 Information sign
-Dangerous sign: It might lead to danger to whom do not pay attention to the Safety Rules.
-Care of the electricity
-Safety rules sign: mechanical failure or operation failure caused by neglecting the Safety
Rules.
-Informational sign on the pump (e.g. rotary direction arrowhead, nameplate, the connection
declarator) keep them intact and clear for convenience.
1.3.2 Training and qualification
All workers for maintenance, inspection and installation must be qualified. The duty, authority
and extent of inspection shall be fixed and clearly. Manufactures shall provide inexperienced user
with training and guidance. The user should understand the manual absolutely.
1.3.3 Safety rules
-Pump shall operate in the scope that specified by the datasheet. Pump shall never overload
from the limit specified in the in any case.
-The failure of auxiliary device (e.g. cooling, minimum flow equipment, lubricating seal
washing device) might lead increase of voltage, inactivation of mechanical seal and increase
of bearing temperature etc. So it is a must to make sure the auxiliary device are working
steadily.
-If the temperature of the pump parts is very high or low that it might be harmful for operator
contacting.
-To avoid refluxes after shutdown of the pump, a reflux prevention device shall be installed.
-Protective devices shall be inspected before start-up of pump (e.g. coupling guard).
-Transportation of dangerous/ poisonous liquid shall comply with law for environmental
protection.
-Working part shall be inspected frequently to make sure that replace the worn parts in time,
e.g. impeller, wearing ring.
-There shall be steady damp device to avoid any accident by dropping of the parts during
assembly and disassembly.
-Connection flanges, thread bores and other opening shall be reliable sealed during transport
1
and storing.
-It shall be carefully decontamination for the medium might do harm to health during its
transportation.
-All the workers for maintenance, inspection and installation should be permitted and skilled,
and familiar to this manual..
1.3.4 Any measurement or restructure is forbidden without commissions
Do not measure and restructure the equipment without manufacturer’s written permission.
Meanwhile spare parts and auxiliary device shall be provided by the manufacture only, for the
quality and safety guarantee. Otherwise, we are not responsible for any problems, lead by using
other manufacture’s spare parts..
1.4 Packages and Transportation
-The package of production comply to the JB2759-80;ǉGeneral Specification for
electromechanical productsǊ
-Separate packaged and delivery; equipments shall be clearly indicated with serial number by
labels or other forms.
NOTE: -Protect the bearing from vibration and impact during transportation(e.g. fixation of
rotor);
-Jam holes of pressure chamber to avoid any accidents. So do the holes of cooling chamber.
NOTE: -To avoid the damage during delivery and storage, small pipelines in and auxiliary
device shall be properly fixed, disassembly to packing separately when necessary.
-Comply with the laws specification for transportation and installation.
-The load ability of device for transportation shall be inspected, the properly total load of
device refers to documentation. Please confirm the load during the transportation, avoidance
of this is forbidden.
1.5 Lift
1.5.1 Inspection
NOTE: Make sure the load ability of
the lifting equipment and the
ropes can bear the weight of
the goods, the weight of the
goods is listed in the data sheet.
Figure1.2-1
1.5.2 Lifting position
-The lifting position of the packing container refer to Figurre.1.2-1..
-The lifting positions of various types of pumps refer to Figure 1.2-2.
NOTE: EGS-L vertical high-speed pump shall disassembly the motor during the lifting; lifting
both of the pump and motor is forbidden.
2
a b
C d
a: double-suction pump b: horizontal one-stage pump
c: horizontal multistage pump d: vertical pump
Figure 1.2-2
-The lifting position of complete equipment refers to Figure 1.2-3.
NOTE: The ropes of lifting the complete pump shall be hanged over the mounting parts of
pumps (e.g. suction flange, motor). It is forbidden to lift the complete pump if the
weight of it is over 7.5 ton , and lift the pump, motor , baseplate singly . Finally ,
assemble on the basis of equipment in the field .
Figure 1.2-3
-Lifting of the parts
The lifting positions of parts according to their specific shapes, use the lifting eye if there
is; using the unthreaded hole is allowable, but the tap hole is unallowable; protect
3
important parts such as screws and mating surfaces from fish tail which affecting the
assembly.
1.5.3 Matters need attention during lifting
-Trussing up the equipment with steel thread before lifting, lifting with uniform speed after
it is in balanced state.
-Lifting eye on the pump parts and motors are not allowed to be used for lifting of the
complete assembled pump or completely assembled pump sets. The lifting eyebolts are
only provided for lifting of the loosened parts during maintenance and disassembly.
-To vertical pump , it is forbidden to lift horizontally or by discharge pipe .
Lifting refers to Figure1.2-4 is forbidden.
Figure 1.2-4
1.6 Storage
1.6.1 The shelf life of the pump is one year in view of no damage of package and no particular
maintenance.
1.6.2 For the pumps tha t can not be installed &start-up as soon as being received, its storage
shall be following the details below:
-To refrain from rust-eaten of pump that lead by the condensation of moisture in the air,
stockhouse should be clean, dry, constant temperature, if possible, and without any
vibration.
NOTE: For the external disadvantages conditions (e.g. damp air, sharp changes of temperature,
acidity, basicity, pollution), contact flanges shall be properly sealed to avoid leakage of
air
1.6.3 If long-term storage in stockhouse or job site is required, or storage in terms of closing
down, for long or storage of spare pumps, it shall comply with the instructions as following:
NOTE:- Wetted parts of the pump once being used shall be taken down, properly clean the parts
that contact with the pumping medium, lubricated them with rust preventer after dry.
4
-Parts(e.g. shaft, flange, coupling) and joints of small pipe shall be painted with the rust
preventer on the machined surfaces, it is suggest that common lubrication shall not be
used instead of rust preventer. The rust prventer can not remove the rust, so surfaces of
all parts shall be cleaned properly before being painted with rust preventer.
-The casing of pump, bearing frame should be injected with oil rust preventer, viscosity is
60-70mm2/s. For bigger pumps, the casing shall be painted with rust preventer liquid
every six months. For the bearing frame, is shall be injected with rust preventer liquid till
immersing the sight window.
NOTE:-If there are gland packing seal in the seal chamber, it should be taken out, replaced by
the protective gland packing seal which should be preserved in stuffing gland during the
storage. The protective filling should be taken out and replaced by operational filling
before start-up.
-If there is mechanical seal in seal case, complete mechanical seal should be preserved in
seal case, injecting the rust preventer liquid though the flushing hole, meanwhile, shaft
shall be rotated some times by hands.
-For the parts with the rust preventer liquid (e.g. casing, sealing chamber, bearing frame)
the condensate shall be veated every six months, refill with rust preventer when
necessary. In order to avoid rust of shaft, the rotor of pump should be rotated by hands,
so that the rust preventer could infilartate uniformly.
NOTE: The time of replacement of rust preventer is 12 months.
1.7 Unpackage Check and accept, management
1.7.1 The interrelated personnel should participate check of the equipment when open package
according to the packing list as following
-Verify the name, model, type, package number, amount, and the state of the package;
-Verify the technical documentation and special tools enclosed are enough or not;
-Appearance check for the main machine, auxiliary equipment, and parts, verify the variety,
specification, amount of the parts.
-Verify the consistency of the with the equipment, verify the consistency of the equipment
and the data delivered eventually.
-Submit the confirmed verification report with signature.
1.7.2 If the equipment and parts will not be installed as soon as the receving, proper safeguard
should be employed, storage should be well arranged, distorting, damaging, aging, hang-up,
and drop-out is forbidden.
1.7.3 Mating parts just like electrical parts or apparatus of the equipment shall be properly
inspected &stored by stored person.
5
ƺ 2. INSTALLATION
2.1.1 Preperation
-Factory acceptance certification of Qualification;
-Certification of qualification for the manufacture, assembly, important parts and
components assembly, and test reports for equipment;
-Outline drawing, sectional drawing, main components assembly drawing, parts breakdown
list, and the Installation and application manual;
-Packing list of the equipment;
-Specification/Standards of installation, requirement and scheme of installation.
2.1.2 Jobsite conditions for Installation
-The building projects finish ultimately, the base shall be ready for installation, substructure
work around the base fished ultimately, and the ground shall be flat;
-Installation of cargo-seal equipment around and lifting of large-scale pipeline upon had
been finished;
-Keep the roads for construction, transportation, fire control expedite, with necessary fire
fighting equipment;
-The lighting, water source, and power supply for construction shall be ready;
-The equipments for hoisting equipment, lifting, transporting shall be ready;
-There are spare reserve for equipment, parts, components assembly and tools.
-If the medium is poisonous, explosive, hot, or any other dangerous medium, its discharge
should be special treated, to avoid endangering the operators and environment.
2.2 Installation, Inspection and treatment of the baseplate
2.2.1 Installation of the base
-In order to absorb the vibration and support the base plate firmly, there will be enough
strength and dimension of the base;
-For the weak base, the base should be treated with the wood pile or concrete.
-For direct coupled-type motor, the weight of the base itself shall be as three times as the
mechanism at least; for coupled-type driver, the weight of the base shall be as five times as
or more than that of the mechanism;
-If the pump driven by motor directly coupled, or by gearbox, the integral baseplate shall be
adopted.
-For the pump unit driven by belt, slide and overturn fo baseplate caused by the pull of belt
must be prevented, when the bases of the pump and driven machine are installed separately;
NOTE: -In the frozen period in winter, the loading facility will be depressed as surface frozen.
Therefore, the burying depth of baseplate shall larger than the length of the soil.;
NOTE: -When the base is the second floor, the center of the base should be in accordance with
the center of the beam, or the base should cross over two beams, also approach the walls
of the building;
NOTE: -After pouring, the concrete can be solided with two weeks. Then pump can be installed;
-The 30̚70mm clearance between baseplate and base concrete shall be left to meet
the measurement of horizontal alignment. Meanwhile, the surface of concrete shall be
holding, concavo-concave.
2.2.2 Inspection
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-When the base is handed over, the certification of quality and measure records should be
submitted. The datum line and the longitudinal and transversal axis should be drawn on the
base obviously. The axis of coordinates should be marked on the building. Observing point
for sedimentation is necessary for significant equipment.
-Visual inspection to base, the flaws of crack, honeycomb, cavity, naked bar and so on are
forbidden.
-Counter checks the dimension and position of the base, according to the related civil
fundamental drawing, outline drawing and equipment technical documentations. The
allowable tolerance shall comply with the specification of Table 2.2-1.
Table2.2-1Allowable deviation for the demission and position of base
Allowable Allowable
Item Name of items Item Name of items
deviation deviation
Coordinate position of base f20
Anchor bolts buried previously
1 ˄longitudinal and horizontal aixes˅
0 ˇ20
2 Datum mark for different flats of base -20 6 Datum mark(top end) 0
f20 Center distance(measurement on

Out drawing for flats of base f2
top end and root)
3 0
Out drawing for flats of boss -2 Holes for anchor bolts preparatory˖
ˇ20
Dimension of recess 0 Center f10
ˇ20
7 Depth 0
Levelness for flats of base(including
Perpendicular for wall of hole(total
the equipment installed on the terrace)
depth) 10
4
5 Moving anchor bolts buried
Per meter
previously with 䫮ᵓ˖
ˇ20
Total legth 10 Datum 0
8
Vertical deviation˖ Center f5
5 Per meter 5 Levelness (䫮ᵓ with groove˅ 5
Total heigth 20 Levelness˄䫮ᵓ with tap hole˅ 2
2.2.3 Treatment
The treatment for the base before the installation as following:
-The low- density and loose concrete shall be shaved by shovel and pane hammer in the
grouting base surface between base and the equipment baseplate, if secondary grouting is
needed, the pitting surface shall be shaved, and the pitting depth can not be lower than
1mm, with denstity 3̚5 per dm3;
-Any tectorium or oil failure on surface of the base for second grouting is not allowed. All
the dust and grain on surface should be blown by compressed and oil-less air. If grouted by
cement paste , the surface should be pensontrated with water until saturation. If grouted
by epikote mortar, all the surfaces should be kept dry before construction;
-Shave the surfaces which the sizing blocks are installed (50mm at least around ), allowable
tolerance of the levelness is 2mm per meter;
-The sundries (e.g. macadam, soil) in bolt hole and accumulated water should be cleared
absolutely.
2.3 Requirements for earthling bolts
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2.3.1 Form and installation of the earthing bolts

-General ground bolts refer to Figure 2.3-1,
NOTE: Concrete these ground bolts after the alignment of the equipment, the concrete should
not be injected into base directly, the deviation resulted from that will lead to the failure
of installation.
-A socket with diameter as 2̚3 times as larger than earthing bolts can be prefitted.
Table2.3-1Moment of tightness and axial pulling force for anchor bolts
Diameter of Diameter of Axial pulling
Axial pulling
the bolts and Moment the bolts and Moment force
force
screws Kilogram*meter screws Kilogram*meter
mm
Kilogram
mm Kilogram
12 2.5~3 900 36 80~82 8500
16 6~7 1500 42 120~130 11500
20 13~14 2500 48 190~195 16000
24 23~24 3500 56 300~310 25000
27 34~35 4800 64 440~460 30000
30 45~70 5500
Figure2.3-1 Figure2.3-2
1.anchor bolt 2.nut 3.gasket 4.baseplate 5.exterior sheathing 1.anchor bolt 2.nut 3.gasket 4.baseplate
6.second grout layer 7.mated sizing block 5. exterior sheathing 6.second grout
8.flat gasket 9. base pitting surface 7. mated sizing block 8.flat gasket
10. grout layer for anchor bolts after initial alignment 9. base pitting surface 10.sleeve 11.base
11.base 12.anchor board
2.3.2 The earthing bolts placed in preformed hole should the below requirements:
-The greasy dirt and oxide shall be out of the bare part of earthing bolts. Thread parts shall
be printed with little grease, bare parts anchor plate shall be painted with rust preventer
paint;
NOTE: -The bolts should be installed vertically. The earthing bolts should not reach the bottom
of holes. The distance between any parts of the bolt and wall of hole must be more than
15mm;
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-Tighten nuts, the bolts are higher than the nuts with the height 1.5-3*pitch, the contacts
between nut and carrier ring, carrier ring and baseplate shall be in good condition;
-Nuts and steel anchor plate stocked by them should be fixed by dot welding;
-When the anchor plate is welded on the ground bolt directly, the height of welded seam
greater than half of diameter of the screw rod.
2.3.3 Tighten moment of ground bolts
Unless the strength of concrete in preformed hole is equal or greater than 75%of the design
strength, ground bolts can not be tightened, valves of the tighten moment refer to Table 2.3-1.
2.4 Installation of pump
2.4.1 Installation of the sizing block
-Install a groupsizing block at both sides of the ground bolts, as closely as possible. When
the space length of ground bolts is less than 300mm, just one side.
-The space length of two group sizing block is about 500mm in general, which is
determined by the weight of machine, structure of baseplate, and distribution of load and so
on.
-Surface of sizing block should be smooth surface without oxide, or fash; for slanting sizing
block units, the smooth finish of cant should be equal or greater than 12.5, and the pitch is
1/20—1/10. For the pumps with high gravity center or big sharp vibration, the preferred
pitch is 1/20.
NOTE: -T slanting sizing block shall be used mattingly. And it a group is consist of slanting and
flat sizing block, it can not beyond 4 floors, slin sizing block shall be located between
slanting and flat sizing block. Mated sizing block units is equal or greater than three
quarters of the whole length, the angles between the two shall be no more than 3 degree.
NOTE: -After the alignment of the equipment, to check the tightness of the sizing block units
should be hammered by hand hammer of 0.25 or 0.5 kilograms, the sizing block units
any loosing is not allowed. The tolerance between the sizing block and baseplate should
be checked by feeler of 0.25mm, for the same cross-section, the sum of length of the
feelers stuffing at both side shall be no more than one third of length /width of the sizing
block .
-Both sides of the sizing block units should be fixed with interlaminar dot welding
immediately, after acceptance of inspection. Sizing block units shall not be welded to the
baseplate.
2.4.2 Installation without sizing block
-Both of the deadweight of pump and the tightening force are loaded by second grout
blanket, this method of installation is called installation without sizing block. This method
is applicable for equipment with smooth bottom surface of the baseplate. For high speed or
heavy-duty items, slay shall be keep pudding during second grout blanket. For the general
perfusion is applicable.
-For installation without sizing block, the alignment of pump is carried out with minitype
jacking apparatus, or temporary sizing block, or jacking screw for installation on the pump.
Perusing with small expansion concrete. With small expansion and compacted whereat,
take out the jacking apparatus or temporary sizing block, when the strength of second grout
blanket reaches 75% of the design strength, then holes should be filled, or unscrewed
jacking screw, the horizontal alignment should be checked again.
9
-The advantages of the installation without sizing block are convenience for adjustment,
steady ,and there will not be any corrosion problem of sizing block. On the other hand, the
second grout is fussy working.
-The two forms of installation without sizing block refer to Figure2.4-2 and 2.4-3.
1jacking screw 2baseplate 3pad plate 1lifting jack (gasket) 2basepalte3mounted pattern
4second grout blanket 5base 4second grout blanket 5base
2.5 Alignment of pump

-The allowable deviation dimension between the horizontal, axial center lines of the pump and
basepalte is f5mm. Axial centerline of pump is the centerline of shaft; horizontal centerline
is generally means the centerline of outlet pipe. If the unit contains gearbox, center lines of
the gearbox, prime motor, and casing should be inspected separately, the allowable deviation
is f5mm.
-The allowable deviation of the marked height on the base is f10mm. The standard of
measurement is datum of height of datum mark in workshop factory or plate area. The sum
height of the sizing block should be controlled within 30-70mm.
NOTE: -Alignment shall be carried out as soon as in its place. The flange facing of the suction
and discharge or exposed shaft location should be selected as reference surface refers to
Figure2.5-1.In general, for casing, the horizontal deviation of cross direction is 1mm/m;
for pump, the axial deviation of is 0.05mm/m, looseness or tightening of the bolts are
forbidden, during the alignment. To adjust the
position of sizing block during the alignment is the
necessary method. The bolts should be tightened
after the alignment. the levelness should be
inspected again after the tightening, If the deviation
can not meet the requirement, the bolts shall be
loosened , then to align again.
-After alignment of pump, the coupling of shaft
and drive end should be aligned initially, to avoid
the case that the coupling cannot be aligned after
second grouting.
Figure2.5-1
1 flanges of pump 2 leveling gauge 3 shaft
10
2.6 Second grout for baseplate

-In general, second grout is necessary before the connection of pipelines, or after the final
alignment of the coupling.
-Common sand-cement grout or epikote grout is applicable for second grout. For the majority
installation of the pumps, the epikote grout is foremost selection with high bond strength and
better-machined surfaces without holes.
-If the environment for installation is corrosive, the preventer shall protect the base and
concrete structure.
-Second grout shall be carried out within 24 hours after the inspection is qualified, the final
alignment of the pump. Otherwise, the second grout shall be carried out with the repetition
and verification for the data of the alignment of equipment.
-The height of the second grout is 30̚70mm, installing the exterior sheathing refers to Figure
2.3-1 and Figure2.3-2, the distance between exterior sheathing and exterior edge of baseplage
shall be no less than 60mm, the height of the exterior sheathing shall be no more than 10mm.
-The second grout shall be continuous, and comply to the related technical documentation of
civil engineering. The is forbidden. If the temperature of the environment is lower than 5
degree, the insulation work or protection of frost shall be taken during the curing period for
second grout blanket.
2.7 Alignment of coupling
2.7.1 Alignment of coupling
NOTE: -The alignment of coupling should be proceeded after the base has been solidified
absolutely including the second grout blanket. Negligence during alignment might lead
destruction of coupling or even damage of coupling, pump and drive device.
NOTE: - Before aligning of the coupling check, in uncoupled case, direction of rotation of driver
and the pump shall be the same.
-Assembly and alignment have to be effected according to the coupling manufacturer’s
instructions. For details please see the Attachment A for installation drawing
instructions of generally couplings.
-Alignment of coupling is effected with dial gauges, refers to Figure2.7-1, seat of the dial
gauges should be fixed on one side of the coupling, the other end should be rotated to
fetch the run-out value, special optical instruments are also in point.
-If there is not spacer for coupling, the radial run-out value shall be fetched by dial gauges,
the run-out of the end face shall be measured by feeler inserted refers to 2.7-2.
11
NOTE: -Alignment is generally carried out by setting gaskets between the engine and the
baseplate, the most thickness of gasket shall be no more
than 13mm, the number shall be less than 5 pieces, all
the gaskets should be crossing the hold-down bolts or
vertical jacking screw, at least stretched 5mm beyond
the edge of the supporters.
2.7.2 Allowable alignment deviation for different
coupling
The reference value of allowable alignment deviation of
coupling (See Figure2.7-3, x, y) refer to Table 2.7-1̚2.7-3.
Table2.7-1Oldham coupling˄claw coupling˅ Figure2.7-3

External conjugate Radial displacement Axial declivity Space between coupling
diameter of coupling˄mm˅ y˄mm˅ z˄mm˅ S˄mm˅
İ300 ˘0.05 ˘0.4/1000 Ĭ2.0
˚300~600 ˘0.10 ˘0.6/1000 Ĭ2.0
Table2.7-2 Cog-wheel coupling

170~185 ˘0.05 ˘0.3/1000 Ĭ2.5
220~250 ˘0.08 ˘0.3/1000 Ĭ2.5
˚300~600 ˘0.10 ˘0.5/1000 Ĭ5.0
Table2.7-3 Elastic plug coupling

70~106 ˘0.04 ˘0.2/1000 Ĭ3.0
130~190 ˘0.05 ˘0.2/1000 Ĭ4.0
224~250 ˘0.05 ˘0.2/1000 Ĭ5.0
315~400 ˘0.08 ˘0.2/1000 Ĭ5.0
475~600 ˘0.10 ˘0.2/1000 Ĭ6.0
Table2.7-4 Diaphragm coupling

External conjugate diameter Radial displacement Axial declivity
of coupling˄mm˅ y˄mm˅ z˄mm˅
İ200 ˘0.05 ˘0.2/1000
200˘Dİ300 ˘0.08 ˘0.3/1000
300˘Dİ400 ˘0.10 ˘0.4/1000
400˘Dİ600 ˘0.10 ˘0.5/1000
2.7.3 NOTES for alignment of coupling

NOTE: -After the installation of the suction and discharge pipes, the coupling shall be aligned
again, to eliminate the affecting of concentricity by deforming of the pipes.
NOTE: -Coupling shall be inspected repeatedly when working for period of time, to eliminate
the affecting of concentricity by deforming of the pipes, especially important for the
pumps transfer medium with high or low temperature
2.8 Assemble the pipeline and auxiliary equipment
12
2.8.1 In-let and out-let pipeline

NOTE-The diameter of the suction and discharge pipeline are designed according to the flowing
speed of the medium, usually the medium speed in the suction pipeline is 2m/s, in the
discharge pipeline is 3m/s.
NOTE-The diameter of suction pipe is 1~2 class bigger than the discharge pipe’s as usual. It’s
especially important when the suction pipeline is long. Because
increasing the diameter of the pipe can decrease the friction loss
in the pipeline so as to enhancing the suction performance and
reducing the possibility of cavitations erosion.
-During the sucking time, the horizontal pipeline should
rise stably toward the pump, when back flowing; the horizontal
pipeline should descend stably toward the pump to prevent air.
Usually the pipe’s angle Į is about e)LJXUH
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pipe must be designed as off-center horizon
installation.(Figure 2.8-2) This layout can avoid the storage of
gas. The length of the conical pipe must be 5~7times to the
difference of the diameter.
-For ensuring the flowing area please pay attention to
the gasket of flanges connection whether alignment to
the central of the flange . Figure 2.8-2
- Suddenly decrease of the cross-sectional area and sudden angle pipe should be avoided or
the frication loss will increase a lot and impact the operation of the pump.
NOTE-When installing the suction pipeline should avoid air leak otherwise the operation of the
pump will be impacted, and even cause cavitations. So please pay more attention to this.
-When design the piping, please support the pipeline in proper way and the pipeline can’t be
strained hard. In order to avoid the hot deformation, install expansion joint on the out-let pipeline.
A proper support and pipe base should be installed between the expansion joint and the discharge
flange (because the foreign force on the expansion joint is much bigger than the scope which
pump can subject). The measures above mainly ensure the force on the pump flange which caused
by the pipe’s gravity and the hot force not exceed the allowed requires.
-Shut-off valve must be installed on the suction pipe, shut-off valve should be installed
horizon or lean down to avoid gas storage.(Figure 2.8-3) All of the suction valves must be open
unless inspection and switchover. Not good
Storage gas
Good Good
Figure 2.8-3
13
NOTE-The discharge pipeline should install shut-off valve and check valve. Check valve should
be installed between the pump and the shut-off valve. Prevent the pump operation from impacting
by the back flow when the pump break or the backflow from other pump .Control the pump with
shut-off valve when start up.
-When finally connect the pipe and equipment, the radial dispersion of the coupling should
be measured by dial indicator. If the equipment’s rotating speed is higher than 6000 r/min, the
radial dispersion should below 0.02mm, and if the speed equal or under 6000 r/min, the radial
dispersion should below 0.05mm, otherwise the pipeline should be adjusted.
-The companion flange should be parallel and concentricity in free state, the deviation
should be according to the list 2.8-1:
List 2.8-1
Rotation speed (r/min) Depth of parallelism of flange face radial

dispersion(mm)
İ0.3 All the bolts can
İ 1500 When the diameter of flangHζPP infix free
WKH depth of parallelism should İ
diameter of flangH
3000~6000 İ 0.15 İ0.50
η6000 İ 0.1 İ0.20
2.8.2 Vent pipeline

-Except self-vent pump all the pump should be installed vent pipe for starting up. Vent pipe
also should be designed on the pump piping to avoid air lock. The vent pipeline can vent directly
or vent to a close vent system according to the pumping medium.
-The casing of the horizontal pump should be installed vent pipeline, valves should be
installed on the vent pipeline. If the medium between the suction and discharge pipeline and
casing can’t be vent directly through the casing, the suction and discharge pipeline also should be
installed valves.
2.8.3 Warming-up pipeline

-When the pump transport the medium with high
temperature (is higher than 200 degree),the
warming-up pipeline is necessary. A small quantity of
fluid is lead out by discharge pipeline, transit the
backer pump, then inpour the suction of the pump.
This can keep the pump bank hot, and prevent the
convenient start-up from the freezing medium in the
backer pump and suction, discharge pipeline. The
pipeline layout refers to Figure 2.8-4.
Figure 2.8-4
-In the Figure2.8-4, pipe A is suction and discharge pipe to prevent congelation, which can be
used with pipelines for shutdown or clean-up, pipe B is primer line for warming-up pipeline,
14
if the caliber of the discharge pipeline is no more than 80, the pipe B shall be instead of
opening the outlet valve in a way, by-pass flow is about 3%̚5% of the normal flow.
2.8.4 Minimum flow piping
Notice- If flow of pump is lower than minimum continuous flow, the pump will vibrate and
medium steaming. Thereby destroy the regular operation of pump. Make sure of flow of
pump is more than minimum continuous flow to avoid that .take method as follows to
keep the flow;
- Installed automatic leakage check-valve, the valve open to keep the flow of pump is
higher than minimum continuous flow; the valve close when the flow increased to avoid
wasting.
- Installed by –pass flow tube between pump and outlet valve, and lead the by-pass flow
tube into suction pool ,a cut-off equipment to fix on the flow has been installed in the
tube , the by-pass tube will flow as the outlet valve opened in this style ,but it will
decrease the efficiency .
NOTE:- minimum flow equipment is out of manufacturer’s scope of supply, users shall disposal it
themselves, the tube must be lead into suction pool by pump. To make cut-off and
disassembly conveniently for repairment, install a cut-off valve is necessary. But before
start up, the cut-off valve must be shut. If some pumps were installed in parallel and use
common minimum flow tube, install a check-valve in feed pipe of each pump is
necessary.
2.8.5 Flush piping and cooling piping of seal
- Assembly of flush piping and cooling piping shall be according to assembly diagram or
corresponding piping system diagram .
- Cooling piping shall be connected with the inlet and outlet of cooling liquid correctly( inlet is
low ,outlet is high), governor valve which adjusting the flow of cooling fluid must be installed
in outlet tube .If the cooling piping can not self vent, exhaust value should be installed in peak
of cooling piping to avoid gas blocking.
- Pressureless drain piping shall be supplied, when the release of leakage, cooling fluid, and
medium is in closed –type system .
- Transport poisonous . flammability . high temperature or other danger medium, the venting or
leakage shall not be harm to operator and environment .
2.8.6 Lubricating oil system piping
- Dust, rust, enameled leather, iron chips is prohibited in any part or auxiliary equipment of
the lubricating oil system.
- The jointing of lubricating oil system piping prefers backing welding of argon tungsten-arc
welding or plumbing welding. Sanding the orifice of pipe before welding, there shall be no
impurity like weld beading. or welding slag after welding .
- Arrangement of piping shall be regular and easy fur maintaining. Spacing between pipe and
the wall shall be proper . The installation of piping shall be steadily . Degree of slope of the
horizontal return piping shall be greater than 5/1000 and lower than oil tank .
- carbon steel piping shall be proceed with pickling passivating treatment , then dry and oil
in time without pollution . If there is oil pollution in piping, caustic wash first.
- Take pressure test first before pickling passivating treatment by if required.
2.8.7 Temperature - measurement system
15
- If the operating point is close to boiling point, thermometer shall be offered to monitor the
temperature of liquid. The thermometer’s permissible depth of penetration is 40 millimeters,
structure of protective sleeve shall be offered when the pressure over 1.6MPa .
- To prevent boiling of the cooling liquid at the sealing face. Please regulating the draining
temperature of cooling water less than 4ć
- To the heavy duty pumps, regulating the temperature of bearing and lubricant is necessary.
Get the temperature with the contact thermometer if required, or automatic . Monitor of the
temperature with the thermometer . The position for assembly and measurement is given in
assembly diagram, and the range of controlled temperature is according to technical
documentation.
2.8.8 Pressure-measuring system
- Monitor the start up and operation of pump by manometer ,the manometer shall be installed
in pressure-measuring frame .
- Install section valve and exhaust valve shall be installed before the manometer to make the
repairs conveniently . Flushing tube of seal shall be monitored by manometer too .
2.8.9 Flow measuring unit
- Flow meter shall be installed in venting line, open the auxiliary piping after start up.
Capacity shall be controlled by the flow meter.
2.8.10 Vibration measuring equipment
- Measure the vibration by vibration measuring set to examine the operation of pump . To
high-rate pump , in order to guarantee the operation safely and steadily , considered that set
vibration sensor to monitor the bearing box and gear box casing, the installation of sensor is
assumed according to the attachment paper.
16
ƺ 3 OPERATION
3.1 Commissioning of the pump
3.1.1 The inspection before commissioning:
-Ground bolts should have been fixed. The second grouting should meet the designing
intension, face work should be finished.
-Cooling, heat-conducting, insulation, rinsing, filtering, dehumidify, lubricating, seal
washing systems and process lines are connected correctly, without leakage. Piping
must be clean and expedite.
-All gauges are sensitive and exact.
-Motor’s insulating resistance and rotation direction should comply with the design
specification (rotating direction should be subject to pump’s direction arrow),
disassemble the coupling to confirm the direction of the driver. Start the driver
commissioning first, if dried by motor, it should run more than two hours;
-Washing the gears with light oil(no gas oil)then drain the oil, lubricate the gear box
with the specified oil according to the technical document.(Refer to 4.4).
-Check the alignment of the two shafts according to the stipulate of2.7.
3.1.2 Preparation for starting up.
-Filling the pump.
NOTE -Before start-up, (including the fist starting up of self-priming pump) all pumps must
priming (the casing must be fully filled with the medium) except submerged pump.
The pump in the flooded condition:
Open the check-valve in the inlet pipeline and all the drainage piping, rotate the rotors slowly,
close the vent until there is no air bladder in pumping medium.
The pump in the suction condition:
Open the check-valve in the inlet pipeline and all the drainage piping, filling the pump (the
inlet pipeline should be installed bottom valve) rotate the rotors slowly, close the vent until there is
no air bladder in pumping medium.
Run all the auxiliary systems (lubricate system, seal flushing system, cooling system) more
than 10 minutes until working steadily, go on next step.
-Rotate the shaft by hand to check whether the equipment runs well; crawl the motor’s
switch to ensure the rotation direction is right.
-Install the coupling guard;
-If installing, open and fix up the valve on the minimum flow controlling piping.
-If the equalizing main return the inlet tank , please open the valve and lock it .
3.1.3 Start-up
NOTE-The max starting frequency can not be beyond 12 times/h.
-Start up the pressureless system
Close the outlet pipeline check-valve (make sure the existence of minimum flow)
Starting up the motor; make the rotor get the operating speed.
Open the discharge valve until the capacity reaches the given value;
-Start up the pressure system
Start up the motor and shut the outlet valve.
To sliding bearing : note the display valve is correct or not .
17
NOTE-The pump’s differential pressure is not allowed below the design point also must not
cause fluctuating of the system’s performance parameters. The value of the suction
pressure meter adds to the differential pressure is the value of the discharge pressure
meter.
NOTE-The numerical reading of the ampere meter can’t exceed the value on the name plate
when full load.
NOTE-The fitted Motor should be selected according to the actual specific gravity of pumping
liquid as required by customers. Before commissioning with water, it should be
considered if the motor could stand the water power. If the liquid’s actual specific
gravity is lower than water, when commissioning with water, please control the valve’s
opening well to avoid the overload of the motor and even damage. If necessary please
contact the pump manufacturer.
3.1.4 The especial attention to the high temperature pump’s commissioning.
NOTE-The casing should preheating before commissioning, the differential temperature
between the casing surface and the inlet piping should be less than 4ćWhen
preheating, the temperature should be rised homogeneously; the differential temperature
should be less than 50ć per hour.
NOTE-When preheating, rotate the rotor by hand half circle in every ten minutes.
If the temperature is higher than 150ć, do it in every 5 minutes.
NOTE-Shut off the in-let valve and the vent valve until preheating to the rated temperature.
NOTE-After shut-down, rotate the rotor by hand half circle in every20~30 minutes unless the
temperature below 50ć.
3.1.5The especial attention to the low temperature pump’s test running.
-Before precooling, open the bypass pipeline;
-Dehumidify the chamber and the piping according to the technical requirements.
NOTE -Precooling the casing to the operating temperature. The cooling speed should not be
exceed ćper hour; When precooling, all vent valves must be opened until
precooling to the rated temperature.
NOTE-If he pumps are made of fragile material emergency cooling should be avoided when
precooling, and the maximum difference in temperature allowed is 50ć.
3.1.6 Unallowable operation when start up.
NOTE-Must avoid the overload, because that’s may damage the mechanical parts. If the pump
is running over its performance scope, that will be overloaded. e.g.
-Exceed the maximum allowable rotational speed.
-Exceed the maximum allowable suction pressure.
-Exceed the maximum allowable temperature.
-Exceed or below the pump’s operation domain.
-Operate with the residual gas in casing.
-Operate without necessary safe guard(emergency valve, over power protection and so on)
-Operate when the discharge valve shutting of and without the minimum flow equipment.
-Operate when the in-let valve closed.
-Operate when the pump’s material is not suitable for the medium.
-Operate to the wrong rotation direction.
-Operate when the lubricate plan of the bearings or the lubricant material is unsuitable.
18
-All of the wrong ways of operation above and others will damage the pump and other
equipments seriously. The chips and hot, corrosive and toxic medium caused by the explosion
of the pressure-containing members will bring a serious influence to person and environment.
And it will be the fatal, when these dangers occurred.
3.2 The checking of the test running.
-The pump must singly run 4 hours under the rated load continuously. All the pumps which
allow water as the medium should use water as test liquid when commissioning.
- Temperature rise of sliding bearing and reciprocating components should be below35ć and
the highest temperature is not permitted over 65ć. The temperature rise of rolling bearing
should be below 40ćˈand the highest temperature is not permitted over 75ćˈthe
temperature of gland and mechanical seal should be according to the technical document .
-The pump’s vibration must comply with the technical document and other related
specification.
-The rise of the motor’s temperature can not exceed the specification of the name plate and
the technical documents. If no required, it should be defined as the difference of the
insulation rating.
-The pressure and the electric current should be according to the designing request. If the
relative density of pumping medium is lower than water, when commissioning with water,
the motor’s electric current should be controlled under the rated value;
-The rotors and other rotting parts should not have disorder noise and friction.
-The temperature of lubricant in all lubricating point , seal fluid and cooling water should be
below the specification of technical documents .
-The auxiliary equipments working well, connection firmly and without leakage.
-The allowing leakage of the pump’s packing seal is homogeneous 5~20 drop/min.
Mechanical seal allowing leakage should be comply with the technical documents. If the
pumping fluid is toxic, harmfulness, inflammable, explosive or precious, the seal’s leakage
have to lower than the design value.
-Detail record is needed when commissioning. If there are some disorders, treat in time.
3.3 Shut-down
- Open the minimum flow adjusting valve first;
-When shut down for short time and the check valve was installed on outlet pipe, the
discharge valve can be open. But for long time and without check valve, the discharge valve
must close.
- Stop the motor, NOTE the motor whether stop stably;
-If keep the high temperature pump in the operation temperature, open the warm valve,
otherwise closed.
-If the high temperature pump need cooling , after shutoff, rotate the rotor half circle by hand
in every 20~30minutes till the casing temperature fall to 5ć
-After the pump totally cooled, the auxiliary equipment can be closed such as cooling system,
seal rinse system and lubricate system;
-If it is necessary to disassemble the pump to check closes the in-let valve and open the vent
valve.
-When there is possibility to freeze or long time shut-off, the liquid in the casing and the
cooling chamber should be discharged. If necessary, please use some other protection (refer
19
to 1.6)
-The drainage toxic, harmfulness, inflammable, explosive or precious liquid is forbidden any
dangers to people and environment.
3.4 Production run
When the commissioning medium is different from the pumping medium, drainage all the
commissioning medium and then weather the chamber and the piping, if necessary disassemble
the pump to check.
After the pump ready to run again, production run and shut off the pump according to the
checking, start-up, shut-off requires which were referred to in 3.1 and 3.3.
3.5 Operation control
When the pump has been started up, adjust capacity and head to the duty point.
3.5.1 The operating point of the pump
Draw the pump performance curve H=f (Q) and the equipment performance curve Hz=f (Q)
on one paper to see 3.5-1, the crossing point of the two curves M is the operating point of the
pump. At the point the liquid’s enhanced energy (H) equal the energy consumption (Hz) when
liquid flows from suction to exit, so the point M is the pump’s steady operation point. If the
pump’s running point A deflect M, H<Hz, the flow rate of the pump increases, the running point A
flow to M. Per contra, if the pump is running at B, H<Hz, the flow rate reduces, the capacity
reduces, move from B to M. So the steady operating point is determined by device and the pump.
The pump’s performance curve has been defined when exit the factory, it’s a nonadjustable curve,
but the device’s curve is adjustable. The device’s curves are different when the coefficient of drag
is changing which is caused by the difference of the jaw opening of the exit flow valve .The
device’s performance curve sees figure 3.5-2 When the coefficient of drag is changing which
caused by the difference of the jaw opening of the exit flow valve
Figure 3.5-1 Figure 3.5-2
3.5.2 The adjustment of pump’s operating point

The adjustment of the pump’s operating point is the adjustment of the device’s performance
curve. Adjust the pump’s operating point by change the jaw opening of the pump’s exit valve. If
the device flow adjust valve’s jaw opening is 100%, but the capacity also can not reach the rated
value, changing the condition of the device to fall the device’s performance curve is necessary. If
the device flow adjust valve‘s jaw opening is not 100%, but the pressure of the exit fall rapidly,
the flow can not reach the rated value, check the pump.
In the course of adjusting the operating point should attention some points as follows:
20
----Measure the speed of the rotation

----read the pressure difference (the pressure of exit deducts the pressure of the suction)
After have the values, record the value of the head of delivery on the table of rated
standard performance, on a certainty speed.

Head of delivery(m)hDensity of liquid (Kg/P
Pressure (Mpa) = ________________________________________
102040
NOTE-The pressure difference can’t below the defined value, or the
capacity will serious exceed the allowed value and may cause
the stream current break, the motor overload. Read the flow
value with flow meter, if there is not a flow meter, converse the head of delivery with
pressure, find the head value on the performance curve, then find the crossing point of
level line and curve H, make a droop line from the point, so can read the flow value.
21
ƺ 4 Maintenance
4.1 Daily maintenance of equipment
NOTE- Check the pump whether running stably on time every day. The pump should operate
without any vibration. Pay attention to the noise, temperature, seal leakage and the
lubrication level when regular operation. If there is some disorder, shut off at once and
find the reason.
NOTE-Every day, periodic check and record the pump’s chief operation parameter such as
suction pressure, capacity, temperature, motor electric current, lubrication pressure,
lubrication temperature and so on. Periodic check the pump’s vibration. Suggest to
statistics these data and drawing a tendency chart for observing the pump’s operation.
The shut-off and check schedule can be made according to the tendency chart.
NOTE-Periodic checks the auxiliary equipment during the operating period.
Measuring apparatus: manometer, heat indicator, ampere meter, please closes the
meters after measuring;
Flow meter and temperature gauge on the cooling equipment;
Temperature gauge and manometer on heating equipment;
Temperature gauge and manometer on the flashing equipment/seal equipment;
NOTE-Periodic check the lubrication filter, avoid the pressure of the lubrication not enough
caused by filter blinding.
NOTE-Check the lubricant filter and avoid less pressure of lubricant caused by blocking of it .
NOTE- Start up the stand-by pumps frequently for emergency.
NOTE-If the pump performance decreased when the piping has no maintenance, it may be
caused by the interred corrosion of the pump, so that the pump must be inspected and
repaired.
-Correct the proper alignment of the coupling at least once a year. Adjust the deviation in
time, avoid breakage.
4.2 Periodic check and maintenance
4.2.1 Half-yearly checking
The checking work must be done in every 6 months as follows:
-To the pumps with shaft packing, check the free offset variable of the packing gland, clean
and lubricate the bolts on the gland. Check the filling for changing.
-Check and adjust the alignment of the pump and the motor if necessary.
-Check the bearing which lubricate by grease if contain enough grease and proper
consistency .
4.2.2 Annual checking
-The annual checking should be thoroughly. More work is needed besides the work of
half-yearly checking, as follows.
-Check the vibration tendency again, if the pump’s vibration tend incline disallowable
(according to the designing)
I First disassemble the bearing housing, wash and check the bearing housing whether there
is scar, abrasion and impurity.
II Wash the bearing housing carefully.
III Check the bearing whether has scar and abrasion.
22
IV After washing, smear the bearings which in good condition with oil and grease. NOTE: If
there is any scar, chose the new bearings according to the technical document.
V Assemble the rotor or main rotor parts, if the rotor is not assembled by magnitude parts,
check the balance before assemble.
-To the pump with shaft packing, disassemble the packing and check the abrasion of sleeve
and shaft.
-To the pump with mechanical seal, if there is the seal leakage record, disassemble them and
send them to the seal manufacturer to check.
-When disassemble the coupled flange for checking the alignment, check the vertical
movement of the axle which is equipped bush bearing at the exceed end of the packing seal
or mechanical seal. Find any motion which exceeds 150% of the design gap. Check the
allowed axial gap of the bearing, if exceed, find the reason and correct.
-If necessary, all the auxiliary pipeline should be checked and clean, such as drainage, seal,
cooling, and lubrication. As well as cooler to permit expedite.
-The pump with gland should be changed packing ,then realign and rejoin the motor and
pump.
NOTE-If possible calibrate all the meters, test the pump and make sure the pump
performance.
4.3 The maintenance of the shaft seal
4.3.1 Packing seal
Configuration and install method is
different for various medium and work
conditions .
- General configuration(Figure4.3-1)
Fill in the room of packing box with soft packing . Figure 4.3-1
The minimum of overflowing pressure on shaft seal
is 0.01~0.02Mpa . Transporting medium
should be lubricating and absolute
clean .
- Configuration with seal loop
Adopt this configuration when the pressure
of shaft seal is less than 0.02Mpa and the lubricating
ability of medium is bad . Seal loop is installed in Figure 4.3-2
center or head of packing box , supply seal fluid
with external pipeline , the least pressure of
seal fluid is exceed the pressure of shaft
seal about 0.1Mpa .
- Gland with cooled configuration
To avoid gasification when export high-heat
liquid , should be cool the gland . Figure 4.3-3
(e.g. the water temperature is over 100ć)
Because of pressure release on shaft seal ,adjusting by a controlling device, the amount of coolant
is about 0.05m3/h and the pressure is about 0.02Mpa . The temperature of the mixture with coolant
and leakage is less than 40ć .
23
- Operation of packing seal

Please wash shaft seal and packing gland before install filler , and check the surface of shaft bush ,
check the real accuracy of shaft bush according to list 4.2-1:
List 4.2-1
Pressure of shaft seal Jumpiness Surface roughness Ra
˘2.5Mpa 0.05mm 1.6
˚2.5̚5Mpa 0.03mm 0.8
˚5̚10.0Mpa 0.02mm 0.4
Push the packing ring into seal cavity in order with packing gland when install filler , the end of
filler should be staggered with 900 one by one and closed to each other . Lay some filler beyond
seal cage to the structure with seal cage , inlet and outlet of liquid seal shouldn’t be blocked as
shaft seal figure . Tighten the packing gland equably , shouldn’t upward bias . Check the distance
between all points of gland flange and packing box is uniform or not , release the packing gland
afterwards and tighten the hex nut .
-General monitor of filler
The lubricate , cooling and few leakage is necessary for regular operation . The leakage between
11L/h (about 1 drop per second)and 15L/h (about the trickle with 2mm diameter)is normal when
the leak temperature is less than 60ć .
To the pump which the pressure of shaft seal is less than 1.0MPa , tighten the packing gland and
should not skew or overstrain . Change all packing ring if the mount and temperature of leakage is
high after retighten .
To the pump which the pressure of shaft seal is over 1.0MPa , retighten the packing gland will
lead to broken the shaft seal , if the leakage is more , please shut down and repair the equipment .
The new packing box should have running-in period , check it frequency in this period , the
leakage will be reduce after a short running time . In order to reach the regular operating point ,
should be installed some auxiliary apparatus , like wash , cool and heat equipment .
-Normal packing materials
Select seal materials should be based on medium . It should be according to the list 4.2-2 .
List4.2-2
medium Packing seal materials
Cold waterǃhot water Saturated asbestos packing
hydrocarbonǃoilǃalkaliǃfood Saturated asbestos packingǃTeflon asbestos packing
Woven carbon fiber packingǃTeflon asbestos packingǃsoft graphite
All polluted liquid of industry
packing
4.3.2 Single end face mechanical seal
The medium is sealed by two parallel friction faces. The two ring seals are pressed together by
the elastic force of the spring and the pressure of the seal liquid. The seal of the ring seal (dynamic
ring and the static seal ring) is realized by the static seal part close to the pump part, as well the
static seal ring have the sustain action. There must be a fluid film between the two surfaces, so the
medium should be as follows:
Good lubricating performance
Vapor temperature is higher than working temperature.
There is no impurity in the seal.
For achieve the operating condition, some auxiliary equipment should be fitted such as
flashing, restriction, cooling, heating, and filter (if there is impurity in fluid) .
The maintenance of the mechanical seal mainly contains the controlling of the auxiliary
24
equipment, leakage and seal temperature controlling. When regularly circulate flashing, the
flushing fluid’s temperature should below the temperature of the contacted casing. When cooling
and heating, the pressure, capacity and temperature are according to the technical data sheet.
The normal of the maximum invisible leakage is 10cm3/h. When the leakage is too muchı
50cm3/h), the leakage of ring seal and the stationary seal part should be realized. If the ring seal
can not grind again, change a new one. Change the stationary seal part (O-ring) when assembly for
each time.
If necessary a no-spark bushing sleeve can be used to ensure a diametric gapİ0.7mm), it is
assembled after the ring seal . When the mechanical seal inactivates, the bushing sleeve can
control the leakage in the minimum domain.
Use a out sourcing liquid source to provide quench water to the bushing sleeve. This can
avoid the solid substance gathering at the air side of the seal; also can divider the heat source.
4.3.2 “Back-to-back” style of double end face mechanical seal
Shaft seal is consist of two mechanical seals (one internal, the other external), which are
assembled back-to-back. Barrier liquid must be allowed between them, the pressure should higher
than the pumping medium (miQı0.1~0.3 Map, mi[İ0.7~1.0Map). The characters as follows:
The seal performance of the ring seal’s contacting surface is better because of increasing
the contacting pressure;
It’s good to lubricate the ring seal;
Prevent the leakage of the medium.
The barrier seal liquid must have the characters as follows:
Neutrality;
Good lubricating performance;
Vapor temperature is higher than working temperature;
No impurity.
The work of the auxiliary system for mechanical seal operation:
Imbibe the leakage of the medium;
Form the overpressure;
Circulate the barrier liquid;
Reduce the temperature of the barrier liquid.
The maintenance of the double mechanical end face seal contains filling the lubrication on
time, control the temperature of the seal and the auxiliary system. Ensure the temperature
difference of the inlet and outlet pipe.
If the seal liquid loss too much, it may be caused by the leakage of the ring seal and stationary
part. In this case if grinding is impossible, change a new one. Change the stationary seal part
(O-ring) when assembly for each time.
4.3.3 “Tandem” double end face mechanical seal
Shaft seal is consist of two mechanical seals (one internal, the other external), they are
assembled tandem. The front seal is flushed by pumping medium, barrier liquid must be allowed
between them, and the pressures can higher or lower than the medium. The characters as follows:
Good reliability, application to the dangerous medium;
The seal can set leakage alarm;
It’s good to lubricate the ring seal;
The medium and the buffer solution must meet the condition as follows:
25
Good lubricating performance;

Vapor temperature is higher than working temperature;
No impurity.
The work of the auxiliary system, for mechanical seal operation:
Imbibe the leakage of the medium;
Form the overpressure;
Circulate the barrier liquid;
Reduce the temperature of the barrier liquid.
For achieve the operating condition, some auxiliary equipment should be fitted such as
flushing, restriction, cooling, heating, and filter(if there is impurity in fluid).
The maintenance of the mechanical seal mainly contains the controlling of the auxiliary
equipment, leakage and seal temperature controlling. When regularly circulate flushing, the
flushing fluid’s temperature should below the temperature of the contacted casing.
The normal of maximum invisible leakage is 10cm3/h is normal. When the leakage is too
muchı50cm3/h), the leakage of ring seal and the stationary seal part should be realized. If the
ring seal can not grind again, change a new one. Change the stationary seal part (O-ring)when
assembly for each time.
4.4 The maintenance of the lubricating system
Centrifugal pump often afford stress which create by continuous operation and serious external
force (axial force , radial force) . In order to make the pump work faultless and the life of
bearing is long , proper lubricating condition is necessary . Normal lubricating styles include thin
oil path lubricating , grease lubricating , oil mist lubricating and thin oil forced lubrication .
4.4.1 Thin oil path lubricating (splashing , oil ring)
To assure the enough lubricating film of thin oil path lubricating , the minimal viscosity of
lubricant is 12mm3/s , and the lubricant should be clean without any impurity . the option of
lubricant is according to table4.4-1
Table 4.4.1
Temperature GB Kinematic viscosity mm2/s Minimal ignition
Oil storage tank Bearing case Viscosity degree 40ć 50ć point
ć
˚40̚65 ˚50̚75 N46 45 25 185
˚65̚70 ˚75̚80 N68 65 36 185
Release and clean , renew all lubricant after 10-15 hours when first operation or repair of thin oil
path lubricating . If the lubricant was polluted by impurity or water , period of change is according
to the table 4.4-2 ;
Table 4.2-2
Temperature
Periodic time
Lubrication Bearing housing
>40~70 >50~75 12 months
>70~80 >75~90 6 months
Check the temperature of oil storage tank and bearing case , the highest temperature is list in table
4.2-3 .
26
Figure 4.2-3
Measuring point Near the bearing Exterior Surface Temperature
scope outside the bearing of the bearing of the lubrication
housing
Normal constant operation İ8ć İ9ć İ8ć
Start the alarm ı90ć ı100ć ı85ć
Shut off the machine İ100ć İ110ć ı90ć
Rake the oil cup backward when inject oil into bearing case pass the oil filler hole till the branch
pipe of oil cup is injected oil , then inject the same oil into oil cup , close the full oil cup . Repeat
previous process till 2/3 the oil cup ‘s capacity . Check the oil cup frequency and refill it in time .
If the decrease of bearing box oil level lead to outlet pipe of oil cup emerged liquid surface , the
oil will flow from the cup till the oil level is recovery and immerse the cant of outlet pipe into oil
The process of change lubrication after shut down the pump :

- put a pallet under the outlet opening to catch lubrication ;
- take the plug screw , discharge the lubrication thoroughly and tighten the plug screw then .
- as previous methods , inject new lubrication into bearing case ;
- treat the used lubrication as legal regulation , and never discharge random ;
4.4.2 grease lubricating
If adopt grease lubricating , recommended the brand, working conditions and
performance of grease is in table 4.4-4 .
Table 4.4-4
Temperature Conical
Name and brand of Dropping
of bearings degree Character and purpose
lubrication temperature
ć 1/10mm
suitable for mini rolling bearing , good water resistance,
˚50̚60 Albany grease 3rd 90 220~250
but low-melting
Lithium base suitable for majority working conditions with given water
˚60̚80 175 265~295
grease resistance and mechanical stability
suitable for high speed and heavy-loaded conditions , the DN
˚80~150 7019 260 280 value of bearing can reach 0.5 million , it is belong to
high-side grease .
Check , supply and change the grease in period , the suggestion is supply it per 2000 hours
and change thoroughly per 1 hour or 2 , the amount of grease per 2 hours as figure 4.4-1
27
Figure 4.4-1
Clean the bearing and bearing room thoroughly when change the grease , check the wear extent ,
if it is serious , please change bearing , the 2/3 capacity of bearing room should be filled witn
grease when assembly bearing . Inject little lubricant into the surplus space to protect and stop the
dust.
28
29
ƺ5 repairs
5.1 dismantling and assembly

The order. detect items and notices of dismantling and assembly are assumed according to the
repair instructions.
5.2 The notices of clean out and assembly
5.2.1 General regulations
- Please measure and take record simultaneity the position and fit clearance of the relative parts
before dismantling. No assembly is allowed without clean and inspection. Assembly shall
according to the tech documentation.
- In the jobsite, the assembly should be carried out according to the tech documentation after clean
up. Please check and clean exactly, to make sure of that there was no any impurity inside,
drying and inspection before close down the pump or any components.
- Please blow the parts with low pressure vapour and clean up all the liquid in time, then lay on
lubricant to avoid rust. To blow the rigid apparatus and rolling bearings with vapour is not
allowed.
- Clean up the rust on the machined surface if there is any rust-eaten.
- All joint surfaces of the combined baseplate shall be flat and glabrous without any warp rust burr
and so on. Please check all joint parts by 0.05mm feeler leaf after combination, to make sure
that the feeler leaf can not be slipped. The oriented key of stress surface shall be inserted into
base refinedly. The fit clearance of the oriented key and keyway of the machine shall be
satisfied of the pump technical documentation.
- All components conduits and adjuncts should be degreasing in none-oil condition.
- The prevent occlude oil shall be laid on when assembly the precious threaded parts or
interconnecting piece matching parts that will working ender the temperature higher than 20
ć.
5.2.2 Assembly of the rolling bearing
- The bearing should be clean flexibility rolling that without any damage, rust or noise when
rolling. Please inspect the assorted dimensions of bearing before assembly.
- The force shall be acted on the end surface of bearing equality . Used the professional equipment
when assemble and disassemble.
- For the cross assort bearing, please heating up with machine oil to assemble and disassembly, but
the oil temperature shall not be higher than 120 centigrade .
- The bearings that endure axial and radial force shall be closed to the shaft shoulder or bearing
snap ring. The axial clearance between the bear cover and bearing outer seat is generally less
than 0.01mm,when two rolling bearings are used but not approach to each other, enlarge the
axial clearance is permitted;
- To the rolling bearing that the clearance can’t be adjusted which are installed in expanding end of
shaft, please remained enough clearance as per the shaft swell increment at work condition.
Please calculate the value of clearance with follow formula :
30
S=L+0.15
L=¢Lt
In formula: S- The clearance of bear cover and bearing outer seat, (mm)
L- shaft swell increment at work conditionˈcomparing to the bearing
flame (mm)
¢- linear expansibility of shaft ˈ(for steelĬ12X1-6)˄1/ć˅
L- dimension between two bearings ˈ˄mm˅
t- temperature difference between shaft and shell˄bearing flame˅
˄generally considered as 10ć~15ć˅,(ć)
0.15- remain axial clearance after shell of shaft , (mm)
- Adjust the end of bearing outer seat and bear cover according to technical documentation when
installed single row separable bearing and conical rolling bearing . if not specially
specified ,please remain enough clearance based on axial windage of bearing standard;
5.2.3 Assembly of the shaft seal components
- Before the assembly of the gland packing seal, it shall meet with regulations as follows:
The surface of asbestos jointing in aluminous box ought to be smeared by machine oil that
mixed with squamous graphite powder;
The packing ring shall be 45ecut and pressed in by lapping, cuts of adjacent rings staggered
about 900 ;
The packing shall be pressed in equality, not too tighten. Depth of press is height of a piece of
packing ring, but it shall be less than 5mm.
Install V, U,Y type of seal ring ,press too tighten is inadmissible, the flute shall face the high
pressure side. The effects of temperature shall be considered to the seal ring with large linear
expansibility.
-Installation of the mechanical seal shall meet with regulations as follows:
Parts of mechanical seal shall not be with any damage or distortion. The sealing face shall not
be with any not have disadvantage as crack or scratch ;
The parts must be clean without dust or impurity especially for the sealing face of rotor ring
and stationary seal ring ;
Rotor ring can be rolling flexibly on the shaft after assembly;
Decrement of mechanical seal must be meet with the technical files ;
Rotor shall be flexibly rolling by hand after assembly;
Flush of mechanical seal and sealing system must be clean without impurity ;
The clearance and contacting status of parts of labyrinth. Gland packing seal parts and other
sealing element shall be comply with equipment technical documentation or as per specified in
‘Rotoring Specification’;
31
ƺ6 Failure analysis
6.1 General failure analysis
The failure of industrial pump generally including ablation, abrasion, mechanical failure,
performance fault and shaft seal failure. These faults are usually affect one another .e.g. the
abrasion of impeller may lead mechanical failure and performance fault, the broken of the shaft
seal may lead mechanical failure and performance fault too .
6.1.1 Ablation and abrasion
The main reason of ablation is unsuitable material, so we should consider the medium and
material of the equipment when ablation arises.
Abrasion moistly occurred during exporting the serum, main reason is the medium contains
solid grain. For the pump exporting serum. The overflowing components shall be in wearable
materials, shaft seal shall be flushed with clean liquid to clean out to avoid impurity, adopt clean
equipment to solve the runner block. Change the damageable parts in time when they are already
partly abrasion.
6.1.2 Mechanical failure
Libration and noise are main mechanical failure. broke or capitation of bearing or assembly
fault are main reasons of libration ,e.g pump and motor are not coaxial. Rigidity of foundation is
not enough or the foundation sinking, pipe confusion etc.
6.1.3 Performance fault
Mainly including capacity/ Head is not enough, pump capitation and motor overloading .
6.1.4 Shaft seal failure
The main shaft seal failure is leakage .leakage of gland packing seal is mainly caused by
unsuitable stuff , axle shaft sleeve, bush abrasion. Leakage of mechanical seal is mainly caused by
the broken of the sealing surface or epochal and drape of assistant seal ring .
6.2 Main failures and settlement of all types chemical pumps
Main failures and settlement of different chemical pumps is given in table 6.2-1~6.2-4
6.2.1 General failure and possibly reason are tabled as blow:
Table 6.2-1 Table about the problems of pump
Symptoms Possible cause

1.No liquid exporting: 1,2,3,5,10,12,13,14,16,21,22,25,30,32,38,40
2.Transport ability is not enough 2,3,4,5,6,7a,10,11,12,13,14,15,16,17,18,21,22,
23,24,25,31,32,40,41,44,63,64
3.Pressure is not enough 4,6,7,7a,10,11,12,13,14,15,16,18,21,22,23,24,
25,34,39,40,41,63,64
4.Losing perforate after start up 2,4,6,7,7a,8,9,10,11
32
5.The pump need more power 20,22,23,24,26,32,33,34,35,39,40,41,44,45,

61,69,70,71
6.Libration and noise arise at rated 2,16,37,43,44,45,46,47,48,49,50,51,52,53,
capacity 54,55,56,57,58,59,60,61,67,78,79,80,81,82,83,8
4,85
7.Libration and yawp arise at low 2,3,17,19,27,28,29,35,38,77
capacity
8.Libration and yawp arise at high 2,3,10,11,12,13,14,15,16,17,18,33,34,41
capacity
9.The axial swing of the shaft 17,18,19,27,29,35,38
10.Vanes of impeller were corroded at 3,12,13,14,15,17,41
eyeball side
11.Vanes of impeller were corroded 12,17,19,29
arrowed the sightless side
12.Vanes of impeller were corroded 37
arrowed the outlet near center
13.Vanes of impeller were corroded in 27,29
outlet near cover plate or round angle of
cover plate and vane
14.Vane cover plate bend or break 27,29
15.Pump is over temperature or jam 1,3,12,28,29,38,42,43,45,50,51,52,53,54,
55,57,58,59,60,61,62,77,78,82
16.The inside parts were corroded too 66
fast
17.Inner clearance is abraded too fast 3,28,29,45,50,51,52,53,54,55,57,59,61,62,66,67
18.Cut-in wortle of axial split shell 63,64,65
19. Cut-in wortle of interval junction 53,63,64,65
inside
20.Leakage of gland packing seal is too 8,9,45,55,57,68,69,70,71,72,73,74
much or the life is too short
21.Packing seal: packing gland was 8,9
fishtail
22.The leakage of mechanical seal is 45,54,55,57,58,62,75,76
too much
23.Mechnical seal: brake the end 45,54,55,57,58,62,75,76
surface. Shaft sleeve. Bellow tube
24.Life of bearing is too short 3,29,41,42,45,50,51,54,55,58,77,78,79,
80,81,82,83,84,85
25.Failure of the Shaft coupling 45,50,51,54,67
Problems of inlet
1. Pump is not filled with;
2. Not enough liquid is filled in the suction pipe;
3. Effective NPSH is not enough;
33
4. Liquid including excessive air or gas;

5. Air bubble in suction piping;
6. Air presences into suction piping
7. Air presences into pump through gland packing or mechanical seal;
7a. Air in the flush pipe of seal presences into pump
8. Seal tube is block;
9. The assembly of the seal box is not correct;
10. The entrance of suction piping immerse into liquid incompletely;
11. Form whirl at suction;
12. Running the pump with the suction value totally or partly shut off;
13. The filter of inlet is blocked;
14. Inlet piping is blocked;
15. To much friction loss of inlet piping;
16. Impeller blocked;
17. Inlet elbow is paralleled with shaft;(for double-suction pump);
18. Two elbow of inlet piping which separation angle was 90 form ramous and rewire;
19. Select the pump with too high specified speed;
Other problems of hydraulics
20. Rotational speed is too high;
21. Rotational speed is too low;
22. Incorrect rotation direction;
23. Double suction impeller is fixed inversely;
24. Did not calibrated apparatus;
25. Diameter of impeller is smaller than specified;
26. Diameter of impeller is bigger than specified;
27. Select the impeller with too big differential head factor;
28. Start up when outlet valve and by-pass tube were shut at the same time;
29. Start up with capacity lower than flow recommended;
30. Hydrostatic head is higher than shut-off head;
31. Friction loss of outlet is higher than calculation value;
32. Total head value of system is higher than design value;
33. Total head value of system is lower than design value;
34. Operation at too high flow;(to the pump of low ratio of revolutions)
35. Operation at too little flow;(to the pump of low ratio of revolutions)
36. Jam of check-valve lead to leak;
37. The clearance of impeller vanes and counter vanes or dummy plate of scroll-case are too
small;
38. The pump has been installed in parallel was not suit for purpose;
39. Fluid density is not fit for work condition of design;
40. Liquid viscosity is not agree with work condition of design;
41. Abrasion of working clearance inside is seriously;
42. Piping of balance is blocked;
43. The source of inspire transient;(the pressure of liquid surface and vapor of inlet flange are
not balanced)
34
Mechanical problems ( general)

44. There is impurity in impeller;
45. Did not centering;
46. Rigidity of foundation is not enough;
47. Screw bolts of foundation are rap;
48. Screw bolts of pump or motor are rap;
49. Base is incompletely grouted;
50. Oversize piping of pump creates force and flexural torque ;
51. Incorrect installation of expansion joint;
52. Start up without heat pump suitable ;
53. Some matching surfaces inner(surface of wearing ring. Impeller. Shaft sleeve. bearing frame
and so on ) are not vertical to center line of shaft;
54. shaft is bend ;
55. Rotor unbalanced;
56. Components of shaft are loose;
57. Decentration caused by abrasion of bearing;
58. Operation arrowed the limit speed;
59. Span length of shaft is too large or shaft diameter is too small;
60. Sympathetic vibration arise at the natural frequency of operational speed and foundation
soleplate or piping ;
61. Rotary components rub in static components ;
62. Hard granule in the operation clearance;
63. Materials of casing gasket are unsuitable ;
64. Installation of gasket is unmeet ;
65. Fixture of shell screw bolts insufficient ;
66. Materials of pump is not suit to the liquid ;
67. Some shaft coupling lack of lubricate of the coupling;
Mechanical problems (seal)
68. Parts of shaft or shaft sleeve in filler was abrasion or packing;
69. The type of filler is not suit to work condition;
70. Installation of filler is wrong;
71. Because of gland is too tighten, result in prevent the fluid lubricating the filler;
72. The filler was pressed into pump because of the gap of root of gland box is too big;
73. Seal liquid mixed with sand grain and impurity;
74. Coolant of cooling gland box is unsuitable;
75. Selection of mechanical seal is not satisfied with work condition;
76. Installation of mechanical seal is unsuitable;
Mechanical problems (bearing)
77. Excessive radial thrust in single scroll-case pump;
78. Excessive axial thrust caused by excessive abrasion of internal clearance or broken and
excessive abrasion of balance equipment;
79. The grade of grease lubricant or lube oil is not correct;
80. Excessive grease lubricant or lube oil in rolling bearing frame;
81. Lack of lubricant;
35
82. The installation of bearing improper; e.g. damage when installed. Incorrect assembly of
combination bearing, unmatched mated bearing;
83. Impurity enter in to bearing ;
84. The lubricant was polluted by moisture ;
85. Excessively cooling of the water-cooled bearing;
6.2.2 Phenomenon analysis of gland box’ failures in centrifugal pump is given in the table
below:
Table 6.2-2 Phenomenon analysis of gland box’ failures
Symptoms Possible cause

One or two packing rings are abraded ,other The assembly of packing is improper
is well
External diameter of packing ring was Packing ring rotated with shaft sleeve or
abraded leak between the packing ring and internal
diameter of gland box. dimension of
packing ring is not correct
Inside race of packing ring was burn and Too heated packing is unsuitable or the
polished osmosis is not enough to lubricate the filler
Enlarge the external diameter of packing Eccentricity of rotation
ring excessively or serious abrasion
occurred in inside race
6.2.3 Vibrating symptoms and reasons of centrifugal pump is given in the table
6.2-3 below:
Table 6.2-3 Vibrating symptoms and reasons of centrifugal pump
Frequency of vibration Cause

Severalfold rotational speed Inferior rolling bearing
Duplation of rotational speed Components of rotor are loose , coupling is
not centering , influence of twin-volute
when the gap is not enough
Rotational speed Rotor is unbalanced . impeller is
blocked .coupling is not centring
Rotational speed multiply by number of Failures of vanes channel – the gap of vanes
vanes of impeller and vanes of collector is poor
Half of rotational speed Vortex motion of oil in the bearing
Low-frequency random Internal recycling or capitation erosion of
impeller
High frequency random Phenomenon of resonance
Sub synchronous frequency at 70%to 90% Force of liquid provokes resonance
of rotational speed vibration
36
37

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Dalian Deep Blue Pump Co.

f20 Center distance(measurement on

2.3.1 Form and installation of the earthing bolts

2.5 Alignment of pump

2.6 Second grout for baseplate

Table2.7-1Oldham coupling˄claw coupling˅ Figure2.7-3

Table2.7-2 Cog-wheel coupling

Table2.7-3 Elastic plug coupling

Table2.7-4 Diaphragm coupling

2.7.3 NOTES for alignment of coupling

2.8.1 In-let and out-let pipeline

Rotation speed (r/min) Depth of parallelism of flange face radial

η6000 İ 0.1 İ0.20

2.8.2 Vent pipeline

2.8.3 Warming-up pipeline

Figure 3.5-1 Figure 3.5-2

3.5.2 The adjustment of pump’s operating point

----Measure the speed of the rotation

- Operation of packing seal

Good lubricating performance;

The process of change lubrication after shut down the pump :

5.1 dismantling and assembly

5.2.1 General regulations

5.2.2 Assembly of the rolling bearing

5.2.3 Assembly of the shaft seal components

6.1.2 Mechanical failure

6.1.3 Performance fault

6.1.4 Shaft seal failure

6.2.1 General failure and possibly reason are tabled as blow:

Table 6.2-1 Table about the problems of pump

Symptoms Possible cause

5.The pump need more power 20,22,23,24,26,32,33,34,35,39,40,41,44,45,

4. Liquid including excessive air or gas;

Mechanical problems ( general)

Symptoms Possible cause

Table 6.2-3 Vibrating symptoms and reasons of centrifugal pump

Frequency of vibration Cause

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