BHIKKI 1180MW CCPP Project Serve Only

OPERATING MANUAL
Original instructions

MD

Service: Boiler Feedwater Pumps

Customer/Contractor:
Cu. No.:
Cu. Order No.:
End User:
Plant:
Site:
Sulzer Equipment No.:
Sulzer Order No.:
Pump type: MD

BA/e 4470 GL

Sulzer Pumpen (Deutschland) GmbH Ernst-Blickle-Straße 29

D 76646 Bruchsal
Tel. (07251) 76-0, Fax 76329
 Contents
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
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
3.2 Preservation and storage
4. DESCRIPTION
4.1 Description of the pump
4.2 Bearing and lubrication
4.3 Absorption of the axial thrust - balance drum
5. INSTALLATION OF THE PUMP
5.1 Mounting
5.2 Alignment of coupling
5.3 Suction and discharge pipework
5.4 Ancillary equipment
Minimum flow device
6. OPERATION
6.1 General
6.2 Commissioning
6.3 Pump start-up and operation
6.4 Inadmissible operating modes
6.5 Shut down
6.6 Restart procedure
6.7 Service control
6.8 Operating faults
7. MAINTENANCE AND OVERHAUL
7.1 Maintenance - Pump general
7.2 - Shaft seal
7.3 - Bearing lubrication
7.4 Overhaul - Dismantling of the pump
7.5 - Inspection of wearing parts
7.6 - Assembly of the pump
7.7 - Tools / Screw tightening torques
ENCLOSURES
Table of enclosures to operating manual

4000/e0-1-00-000
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

1
2015-02-12 Add fasteners & auxiliary piping info Amanda Gu

0 20 - - First issue %DX

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
1.4 Service Data – Service Control
Sulzer Order-No.:
Item-No.:

1.4.1 Main Data

Operating Conditions rated max. min.
3
Discharge Capacity m /h normal:
Suction pressure bar G
Discharge pressure bar G
Differential pressure bar
Differential head m
NPSH – available @ Rated Flow m
Liquid Data min. normal max.
Liquid (medium delivered) Feedwater
o
Pumping temperature C
Vapour pressure bar A
3
Density kg/m
Viscosity cP
Performance
Speed rpm Min. Speed: 1400
Rated Power kW
Efficiency @ Rated Capacity %
3
Min. Cont Flow Thermal m /h
3
Min. Cont Flow Stable m /h
Max. Head @ Rated Impeller m
NPSH – required @ Rated Flow m

1.4.2 Lubrication
Oil class (DIN 51 515) ISO VG 46 see also 7.3
Oil Reservoir Quantity Liters
°
Oil Electric Heating ON / OFF C < 25 / > 40 (if necessary)
°
Oil Cooler - Oil Temp. IN / OUT C 70 / 50
°
Bearing Temperature ALARM / TRIP C > 80 / > 90
Oil Circulation Quantity l/min TBA
Oil Pressure (normal ) bar G >2
- Driver ON / OFF bar G > 1.5 / < 0.5
- Emergency pump ON / OFF bar G > 1.5 / < 0.5
Oil Filter – Diff.-Press. ALARM bar G > 0.4

1.4.3 Cooling
3
Total Cooling water requirement m /h tba
Pressure normal / max. bar 2/7
°
Temperature inlet/outlet max. C 33 / 41.2
Parts to be cooled Heat exchanger / Oil Cooler
3
Cooling water requirement m /h tba
Parts to be cooled Heat exchanger / Mechanical seal
3
Cooling water requirement m /h tba

1.4.4 Heating not required

0000/e1-4-02-000
1.4 Service Data – Service Control
1.4.5 Flushing (shaft seal) API Plan 23
Recirculation from seal with pumping device through cooler and back to seal.
Flushing / Sealing medium medium delivered
3
Quantity min. m /h by pumping device
Pressure bar internal
°
Temperature of flushing medium C 20 … 70

1.4.6 Flushing (wear ring) not required

1.4.7 Quench not required

1.4.8 Safety technical limit data

Design pressure (pump casing)
°
Suction side bar @ C
°
Intermediate take off bar @ C
°
Discharge side bar @ C
°
Design Temperature C
Max. Allowable Working Pressure
°
Suction side bar @ C
°
Intermediate take off bar @ C
°
Discharge side bar @ C

0000/e1-4-02-000
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
- Non-observance of the safety regulations which might cause an endangering of people are marked

with the general sign for danger

Warnings of electrical voltage are marked

specifically by

Safety regulations the non-observation of which may cause danger for the machine and its operatability are
marked by

ATTENTION

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

Thepersonnelforservice,maintenance,inspectionandassemblyhastoholdthenecessary qualificationsforthis
kindofjobs.Rangeofresponsibility,competenceandthemonitoringofthe personnelhavetobefixedclearlybythe
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
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).

- Thespecialsafetyinstructionsinthefollowingparagraphsofthisoperatingmanualhavetobe
observed.

2.6 Safety instructions for maintenance, inspection and assembly jobs

- Theuserhastoensure that all maintenance, inspection and assembly jobs will be carried out by
authorized andskilledpersonnelonly, who have been adequately informed by studying the operating
manual carefully.

- Basically any works on the machine may be carried out onlyduringshut-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.

- For reasons of security, long hair must be tied back or otherwise secured, garments must be close-
fitting and no jewellery – such as rings – may be worn. Injury may result from being caught up in the
machinery or from rings catching on moving parts.

- Pumps or aggregates delivering mediahazardous to health have tobedecontaminated.

- Immediately following the endoftheworks,allsafetyandprotectivedeviceshavetobereassembled

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

- Alterationsorrebuildingmeasuresonthemachineareonlyadmittedinagreementwithmanufacturer.
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.

2.8 Inadmissible operating modes

- The operationalsafety of the delivered machine isonlyguaranteedbyproperuseacc.tothedata under

item1.4oftheoperatingmanual.

- The limitsgiveninthedatasheetmustnotbeexceeded in any case.

0000/e2-0-00-000 Page 2
3. TRANSPORT AND STORAGE
3.1 Transport / Lifting
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.
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.
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 crate
the ropes has to be suitable to take up the weight of the goods to be
lifted. 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.
Fastening of the sling ropes on crates Sketch 3.1-1
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 If required use traverse

Sketch 3.1-3 Fastening spots for the pump aggregate

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
3.2 Preservation and storage
Preservation for despatch
Standard
When the pumps are shipped, smooth outside faces are sprayed with Tectyl 506 and pump internals with
Mobilarma 524. Attention: this is not suitable as long-term preservation; 6 months are max. allowed time for
storing.
Seaworthy packing
If the pump is despatched with PE-foil welding with moisture absorber (sea-worthy packing) the pump can be
stored up to one year without any special maintenance if the packing is not damaged.
Special packings
On special request the pump can be packed in aluminium foil. In this case the preservation time amounts to 2
years.
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.
Intermediate storage
Centrifugal pumps which are not installed and commissioned immediately after delivery can be stored for the
period determined by the dispatch preservation.
To avoid the forming of condensate and consequently corrosion (especially in the gap areas),
ATTENTION
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:
In case of unfavourable ambient impacts such as moist atmosphere, greatly varying
ATTENTION
temperatures (day/night), acidy or alcaline ambience, danger of contamination (dirt etc.) the
connection flanges of the pumps have to be plugged airtight.
Longterm storage - preservation
In case a longterm storage is to be previsaged in the store of the client or on site or pumps affected by a
longer shutdown of the plant or standby pumps are to be preserved, the following instructions have to be
observed:

ATTENTION If pumps have been in service before, pump parts having been in contact with the pumped
liquid must be cleaned and after drying be moistened with a preservative. For this purpose
the disassembly of the hydraulic part of the pump becomes necessary in most cases.
I. Protection of unencumbered, bright parts of the pump
e.g. - pump shaft
- raised faces of flanges
- 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.

We recommend rust preventatives

- Rust Ban 397 from ESSO
- Tectyl 506 from VALVOLINE
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.

M000/e3-0-00-000 Page 2
II. Protection of the interior of the pump
e.g. - pump casings
- stuffing box chambers
- bearing frames etc.
For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm2/s
should be used.
We recommend the rust preventatives
For gaskets in Perbunan (NBR), Viton (FPM), Teflon (PTFE):
- Mobilarma 524 from MOBIL
- MZ 110 from ESSO
- Ensis motor oil 30 from SHELL
For gaskets in ethylene-propylene (EPDM):
- Klüber Syntheso D 220

III. Proceeding in case of longterm preservation

1. Shaft seal
1.a Centrifugal pumps with soft packings
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.
For packing material, we recommend:
- synth. fibres, with PTFE impregnation (e.g. Chetra 1711 GS or Hecker 1820)
The packing chamber is filled completely with the separate packing rings (stagger joints at 90 degree
intervals).
Note: Before commissioning, make sure that the preservation packing is removed and replaced by packing
rings of the quality provided for operation.
1.b Centrifugal pumps with mechanical seals
The complete mechanical seals remain within the stuffing box chamber. Pour rust preventative through the
circulation and quench connections (see II.) and turn pump shaft manually several times while filling in the
preventative.
2. 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 pump casing with rust preventative
(see II.). W hile 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.
3. Bearing frame
Also fill with rust preventative (see II) until lower edge of the shaft.

IV. Maintenance of the stored centrifugal pumps

At the parts which are filled with rust preventative (pump casing/stuffing box housing/bearing frame) the
condensate should be drained every 6 months; rust preventative should be added, if required. To avoid
corrosion damage at bearings, the pump rotor should manually be turned simultaneously, so that the
preservation oil will be distributed over the running surfaces of the bearings.
ATTENTION According to manufacturers indications, the rust preventative has to be discharged and the
spaces have to be refilled every 12 months*. 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.

M000/e3-0-00-000 Page 3
4. DESCRIPTION
4.1 Description of the pump

Sketch 4.1-1 Typical view

Pumps of the MD 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 confined O-rings or metal-to-metal seals 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 stuffing box 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.

4.2 Bearing and lubrication

Bearing housings: The bearing housings flanged on both pump sides are equipped with forced feed oil
lubricated sleeve journal bearings. A double acting pivot shoe thrust bearing takes up the axial rotor forces at
the non-drive side bearing housing. The bearings require a continuous supply of lubricating oil, which is
provided from an auxiliary lube oil system.
Lube Oil System: The lube oil system contains a reservoir (oil tank), oil pump (main and auxiliary), pressure
relief and non-return valves, oil cooler, oil filter, feed piping to bearing housings and return lines. Various
monitoring and control devices are usually used. These devices are pressure and temperature indicators,
pressure and temperature-actuated switches, oil flow and oil level indicators, alarms and emergency shut
down devices. The oil pump draws the oil from the reservoir and delivers it under pressure to the bearing
housing where it lubricates the bearing. The oil leaves the housing through the drain and recirculates to the
reservoir. Oil flow rates are typically controlled by an orifice installed in the bearing housing connection. For
further information refer to the lube oil system manual.

4470/e4-1-01-000 page 1
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
605.01 balance chamber 'b' (suction pressure + frictional
resistance in the balance pipe) creates an axial
b a force 'F' on the balance drum. This axial force is
F opposite in direction to the pump axial thrust. The
603.01 A magnitude of 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
axial thrust chamber. A perfect balance is only achieved if
there is no build up of pressure in the balance
Sketch 4.3-1 Balance disc working principle 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 pipe
ATTENTION
are not strictly observed.

To prevent a pressure build-up in the balance chamber there must be a drain for admitted
ATTENTION
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:
suction tank
suction casing.
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.

ATTENTION A valve should be fitted in this pipe for maintenance purposes. Steps must be taken to
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 therfore to be built into this tube. Adjust opening
pressure at 5 bar over inlet pressure.

4470/e4-1-01-000 page 2
5. INSTALLATION OF THE PUMP
5.1 Mounting (see dimension drawing / installation plan)
General
Good planning and preparation result in fast, simple and correct installation. Safe running conditions with
maximum accessibility are assured. W hen 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 plastic plugs 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. W ith large units, suitable door and
wall openings are to be provided for transport to the installation site.

Grout selection
Select a nonshrinking grout that is compatible with the highest and lowest temperatures to which it may be
2
exposed. Use concrete from a concrete company with a final strength of 25 N/mm (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 baseplates should contain 300 to 350 kg cement
3 3 3
per 1 m of concrete. The sand and gravel proportion for 1 m of finished concrete (1.2 m mixture) is
as follows:

For grouting of the foundation bolts: 65% Fine sand grain size 1 - 5 mm
35% Coarse sand grain size 5 - 10 mm
water as required
The use of so called „fast cement“ with short setting time is possible.

For grouting (filling) of the baseplate: 40% Fine sand grain size 1 - 5 mm
60% Coarse sand grain size 5 - 15 mm
100 - 140 liters of water
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.

0000/e5-1-00-000-API page 1
Installation of pump and driver
ATTENTION With separate baseplates for pump and driver first erect the pump, then align the driver.
- Roughen and clean the foundation. W alls 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.
- Attach wire rope slings to the baseplate transport eyes (see 3.1 transport/lifting) and lift the baseplate
with pump and driver. 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.

Levelling
- 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).
Check levelling in the direction of the pump axis and also at right angles along the
ATTENTION
horizontal flange with a spirit (machinist’s) level. The flanges must be vertical on
horizontal branches. See sketch 5.1.1. Max. permissible variance 0.5 mm over 1m.
- 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 thicknesses. 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

5.1-1 Levelling the unit 5.1-2 Grouting foundation bolts

Grout in the foundation bolts

- Before grouting wet the foundation holes. Fill foundation holes with concrete.
- After setting tighten the foundation bolts (see table 5.1-1) 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).

0000/e5-1-00-000-API page 2
Completion of grouting (when properly aligned)
ATTENTION Grouting of the machine into the foundation is a very important part of the installation.
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 grout hole
baseplate
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
o
temperature of the foundation should not fall below 10 C. The
o o
optimum temperature for the setting process is 20 C +/-10 C.
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 5.1-1) and check coupling
alignment, see 5.2 (alignment report).

Tightening torques for foundation bolts (Table 5.1-1)

Thread size (nominal diameter) M 12 M 16 M 20 M 24 M 30

Tightening torque before grouting of 15 30 70 140 280

baseplate
in Nm
FINAL after grouting of 20 50 100 180 350
baseplate

0000/e5-1-00-000-API page 3
5.2 ALIGNMENT OF COUPLING
General
ATTENTION Before 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.
Flexible couplings need very careful alignment of the shafts which can be achieved by placing
ATTENTION
thin shims under the machine feet. Negligence in alignment will destroy the coupling and
damage the pump and motor bearings, too.

Misalignment types
There are three basic types of misalignments between the pump and driver shafts:

Sketch 5.2-1 Sketch 5.2-2 Sketch 5.2-3

Angular misalignment Parallel offset Axial distance
Shafts with axes that Shaft with axes parallel Shaft with axes parallel
intersect at a point but offset but wrong distance

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 7.6.

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, then the gap have to be compensated by shimming.
If the base plate has not grouted jet, the “soft feet” may also be compensated by re-adjustment of the
baseplate.
ATTENTION 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 .

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

Nom.-Diameter M A in Nm
Non- drive end Drive end Non- drive end Drive end
M 16 40 60
M 20 80 120
M 24 140 220
M 27 220 350
M 30 320 480
M 33 450 680 Tightening torque Tightening torque
M 36 600 900 acc. to table acc. to table
M 42 1000 1500
M 48 1600 2400
M 56 2600 3900
M 64 3900 5900 Sketch 5.2-4 Pump foot tightening torques

4470/e5-2-00-000 page 1
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.
Shaft
Pump thermal growth
MD Pumps are designed with casing feet at axe level,
ATTENTION therefore the thermal growth can be negligible. See
Thermal growth X
Sketch 5.2-5.
negligible
Driver thermal growth
The thermal growth of the driver equipment must be obtained from Skizze 5.2-5 Pump thermal growth
manufacturer instructions.
ATTENTION Thermal growth varies with load and ambient conditions. W ith drive equipment by gear or
steam turbine an additional lateral and/or axial thermal growth have to be considered.
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
ATTENTION
distance between shafts is adjusted. Refer to driver manufacturer instructions.
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.
ATTENTION Each alignment check / control has to be done only with pump in cold condition and under
consider of the thermal growth of pump and driver. Hot alignment procedure after stop from
hot service are not allowed.
Coupling alignment procedure
Every alignment check must be preceded by a run-out
measurement at the coupling flanges. Record the results
always in a log. All readings for radial and axial
misalignment are determined in the gauge positions: top,
o
bottom, right and left, i.e. every 90 , while both shafts are
simultaneously turned.
Alignment should be carried out with clock gauges in
radial and axial direction (see sketch 5.2-6).
The maximum admissible axial misalignment is 0.05 mm Sketch 5.2-6
on diameter, although = 0.03 mm is preferrable. Typical spacer coupling alignment procedure
The maximum admissible radial misalignment is 0.1 mm
on diameter, although = 0.05 mm is preferrable.
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 5.2-7 Optical Alignment
Coupling safety guard
The pump only have to operate 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.

4470/e5-2-00-000 page 2
5.3 SUCTION AND DISCHARGE PIPEWORK
General
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.
ATTENTION In case the possibility of dangerous recirculation may occur after shut-down of pump,
especially with "emergency trip out", back-flow preventors (check valve) have to built in.
Assembly
ATTENTION The pipework must be supported in an adequate manner to ensure that no inadmissible
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.
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

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.
ATTENTION Adjustments must be made to the piping, if these limits are exceeded or serious damage to
the pump may result.

4000/e5-3-00-000 page 1
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 branches
ATTENTION
have a smaller nominal bore than the fittings suitable taper pieces should be installed.
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 duty and standby
pumps which may have common suction pipework since only one pump operates at any time.
Cleaning the Pipework
Before a pumpset is commissioned, all traces of foreign bodies and impurities must be
ATTENTION
carefully flushed out of the supply tank and pipework. Where pipework has been welded, all
welding slag etc. must be removed.
Suction strainer
In order to prevent any of the above impurities entering the pump, it may be
necessary 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 diameter.
Monitor the pressure drop across the strainer by a differential pressure ø0,2mm 0,315 mm
gauge. If at any time, a reduction in pump suction pressure is observed, the
strainer should be removed and cleaned. Sketch 5.3-5 W ire cloth
ATTENTION The differential pressure �0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5 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.
The given values are limits for the load on the strainer. As NPSHavailable at the suction branch
ATTENTION
is reduced by the max. admissible differential pressure at the strainer whereas NPSHavailable
has always to exeed NPSHrequired , lower regulation limits for ALARM / SHUT OFF may have to be set
accordingly.
Pressure test
ATTENTION The pipework should be pressure tested in accordance with the statutory regulations.

4000/e5-3-00-000 page 2
5.4 ANCILLARY EQUIPMENT
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. All the auxiliary flushing piping and C&I cable tray can’t be treaded and climbed to
prevent the destroyed and accident.
The following instructions may be used as a guide insofar as they apply to the pump as delivered.

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.
- 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.

Pressure measuring equipment

- The start-up and monitoring of the operating point of the pump is made easier with pressure gauges.
See also 6.1 and 6.3. 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.

Bearing monitoring (impact impulse measurement, only possible with antifriction bearings)
- Advancing bearing damage can be recognised and monitored by means of impact impulse
measurement. This requires a special measuring unit which is connected near the bearing through
screw fittings (e.g. SKF connecting nipple No. 1649013 and SKF measuring unit MEPA 21 A).

0000/e5-4-00-000 Page 1
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
o
temperature smaller than 40 C avoids deposits in the cooling water pipings.
- At pumps with high loaded bearings numeros 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.

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.

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.

0000/e5-4-00-000 Page 2
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.
-----------------------------------------------------------------------------------------------------------------------------------------------------

Minimum flow device

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. 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 leakoff non-return valve.

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. W ith 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.

Separate pipes must be laid for minimum flow pipe and balance pipe if both are required to be led back to
the suction tank.

Never operate below pump minimum flow (see 1.4.1). Operation at minimum flow should
ATTENTION
be maintained for no longer than 2 hours in any 24 hours of operation.

M000/e5-4-01-000
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. All fasteners should be checked and tightened to prevent leakage
according to operation conditions before pump hydro testing or start running.
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 pump bearing housings with light oil and allow to drain. Fill pressure lubrication system, see
also 1.4.2 / 7.3 / lubricant table T3 and lubrication system manual. Flush lubricating oil pipes. Check and
if required re-adjust switch points of the system. Confirm that all checks are complete on the pressure
lubrication system.
c. 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).
d. Alignment Check alignment of coupling (see 5.2)
e. Filling the pump

ATTENTION In case of hot product: To prevent thermal shock the pump should slowly and controlled
filled up with small fill up rate.
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 • If existing (see installation plan): Open
vent (not valid for self-venting casing) vent (not 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 • Fill pump (suction pipe must have foot
pumped medium flows without bubbles valve)
• Fully open shut-off valve in inlet line • As far as existing: Close vent when
• Mount coupling guard pumped medium flows without bubbles
• Mount coupling guard
Before starting the pump, the suction piping, pump case and shaft seal chamber must be
ATTENTION
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).
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)
M000/e6-1-00-000 Page 1
6.3 Pump start-up and Operation
a. Start auxiliary equipment
Cooling (pump, heat exchanger-mechanical seal, oil cooler)
Check flow: In case of open system at the drain pan; in case of a closed system at flow indicators.
X
During operation control temperature between inlet and outlet. Open valves until ∆t is about 10 °C.
Heating (pump)
In case of a low ambient temperatures open valves for heat transfer until temperature for start-up is
obtained. Also after shut-down to avoid freezing.
Flushing/sealing (shaft seal)
In case of external flushing/sealing do not start pump before flushing /sealing pressure
X
specified in data sheet (see 1.4.5) is obtained. Check temperature. Note: In case of sealing system
see also manufacture’s instruction for start-up.
Oil system (oil reservoir, oil pump, filter, oil cooler)
X Check oil level of reservoir. Visual inspection at sight glass. At automatic level control a signal is
given in case of a too low oil level by the level control switch and the driver is automatically locked.
X Heat oil before start-up to about 40 - 45 °C. When this temperature is obtained, signal or
automatic stop of the heating. Also signal in case of too low temperature.
X Control filter. If filters are soiled, too low oil pressure can result after a long period of operation.
reverse filter and clean. Differential pressure see 1.4.2
X Check cooling water temperature, oil temperature and flow at oil cooler, see 1.4.2 and 1.4.3

b. Check inlet pressure of pump, start booster pump, if fitted

c. Start-up with non-pressurized system Start-up with pressurised system

• Close shut-off valve in the discharge (precondition is non-return valve in discharge
pipe. Minimum flow must be guaranteed pipe)
by minimum flow device, by constant • Start driver with open discharge valve
bypass or by 10% opening the discharge
valve (see also 5.4 Minimum flow
device).
d. Start-up
Pump starts automatically after switching-on the oil system.
Switch on oil pump. If the oil pressure necessary for the start-up of the driver cannot be obtained at
the interlocking device, turn the relief pressure valve a little higher. (Only permitted in case of first
start-up, after a longer period of operation the soiled filter can cause non-performance of cutting-in-
oil-pressure).
X Pump starts after switching-on the electrically driven auxiliary oil pump.
In case of main oil pump mechanically driven by pump, it is necessary to start a auxiliary oil pump to
obtain the cutting-in-oil pressure for starting the pump unit. If the oil pressure necessary for the
start-up of the driver cannot be obtained at the interlocking device, turn the pressure relief valve a
little higher. (Only permitted in case of first start-up, after a long period of operation the soiled filter
can cause non-performance of cutting-in-oil pressure). The auxiliary oil pump is automatically
switched off as soon as the main oil pump produces the oil pressure required. See also 1.4.2.
Oil supply by turbine or turbo gear type coupling.
The pump bearings are connected to the oil circulation of the turbine (or turbo coupling). Before
start-up of the unit a minimum oil pressure of 1.5 - 2.0 bar has to be ensured at the pump bearings
(if necessary by locking). An oil temperature within given limits and a sufficient oil quantity have to
be guaranteed. See 1.4.2 and operating instruction for start-up turbine (or turbo coupling).

4400/e6-0-00-000 page 2
 In case of turbine drive or variable speed coupling, bring the pump rotor rapidly to minimum
ATTENTION
operating speed.
As soon as operating speed is reached, there should be pressure at discharge. Shut down
ATTENTION
immediately if this does not happen. Vent pump and suction pipe.

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.
Electric motor drive: Observe ammeter reading. The full load amps given on the rating plate of the
motor must not be exceeded.
e. 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.

6.4 Inadmissible operating modes

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, 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 materials of the pump are not
suitable (chemical, solids ...)
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)

a. If a non-return valve is fitted in the discharge pipe (and intermediate bleed off 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.
X Start the electrically driven auxiliary oil pump.
b. Stop the driver, when doing this pay attention to whether the rotor runs down smoothly.

4400/e6-0-00-000 page 3
c. Shut-down oil supply system 15 minutes after having switched-off driver.
Standby service
Ancillary systems as cooling- , sealing- and quench systems are operational. Maintain the pressure
lubrication system for immediate pump start-up. If possible the pressure lubrication system should be
started once every month and run for 30 minutes (without starting pump). This will inhibit condensation
from accumulating within the lubrication lines and bearing housings.
Extended shut down
d. 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.
e. If existing, close quench piping.
f. 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
g. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including
external heat exchangers and pipings.

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 shaft.
b. Proceed restart as given in section 6.3 Start-up and operation.

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 100 start / stops (max. 4 starts / day)
- Commercial operation: up to 2 starts / day
Cumulated number of starts max. 400 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.

4400/e6-0-00-000 page 4
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 )
3
generated head (m) x density of liquid (kg/m )
generated pressure (bar) =
10 200

ATTENTION The generated pressure must not fall below the value given in the pump data sheet, otherwise
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)

4400/e6-0-00-000 page 5
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 (7.5)
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
(7.4 to 7.6)
Unbalanced rotor – causes vibration Check balance of coupling, driver
and pump rotating parts
Shaft bent Disassemble and check shaft runout
(7.4 to 7.6)

4400/e6-0-00-000 page 6
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 (7.4 to 7.6)
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. Wrong lube oil quality Verify that recommended lubricant is
used (7.3, T 3). Change lube oil.
Wrong lube oil pressure or quantity Check and correct (1.4)
Wrong lube oil temperature Check and correct (1.4)
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
(7.4 to 7.6)
Excessive pump thrust Check hydraulic balance device,
balance pipe. Disassemble and
inspect pump internal clearances (7.4
to 7.6)
Shaft bent Disassemble pump and check shaft
runout (7.5)
7 Lube oil leakage Oil return lines blocked Check and correct.
Oil quantity too high Check and correct (1.4)
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 (7.4, 7.6)
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.

4400/e6-0-00-000 page 7
7. MAINTENANCE AND OVERHAUL
7.1 Maintenance 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 sealings, auxillary 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
For further information about these inspections see chapter 7.1 to 7.3
If any vibrations, unusual noises or faults are observed stop the pumpunit at once.
ATTENTION
Ascertain the cause and rectify (refer to 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
7.4 to 7.7 for details on overhauling the pump.

ATTENTION The pressure in the balance chamber should always remain constant. If the balance
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 or shaft vibration during running.

0000/e7-1-1-000 page 1
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%
ATTENTION
Flow 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. The report sheets for supervision, inspection, maintenance and alignment included
in this manual shall be copied and used.

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 disc and counter disc
• 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)

0000/e7-1-2-000 page 1
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

Overhaul
Monthly
Weekly

During
Yearly
Measuring devices

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 / 6.3 X @

discharge)

• Balance chamber 4.2 / 7.1 @

Temperature • Medium delivered 1.4.1 X

• Pump bearing / oil sump 7.3 @

Further checks and inspections

Oil level • Oil sight glass / Constant level oiler 7.3 X

Leakage • Shaft seal / Mechanical seal cover 7.2 @

• Flange sealings (main connections) - X

• Lubricating oil from bearing housing - X
Vibration • Vibration measurement 7.1 @

• Bearing vibration 7.1 @

Maintenance works

Oil change • Bearing housings 1.4.2 / 7.3 @

Coupling • Check alignment 5.2 @

General • Bearings, balance discs, shaft seal, 7.4 / 7.5 / @

overhaul / wear impellers, wear rings ... 7.6 / 7.7
check

@ These parameters should be recorded in an operating log and used as a basis for maintenance
works.
@ 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/e7-1-3-000 page 1
 Title:
Report SUPERVISION CHECK LIST

Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................

Start-up normal abnormal Remark:...........................................................

Run 口
口 ........................................................................ Noise 口
口 ........................................................................ Vibration 口
口 ........................................................................
........................................................................
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 ...
 Title:
Report INSPECTION CHECK LIST

Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................

1. Leakage normal abnormal Remark:....................................................

Pump suction 口
口 ................................................................. Pump discharge 口
口 .................................................................. Shaft seal 口
口 ..................................................................

2. Gauges Remark:....................................................
Pump suction .............. bar .................................................................
Pump discharge .............. bar .................................................................
Balance chamber .............. bar .................................................................

3. Bearings normal abnormal

o
Temperature 口 口 .................................. C D-side / ND-
side
Oil level 口 口 .................................. O.K. Yes /
No
Oil refilled 口 口 .................................. Refill QTY.
liters
Oil leakage 口 口 .................................. Yes /
No

4. Vibration / Noise normal abnormal Remark:....................................................

Bearing hous.D-side 口
口 ..................................................................
ND-side 口
口 .................................................................. Pump casing 口
口 .................................................................. Noise 口
Remark: 口 .................................................................
R 0000 / 7-0-00-002
.................................................................
Date: Sign: Page ... of ...

Comments:.................................................................................................................... .........................
...............................................................................................................................................................
................................................................................................................................................................
 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:
口 Lubricating oil change Lubricant type : .........................................
口 Leakage checked Quantity: ...................................................

Comments: .....................................................................................................................
.....................................................................................................................
.....................................................................................................................
......................................................................................................................

Mechanical part:
口 Coupling alignment checked (reported)
口 Bearings opened and checked
口 Mechanical seal checked
口 Balance disc and counter disc opened and checked
口 General overhaul with pump hydraulic part opened and checked
口 Rotor newly adjusted (axial / radial center position)

Parts changed:
口 Mechanical seal - Drive side / Non-drive side
口 Balance disc / counter disc
口 Bearings - drive side / non-drive side
口 Shaft
口 Pump impeller wear rings
口 others: ..........................................

Comments:.................................................................................................................................................
...................................................................................................................................................................
...................................................................................................................................................................

Remark:
R 0000 / 7-0-00-003
Date: Sign: Page 1 of 1
 Title:
Test Certificate COUPLING ALIGNMENT

Plant / Location:.......................................................................................................................................
Aggregate Specification:.........................................................................................................................
Pump type:.............................................................. Driver:..............................................................
Serial-No.:............................................................... Type / No.:.......................................................

Alignment before pipework connection: 口 Remark:..............................................

Alignment after pipework connection: 口 ...........................................................
Alignment before commissioning: 口 ...........................................................
Alignment after commissioning (hot or maintenance): 口 ...........................................................

1. Axial distance check

Coupling gap (mm)
Specified gap:
Pump Driver Pump Driver Tolerance:
Spacer coupl. Non-spacer coupl.
Actual gap:
Coupling type:.................................................... Spacer: ...............mm Yes 口 No 口

2. Check of radial misalignment (see also 2.1)

Radial misalignment (mm)
Measuring p. Left Right Top Bottom
Measured:
Pump Driver
Prescribed: 0 ... 0.1 (0.05 preferable)

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 口 No 口 Rework: Accepted:
Driver foot checked: Yes 口 No 口 Yes 口 No 口 Yes 口 No

口 Anchor bolt checked: Yes 口 No 口 TC 0000 / 5-2-00-000

Date: Sign: Page 1 of 1
7.2 Maintenance - Shaft seal
Single-acting mechanical seal with throttling bush
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.

A non-sparking throttling bush with a small diameter clearance, installed in the mechanical seal cover, limits
the leakage in the case of a mechanical seal failure to a minimum. At the same time the outlet of normal
leakage along the shaft is avoided and a limited feed of quench agents becomes possible.
The quench outlet has always to be opened during operation. The quench inlet may be
ATTENTION
closed, if there is no quench feed.

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
- quench
- 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 Einfach Gleitringdichtung mit Drosselbuchse

7.3 MAINTENANCE - BEARING / LUBRICATION
Plain bearing with forced-feed oil lubrication

General
ATTENTION Bearings of 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 troublefree operation. The oil must not contain any foreign substances, acids or resins.
Oil viscosity
2
In order to ensure the formation of a sufficient lubrication film an oil viscosity of at least 12 mm /s at operating
temperature of the bearing is required. Therefore you have to use a
Turbine oil according to DIN 51 515 TD-L ISO VG 46
2
In the case of this oil the Kin-viscosity at 40 C in 46 mm /s. (See also “Recommended Lubricants” T3).
Change intervals (Regenerating)
If pollution by foreign substances and water is low change intervals can be as follows:

Temperature C Change interval * measured in the

at the bearing in the oil flow* oil recirculating line,
(between bearing
50 - 70 40 - 60 every 12 month and oil tank)
70 - 80 60 - 70 every 6 month

At bigger oil quantities in plants with pressure oil circulation it could be economical, instead of the renew the
oil, to take out monthly after the above mentioned terms of change a few oil to examinate it for:
- share of condensate
- capability of air separation
- number of neutralization
- aging
If this examination has for result, that the limit values acc DIN 51 515 are exceeded (even it comes up only for
one point), let clean and regenerate the oil immediately by the sales service of the supplier. Until the next
term of change the oil filling can then be used maintenance-free. If this oil maintenance is executed carefully,
we know from experiences that the term until the complete oil of change can be extended to an operating
time of max. 5-8 years.
Max. allowable temperatures
Measuring spot
Mode at the bearing in the oil flow* * measured in the oil
o o
recirculating line,
Continuous operation < 70 C < 60 C between bearing
Alarm at > 80 C
o o
> 70 C and reservoir (oil
tank)
o o
Shut down aggregate > 90 C > 80 C

Check temperature at the measuring spots regularly. The oil temperature should not exceed the maximum
allowable shown in the table.
Low ambient temperatures
o o
At low ambient temperatures (below +10 C) the lubrication oil have to be heated up to +40 C before starting
the pump.
Oil level (lube oil system)
Check the oil level in the reservoir (oil tank) regularly at the measuring point (oil dipstick or sight glass). Refer
to lubrication oil system manual.
ATTENTION A sudden oil level drop can indicate a leak. Stop operation and inspect unit.

M000/e7-3-02-000 page 1
Oil pipe cleaning procedure
In case of first commissioning or of an overhaul, the oil pipes have to be cleaned thoroughly.
It is important that all lube oil feed lines, especially the lines from oil filter to the beari ngs are
ATTENTION
absolutely clean and free of any foreign substances or dirt. Therefore carry out the cleaning
procedure with care. Negligence leads to a premature wear of the bearings.
Preliminary work
- Isolate the driver to prevent start-up
With electrical driver: Remove residual current (take away safety fuses). Have electrical connections
disconnected by an electrician.
- Remove the lube oil feed lines from oil filter to the bearing housing and clean it by flushing with light oil
and blow it out with clean compressed air
- Mount oil lines on oil filter again but not on the bearing housings
- Rinse bearing housings with light oil and let it drain, close connections
Pipe flushing
- Join oil feed lines by flexible tube with the oil return lines
- Fill of oil reservoir (oil tank) with lube oil (see 1.4.2, 6.1 and description of the lube oil system)
- Start auxiliary (booster) oil pump and flush the lube oil lines for at least 3 hours
- Check double oil filter difference-pressure
(normal pressure-difference see 1.4.2 or data sheet of lube oil system)
If you notice a higher pressure difference between oil inlet and oil outlet, switch to the clean filter element
and disassemble the contaminated filter for cleaning (see description of the double-oil-filter)
- After flushing connect the lube oil feed lines and the return lines to the bearing housings
- Drain oil reservoir (oil tank) and fill of with new oil or let the oil clean and regenerate by the sales service of
the oil supplier
Recommended Lubricants
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 ist
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
o o
0 C and 40 C.
The lubricants have been listed in alphabetical order which does not say anything about their quality

Supplier Turbine oil according DIN 51 515 TD-L

ISO VG 46
AGIP AGIP OTE 46 EP
ARAL ARAL Kosmol TL 46
BP ENERGOL THB 46
Castrol CASTROL Perfecto T 46
DEA ETERNA LTD EP 46
ELF TURBELF SA 46
ESSO ESSO TERESSO 46
MOBIL OIL MOBIL D.T.E. Oil Medium
SHELL SHELL TURBO OEL T46
TEXACO TEXACO ETERNA LTD 46
WINTERSHALL WIOLAN DW 46

If other oil types or oils of other suppliers are used the old oil has to be drained beforehand.

M000/e7-3-02-000 page 2
7.4 OVERHAUL - DISMANTLING OF THE PUMP
When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts, gaskets, O-ring
seals...) 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: This pumps should only be disassembled 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 premature failure of the pump.

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 drivers: 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. A certificate attesting that it is absolutely safe must be included.
The service personnel will have to be careful however in spite 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 7.4-1), take off
key (940...). Use care to avoid coupling hub or pump shaft damage.

ATTENTION To avoid damage to the bearings or to the shaft

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. Moderate
heating of coupling hub may be required.
Sketch 7.4-1 Removal of coupling

4470/e7-4-02-010 page 1
Dismantling of bearing - non-drive side
- Remove hexagon socket screws (914.03) from bearing cover. Carefully loo sen and take off bearing cover
(361.03). In case of shaft driven lube oil pump: Loosen and remove bearing cover (360.05) together with oil
pump. Be careful: Remaining lube oil will flow out
- Remove the hexagon socket screws (914.05) of the upper half fast ening on the bearing bracket lantern.
Remove also the hexagon socket screws (914.04) fastening upper and lower bearing housing halves.
- Remove dowelling (tapered pins) on bearing bracket flange / bearing lantern (560.02) and between upper
and lower bearing housing (560.01). Screw in (tighten) hexagon nuts (920.07, 920.06) to break the
tapered pins out of their seat.
- To dismantle the bearing housing upper half (352.01) screw in (tighten) hexagon head jack screws
(901.05). Lift upper bearing housing half carefully to avoid damage to the bearing parts.
- Take out the external parts of the thrust bearing (distance disc 551.06, bearing pad carrier 392.01 and
thrust bearing pads 387.01). Note: Clean and wrap each bearing part individually in soft material to protect
against damage.
- Screw off shaft nut (920.16). Note: Locking pins pressed against the shaft by the adjusting screws, are in
the bearing fastening nut. 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.
- Remove thrust bearing plate (384.01). Note: The thrust bearing plate have a shrunk fit on the shaft. For
removal the thrust bearing plate is equipped with pull off threads. Use this threads and remove thrust
bearing plate in cold condition.
- Take out the internal parts of the thrust bearing (thrust bearing pads 387.01, bearing pad carrier 392.01
and distance disc 551.06) . Note: Clean and wrap each bearing part individually in soft material to protect
against damage.
- Remove upper half of bearing shell (311.01). In case the bearing halves are sc rewed together, remove
screws. Lift shaft a little and turn out lower half of bearing shell.
- Remove the hexagon socket screws (914.05) and take off lower half of bearing housing (351.01).
- Screw off hexagon nuts (920.02) and loosen and remove bearing bracket lantern (344.01).
- Loosen grub screw (904.04) and push deflector (507.02) off the shaft, remove split ring (501.02).
Removal of shaft seal – non-drive side
- Remove fastening nuts (920.05) at the seal cover and take off seal cover with all the stat ionary
components of the mechanical seal. Be careful: Remaining medium will flow out.
- Draw shaft sleeve with the rotating parts of the mechanical seal fastened to it off the shaft (the shaft
sleeve is supplied with a groove to apply the tool).
- Loosen shaft seal housing (441...) by removing the hexagon socket screws (914.01) and pull it off. Be
careful: Remaining medium will flow out.
Replace 2 fastening screws from bearing cover
Removal of hydraulic balance device opposite to each other by the holding device and
secure the rotor by the shaft centering thread.
Remark: The balance drum have a shrunk fit on the shaft.
The removal requires experience or first hand advice from a holding device
Sulzer representative and can be considered a two person
job.

ATTENTION To avoid damage to mechanical seal parts,

arrest the shaft before drawing off the
balance drum and drum liner. 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 7.4-2.
- Pull sleeve (520.01) off the shaft, take off key (940.04).
shaft
- Mount assembly device: (consisting of studs and nuts, Bearing housing
shaft nut and flange piece) as shown in sketch 7.4-3. drive side
Screw studs into balance drum threads, fit disc and screw Arresting the rotor
Sketch 7.4-2
on inner nuts. Push flange piece onto shaft, fit disc and on drive side
screw on and tighten shaft nut. Fit discs and screw on
outer nuts.

4470/e7-4-02-010 page 2
 o
- Use a “soft” flame to heat the balance drum (603.01) to max. 140°C (280 F). Use wet cloths to keep shaft
cool while heating balance drum. Begin at outer diameter and work towards center. Do not allow the hot
inner blue flame to touch the pump parts.
Risk of burning, be carefully when handling hot parts. Use thick isolating gloves.

- When sufficiently heated, push balance drum towards drive side by tightening the inner nuts against the
flange piece. Remove split ring (501.01) and distance ring (504.01). Draw-off balance drum (601.01) by
loosen the inner nuts and tightening the outer nuts. See sketch 7.4-3
- Draw balance drum liner (605.01) with assembly device out of discharge casing (107...). Be careful:
Remaining medium will flow out. Take off key (940.02).
Push balance drum towards drive side
Outer nut Inner nut Stud Split ring
(501.01)

Shaft nut

Disc

Flange piece Balance drum

Draw-off balance drum 603.01)

Skizze 7.4-3 Removal of balance drum

Removal of bearing - drive side

- Remove holding device (mounted for removal of balance device).
- Unscrew hexagon socket screws (914.02) from bearing cover (360.03) and take off bearing cover.
- Remove the hexagon socket screws (914.05) of the upper half fastening on the bearing bracket lantern.
Remove also the hexagon socket screws (914.04) fastening upper and lower bearing housing halves.
- Remove dowelling (tapered pins) on bearing bracket flange / bearing lantern (560.02) and between upper
and lower bearing housing (560.01). Screw in (tighten) hexagon nuts (920.07, 920.06) to break the
tapered pins out of their seat.
- To dismantle the bearing housing upper half (352.01) screw in (tighten) hexagon head jack screws
(901.05). Lift upper bearing housing half carefully to avoid damage to the split bearing shells (311.01).
- Remove upper half of bearing shell (311.01). In case the bearing halves are screwed together, remove
screws.
- Lift shaft a little and turn out lower half of bearing shell.
- Remove the hexagon socket head screws (914.05) and take off lower half of bearing housing (351.01).
- Screw off hexagon nuts (920.02) and loosen and remove bearing bracket lantern (344.01).
- Loosen grub screw (904.04) and push deflector (507.02) off the shaft, remove split ring (501.02).
Removal of shaft seal - drive side
- Remove fastening nuts (920.05) at the seal cover and take off seal cover together with the stationary
components of the mechanical seal. Be careful: Remaining medium will flow out.
- Pull shaft sleeve together with the rotating parts of the mechanic al seal fastened to it off the shaft (the
shaft sleeve is supplied with a groove to apply the tool).
- 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.

4470/e7-4-02-010 page 3
Dismantling of the hydraulic pump part
Continue dismantling vertically
Sling a rope around discharge casing support feet
and lift the hydraulic pump part carefully into
vertical position. See sketch 7.4-4. Support the
pump casing so that components of the pressure
stages can be removed. See also sketch 7.6-2.
Be careful: Remaining medium will flow out.
Remark: The impellers have a shrunk fit on the
shaft. The removal requires experience or first hand
advice from a Sulzer representative and can be
considered a two person job. The impeller bores
and corresponding shaft fits are different diameters
at each location. Before dismantling, mark the
stage casings, diffusers and impellers with the
stage number and its position, as they must be Sketch 7.4-4 Lift hydraulic pump part
refitted in the same place. in vertical position
- Remove nuts (920.01) from the tie bolts (905.01) and withdraw the tie bolts.
- Loosen and remove the delivery casing (107...) by careful 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 (541.01) in the diffusers can be replaced. Remove setscrews and push wear rings and
interstage bushes with a power press out of their seats.
Note: The wear rings and interstage bushings are shouldered, press out from drive side towards non-drive
side. Be careful, do not damage seat surfaces.

After disassembly
All pump parts should be cleaned and prepared for short term storage by applying a mineral oil based rust
preventive to all machined surfaces. 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 wherever possible store shaft by hanging vertically to maintain
staightness.
Inspect all parts for wear or damage, see 7.5.

4470/e7-4-02-010 page 4
7.5 OVERHAUL - INSPECTION OF WEAR PARTS

ATTENTION 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 will lead to a premature failure of the
pump.

Impellers
Inspect impellers for wear or damage. Look for cavitation marks (pits) in the suction area, (especially in the
first stage impeller), erosion of vanes and cracks in the shroud. Smooth minor irregularies with a fine file or
emery paper, replace impellers if necessary.
Wear rings and clearances
Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum and the
maximum (worn) diametrical clearances are given in the table below.
Replace wear rings and interstage bushes when pump performance drops below acceptable system
standard or the recommended maximum clearances have been reached or exceeded. Fit new wear rings in
the stage casings and new interstage bushes in the diffusers.
Remark: Each clearance enlargement causes efficiency loss in pump.
Table 7.5-1
Pump size 80-260 100-300 125-330 150-360 200-400 Index
Min. clearance in mm (in.)* 0.35 (0.014) 0.4 (0.015) 0.45 (0.018) 1)
(with new parts) 0.5 (0.020) 0.55 (0.022) 0.6 (0.024) 2)
Max. clearance in mm (in.)* 0.7 (0.028) 0.8 (0.03) 0.9 (0.035) 1)
(with worn parts) 1.0 (0.040) 1.1 (0.043) 1.2 (0.047) 2)

* clearance in relation to diameter in mm (in.) Index: 1) cast iron or soft nitrided steel
2) stainless steel

Clearance measurement: See sketch 7.5-1. 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

Sketch 7.5-1
Wear ring replacement
Case wear rings: See sketch 7.5-2. 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. Carefully tap new rings into place,
chamfer towards inside, with a soft face mallet or with a press. Check that the
ring contacts circumference (case shoulder). Drill and tap new locking screw Sketch 7.5-2
holes half in case half in the wear ring. Fit and secure setscrews by peening.

Interstage bushes: See sketch 7.5-3. Remove interstage 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 peening.
Sketch 7.5-3

4470/e7-5-01-009 page 1
Balancing
It is recommended that impellers are individually balanced on a balancing machine. Dynamic balancing 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 bearing 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. Inspect shaft seats and shoulders for cleanlines, nicks and burrs; if necessary replace them.
Remove carefully any burrs caused by setscrews.
True running of the shaft Support shaft at bearing area (use V-blocks or rollers) and check for
concentricity. The max permissible runout is given in the table below.
Table 7.5-2
Operating speed 3000 rpm > 3000 rpm
max. permissible runout 0.025 mm (0.001 in.) 0.02 mm (0.0008 in.)

If the runout 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 deeply scored or are crazed, as a unit, never replace only one ring.
Check shaft sleeves 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.
ATTENTION Assembly must be done very carefully and under conditions of extreme cleanliness. The seal
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.

Bearings
Tilting pad thrust bearing
The parts of the thrust bearing subject to wear are the thrust pad segments and the thrust bearing plate.
Inspect every thrust bearing pad for grooves, extreme wear or any ”smearing” of the running surface. If pads
damaged verify that thrust bearing plate running surface is clean and undamaged.
In case of bearing pad surface damage the complete set of pads has to be replaced. If the thrust bearing
plate is damaged replace thrust bearing plate and the complete set of bearing pads.
Sleeve journal bearings
Check correct dimension and surface quality of bearing shells and shaft at bearing area. Replace bearing
shells when showing eccentric wear or surface damages apart from a few grooves.
In case of re-machined shaft surface use undersize bearing shells. The running clearance between shaft and
bearing shell has to correspond to the following tolerances on fit:
Table 7.5-3
Pump size 80-260 100-300 125-330 150-360 200-400
Tolerance fit H7 to e8 H7 to d6

4470/e7-5-01-009 page 2
Balance drum / Balance drum liner
Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size. Use
several measurement locations along the centreline (see sketch 7.5-1). Replace balance drum and balance
drum liner as a unit when the recommended max. clearances have been reached or exceeded.
Remark: Each clearance enlargement causes efficiency loss in pump.
Table 7.5-4
Pump size 80-260 100-300 125-330 150-360 200-400 Index
Max. clearance in mm (in.)* 0.4 (0.016) 0.5 (0.02) 0.6 (0.024) 1)
(with worn parts) 0.5 (0.02) 0.6 (0.024) 0.7 (0.027) 2)

* clearance in relation to diameter Index: 1) cast iron or soft nitrided steel

2) stainless steel

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 screwd 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 runout 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 runout is given in the follwing 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 runout 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.

4470/e7-5-01-009 page 3
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.

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 pressure Drawing Drawing
Pump size No. No.
100-300 19 A M 95 x 2 162 43 5 340 4-061 420 4-088 974
125-330 24 A M120 x 2 188 44 5 380 4-086 836 4-648 082
150-360 24 A M120 x 2 188 44 5 450 3-086 836 4-089 060
200-400 26 A M130 x 2 198 44 5 460 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.

4470/e7-5-01-009 page 4
7.6 OVERHAUL - ASSEMBLY OF THE PUMP
References Refer to specific drawings (section drawing(s), parts lists, installation plan).
All assembly works have to be carried out with the greatest possible care. Negligence will
ATTENTION
lead to premature failure of the pump.
These pumps should only be assembled by qualified specialists with suitable tools and by strictly
observing the instructions.

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

Note with pump sizes:
80-260 from 8 stages; 100-300 from 7 stages; 125-330, 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 7.6-1.
The assembly of the internal block has to made vertically.
oben

Shaft
(210...)

Sketch 7.6-1 Mounting oblique stage casings First stage

Suction impeller (231...)
- Clean shaft, impeller bores and coat the contact surfaces slightly
casing
with lubricant.
(106.01)
- Place the suction casing (106.05) vertically on supports so that
shaft, impellers, diffusers and the components of the pressure
stages can be pushed onto it. See sketch 7.6-2.
- Slide shaft with first stage impeller mounted on it into the suction
casing.
- If present: place O-ring (412.01) for sealing of the stage casing
on the centering of the suction casing.
- Insert diffuser (171.02) into the stage casing (108.02) and
mount stage casing - if necessary, knock with a rubber hammer.
Place O-ring seal (412.01) for sealing of the next stage casing.
- Slide the next stage impeller (230.02) over the shaft. Supports
- Fit another pre-assembled stage casing (with diffuser and O- Sketch 7.6-2 Vertical assembly
ring seal).
- Assemble remaining stages in the same way.
- Slide delivery casing (107.05) with inserted last diffuser (177.01) and O-ring seal (412.12) on the spigot of
the last stage casing (108.02).
- Fit tie bolts (905.01), discs (550.01) and nuts (920.01). Clamp the whole hydraulic assembly together
evenly and crosswise.
- see table 7.7.2 for tightening torques-

4470/e7-6-01-003 page 1
Assembly of the balance device (shrink fit design)
- Insert key (940.02) for balance drum into shaft. Heat balance drum (603.01) in an electric oven at a
o o
temperature of 100-120 C (210-250 F)..
- Insert O-ring seal (412.08) into balance drum bore and push the heated balance drum with gloved hands
over the shaft into its fit on the shaft. Insert split ring (501.01) and key (940.04) into shaft and slide sleeve
(520.01) with collar over it. Mount assembly device (see also sketch 7.4-3) and pull balance drum against
the split ring. Let balance drum and shaft cool down. Remove mounting device.
Risk of burning, be carefully when handling hot parts. Use thick isolating gloves.
- Fit O-ring seal (412.07) into the groove of the balance drum liner (605.01). Push balance drum liner into
the delivery casing and allow the cylindrical dowel pin (561.02) preventing rotation to engage in the hole.

Assembly of the shaft seal housings

Continue assembly horizontal
Sling a rope around discharge casing support feet, lift the hydraulic pump part by a crane and position it
carefully in horizontal position. See sketch 7.4-4. Support the hydraulic pump part at suction and discharge
casing feet.
- Drive side: Insert key (940.04) for shaft sleeve.
- Insert O-ring seal (412.02) in groove of the shaft seal housings (441.02). Locate shaft seal housings on
delivery casing (107.05) and suction casing (106.05) using hexagon socket screws (914.01). Note: Be
sure venting bores of seal chambers (if present) are on top.

Assembly of bearing lantern

- On both sides of the pump: Place O-ring (412.02) in the groove of shaft seal housing (on design with
cooling likewise insert O-Ring 412.04) and mount bearing bracket lantern (344.01). Lube threads and
support surfaces for nuts, tighten evenly and crosswise.
- see table 7.7.2 for tightening torques-

Measurement and adjustment of the nominal axial position of rotor

Measurement is not necessary, if the installation length of the turbinepump parts have not changed
through re-machining during repair, but it is essential, if new parts (shaft, impellers, stage casings,
shaft seal housing, bearing lantern or bearing housing) 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 nominal 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.

ATTENTION All assembly works for the measurement have to be carried out without use of seal rings
and with greatest possible care.
o
- Non-drive side: Heat thrust bearing plate (384.01) in an electric oven at a temperature of 100-120 C
o
(210-250 F) and push the heated thrust bearing plate with gloved hands onto its fit on the shaft (pull-off
threads towards non-drive side). Screw on and tighten shaft nut (920.16). Remark: Do not overtighten
shaft nut.
- Lift bearing housing lower half (351.02) into position, screw on and tighten hexagon socket screws
(914.05).
- Push rotor into its final axial position towards non drive side.

4470/e7-6-01-003 page 2
- Measure from inner side of thrust bearing plate (384.01) to the contact surface of the spacer disc (551.06)
in the bearing housing dimension "B". See sketch 7.6-3.To obtain the right rotor position the rotor must be
set by the dimension "L" indicated in the table 7.6-1 towards drive side. The dimension "C" required for
correct axial position of the rotor can be calculate as follows:

Dimension C = B - L

- The total thickness of the thrust bearing pads (387.01) of the bearing pad carrier (392.01) and the spacer
disc (551.06) must come up to "C". Because the thickness of the thrust bearing pads (387.01) and of the
bearing pad carrier (392.01) is already determined, the dimension "E" can be obtained. The difference to
"C" is the thickness "X1" of the spacer disc (551.06).

Dimension X1 = C - E
- The spacer disc (551.06) must be remachined to this dimension “X1” or combined with thin discs, which
can be delivered 0,25 and 0,125 thick.
Determination of bearing axial clearance
- The thickness "X2" of the outer spacer disc (551.06) results by adding dimension "D" (thrust bearing
plate 384.01, thrust bearing pads 387.01, bearing pad carrier 392.01), the calculated dimension "X1" and
dimension "F" at bearing cover. Subtract this value from bearing housing inside dimension "A". The
thrust bearing needs an axial clearance for building up the lubrication film, therefore it is necessary to
consider that 0,35 mm must be added to the total dimension of all thrust bearing parts.

Dimension X2 = A - (X 1 + D + F + 0.35 mm / 0.014 in.)

Table 7.6-1
Pump size Dimension „L“
in mm (in.) A
50 – 220 3.5 (0.14) F D
80 – 260 X2 E X1
100 – 300 4 (0.16)
125 – 330
150 – 360
200 - 400 5 (0.2)

Bearing clearance 0.35 mm

Rotor running position

Rotor displaced into its final

axial position towards L
non-drive side

Sketch 7.6-3 Measurement and adjustment of rotor position

- After measurement remove thrust bearing pad (384.01) again (refer to 7.4 disassembly).

4470/e7-6-01-003 page 3
Rotor centering procedure
Rotor centering is required, if the hydraulic pump part (stage casings) had been disassembled or if new
parts as bearing housing, bearing lantern or shaft seal housing have been re-machined or renewed.
Otherwise continue with paragraph „Assembly of the shaft seals”.
- Drive side: Assemble bearing housing lower half (351.01), loosen fastening screws (914.05) somewhat,
so that the bearing housing can be shifted by means of the adjusting screws (901.03) at the flange of the
bearing bracket lantern.
- Non-drive side: Assemble bearing housing in the same way as described for drive side.
- Attach a measuring gauge (the measuring pin has to be positioned at right angle to the shaft) to as certain
at the bearing area by what dimension the shaft can be lifted. Divide the result by two and note. See
sketch 7.6-4.
- Adjust bearing housing lower half by the lateral adjusting screws in such a way as to allow an easy
inserting of the bearing shell lower half of the plain bearing, lube bearing shell and shaft with oil.

Measuring gauge
Measure Adjust shaft Measuring
shaft radial center position gauge
movement lateral
1
T / 2T
Pump

Shaft

Adjust bearing housing lower half Bearing shell

in such a way as to allow an easy
inserting (turn in) of the bearing Shaft
shell Adjusting screw
Bearing housing
lower half
Lower adjusting screw

Sketch 7.6-4 Adjust center position of the rotor

- Screw in lower adjusting screw until shaft is lifted by the dimension calculated before. Besides check with
additional measuring gauge laterally that shaft does not move in horizontal direction.
- Secure adjusting screws with adjusting nuts, fasten bearing housing lower half tightly. Observe both
measuring gauges, the shaft position must not change.
- Set upper half of bearing shell into position and if present screw both halves together.
- Drive side: Adjust bearing housing on the drive side in the same way.
- Assemble bearing housing upper halves (352.01) on both sides (do not use any sealing or sealing mastic
between upper and lower half).

Check of free running state of the rotor

ATTENTION Due to manufacturing of the pump parts within the given tolerances the rotor theoretically
should be in center position, i. e. could usually 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.
- If check is satisfactory dowel bearing housings in new position. Existing taper pin holes can be
reamed to the next size taper pin or, if required drill new holes. Remove bearing housings again and
continue with paragraph „Assembly of the
- Causes and measures in case of touching of the rotor. Center position of the rotor not correctly
adjusted, adjust once again. Oblique turned stage casing not correct installed (see sketch 7.6-1). Tie bolts
(905.01) of the hydraulic pump part not correct tightened (torque, sequence ...).

4470/e7-6-01-003 page 4
Assembly of shaft seals
- Drive side: Insert O-ring in the groove of the shaft sleeve bore. Assemble the rotating parts of the shaft
seal on the shaft sleeve. Push pre-assembled shaft sleeve onto shaft.
- Slide on seal cover with the pre-assembled stationary parts of the shaft seal, but do not fasten yet.
- Insert O-ring (412.13) in the bores of deflector (507.02), fit split ring (501.02) into the shaft groove and
push deflector with collar over it. Fix deflector with pin (904.04), be sure that pin is engaged in the
retainer bore of the shaft.
- Non-drive side: Assemble shaft seal and bearing bracket on the non-drive side in the same way as
described for the drive side.
Assembly of bearings
Absolute cleanliness is essential. Ensure cleanliness of shaft, bearing housing, and all bearing parts.
Remachined parts must be free from burrs and sharp edges. Journal bearing surfaces and thrust bearing
shoes must be thoroughly lubricated before assembly.
Assembly of radial bearings Bearing shell Bearing housing
- On both sides of the pump: Lift bearing housing lower halves lower half
(351.01, 351.02) into position and screw on fasteners fingertight.
Shaft
Insert taper pins through bearing housing flange into bearing
lantern. Seat taper pins, then properly tighten bearing housing
fasteners.
- Lube radial bearing shells and shaft with oil. Turn in bearing shell
lower halves (if required lift shaft a little). See Sketch 7.6-5
- Set bearing shell upper halves into position and if present scr ew
both halves together.
- Drive side: Lift bearing housing upper half (352.01) carefully into
position (let the cylindrical pin preventing rotation of bearing shell
engage in the hole). Do not use any sealing mastic between upper Sketch 7.6-5 Bearing shell assembly
and lower half. Seat taper pins, then properly tighten bearing
housing upper halves fasteners.
Assembly of the thrust bearing
- Non-drive side: Mount inboard thrust bearing parts. Assemble the spacer disc (551.06 with nominal
dimension) and bearing pad carrier (392.01) with thrust bearing pads (387.01). Allow the anti-rotation pin
(562.04) to engage in the hole.
- Push rotor towards non-drive side.
o o
- Heat thrust bearing plate (384.01) in an electric oven at a temperature of 100-120 C (210-250 F). No
other method is acceptable.
- Insert key (940.06) for thrust bearing plate (384.01) and slide the heated thrust bearing plate with gloved
hands onto its fit on the shaft (pull-off threads towards non-drive side). Let the thrust bearing plate cool
down and screw on and tighten shaft nut (920.16), secure shaft nut by tightening the locking pins.
Remark: Do not overtighten shaft nut.
Risk of burning, be carefully when handling hot parts. Use thick isolating gloves.
- Push rotor towards drive side (running position).
- Insert outboard be aring pad carrier (392.01) with thrust bearing pads and spacer disc (551.06 with
nominal dimension). Thoroughly lubricate thrust bearing parts with oil.
- Fit gasket (400.02) at bearing cover (360.05) seal face. Lift the bearing cover into place and allow the
anti-rotation pin (562.04) of the outboard thrust bearing to engage in the hole. Screw on fasteners
(914.03) into lower bearing housing half in a loose way only.
- Lift bearing housing upper half (352.02) carefully into position (let the cylindrical pin preventing rotation of
radial bearing shell engage in the hole). Do not use any sealing mastic between upper and lower half.
- Seat taper pins, then properly tighten bearing housing upper half fasteners. Tighten fasteners evenly and
crosswise between upper and lower bearing housing halves. Then tighten fasteners between bearing
housing upper half and bearing lantern (344.01).
- Screw on bearing cover upper half fastener. Tighten bearing cover fasteners evenly and crosswise.
- Shaft driven main oil pump: If present mount oil pump. Fit shaft coupling onto oil pump shaft. Insert key
that drives the oil pump. Fit gasket and install oil pump onto bearing cover, taking care to align coupling
keyway with drive key (see sectional drawing).

4470/e7-6-01-003 page 5
Final assembly
- Drive side: Fit gasket (400.01) on bearing cover (360.03) sealing face and fasten bearing cover with
hexagon socket screws (914.02).

- Mechanical seals: Tighten seal covers fasteners (nuts 920.05) evenly and crosswise.
coupling half nut
- Mount coupling half:
ATTENTION To assemble coupling half remove parts
susceptible to heat (e.g. rubber buffer,
sealing rings etc.) and heat coupling half by homogeneous,
o o
dry heating (e.g. oven, electric ring) to about 80 C (175 F).
Push coupling half onto shaft, when cooled remount the
disassembled parts (couplings with bores up to 50 mm
diameter may also be assembled in cold condition by means
of a suitable device). pump shaft bar stud
Sketch 7.6-6 Assembly of coupling
Install pump
- Transfer the pump to assembly site. Mount pump onto baseplate, align pump flanges and connect main
pipework. See also 5.3.
Coupling
- Check coupling alignment (see 5.2) and couple the driving unit
- Fit the coupling guard.
Ancillary equipment
- Install auxiliary lines (circulation lines...) and instruments (thermometers, constant level oiler, pressure
gauges...)
ATTENTION Do not mix up connections. Carefully check piping system.

Bearing housings
- Fill bearing housings with oil (see 7.3)
Electrical installations/connections for motors and controlling devices may only be carried out by
qualified electricians.

ATTENTION When re-commissioning, all steps described in Section 6.1 must be repeated.

4470/e7-6-01-003 page 6
7.7 TOOLS / SCREW TIGHTENING TORQUES
7.7.1 Special tools
Assembly equipment for the balance parts
Qty. Part Sketch
1 1 Flange piece Ø200x43 1 2
4 2 Stud M16x650
8 3 Disc A17
8 4 Nut M16 5
1 5 Shaft nut KM 10 (M50x1,5)
1 6 Disc 50x62x3
6

4 3

Rotor concentricity check (see also 7.5)

Part Hydraulic nut: 1
3 2
1 1 Hydraulic nut SKF Type HMV
2 1 Thread sleeve
3 1 Sleeve

Oil injection kit 729101B consisting of:

4 1 Oil injector 226400
5 1 Injector attachment 226402 7 4
6 1 High pressure pipe 227957
1 Connection nipple 228027 5
7 1 Pressure gauge 1077589
1 Tool case 729111B
Tool case dimension: 340x310x95 mm
Mass incl. tools: 10 kg Designation 6
complete kit: 72901B (excluding
pressure gauge 729101AB)

4470/e7-7-01-000
7.7.2 Screw tightening torques

Hydraulic pump part tightening

Clean and lubricate threads nuts and support surfaces. Fit tie bolts (905.01), and screw on nuts
(920.01) and the “SUPERBOLT” (920.44).
Refer also to the “SUPERBOLT Instruction for tightening, loosening and maintenance” included in follow
sections.
Step 1 (Case setting): Tighten in the below given sequence “SUPERBOLT” 1 to 4 with the “Pre-load
value” (4 jack bolts). Develop the pre-load value in three steps with a maximum of 33 % of the torque
value being reached on the initial pass.
Step 2 (50 % value): Adjust on “SUPERBOLT” 5 to 8 the gap to 1 mm wide and tighten as described (4
jackbolts) with the 50 % value. Than adjust on “SUPERBOLT” 1 to 4 the gap to 1 mm and tighten.
Step 3 (100 % Final torque): Tighten opposing pump case tie bolts in an alternating sequence as
illustrated below when developing the "Final torque".
Step 4 and 5: Now tighten each SUPERBOLT circular (all jackbolts) up to the “Final tightening torque”.
Tighten opposing pump case tie bolts in an alternating sequence as illustrated.
SUPERBOLT Pretensioning system
Pump size
Operating Superbolt size Tightening torques in Nm (lft.ft)
pressure Pre-load value 50 % Spannung Final
920.44 4 screws 4 screws tightening
[bar] torque
MD100 – 300 220 MT-M 52x1.5/W 30 (22) 40 (30) 80 (60)
MD125 – 330 250 MT-M 60x2/W 40 (30) 90 (65) 180 (130)
MD150 – 360 250 MT-M 60x2/W 40 (30) 90 (65) 180 (130)
MD200 – 400 250 MT-M 80x2/W 40 (30) 85 (63) 170 (125)
Table 11.1
Tightening torques in Nm (lft.ft)
Pump size
Bearing bracket Mechanical seal Bearing housing Bearing cover
lantern cover
Part no.: 902.02 / 920.02 902.05 / 920.05 914.05 914.03 / 914.02
Class: 1.7711+QT A4-70 8.8 8.8
MD100-300 280 (205) 90 (65) 52 (38) 52 (38)
MD125-330 280 (205) 170 (125) 130 (96) 52 (38)
MD150-360 280 (205) 170 (125) 130 (96) 52 (38)
MD200-400 430 (315) 170 (125) 130 (96) 130 (96)
Table 11.2
Note: Tightening torques are only valid, if thread and support surface for nuts (respectively screw head supports) are
lubricated.

Hydraulic pump part Brg. bracket lantern

Brg. bracket lantern Tie bolt 905.01 Nut 920.02
Nut 920.02
Bearing cover
Screw 914.02

Bearing cover
Screw 914.03 Mech. seal cover
Nut 920.05

Sketch 7.7.2. Fastener position and tightening torque

4470/e7-7-01-000
 ®

GB
P&S Tensioning Systems Ltd.
Rickenstrasse 55
CH-8735 St. Gallenkappel
Switzerland
Tel. +41-(0)55 284 64 64
Fax +41-(0)55 284 64 69
Internet: www.p-s.ch
E-Mail: [email protected]

®
SUPERBOLT
Pretensioning Systems

Instruction for
Tightening –
Loosening –
Maintenance –
With SUPERBOLT Tensioners
you have chosen a technologically superior product.
It is purely mechanical and, therefore, very safe.

The following simple steps will help you with your application.
Thereby you increase safety, speed and service life.

NEW: These instructions are also available as information film (VHS or CD).
All up-to-date instructions are accessible from our wesite.
1. Tightening procedure
1.1 Check:
Which jackbolt torque?
M = 100% of recommended torque, see – your internal directives
– P&S cerficate
– P&S data sheet

Attention: The engraved jackbolt torque is the maximum value typically allowed and can
be unsuitable for your application.

1.2 Which tools?

– suitable torque wrench
– matching socket, heavy duty line
– lubricant

1.3 Prepartion:
– Clean main thread and contact areas and lubricate well with suitable anti-seize lubricant.
– Make certain that the jackbolts on the SUPERBOLT tensioner do not protrude beyond
the load surface and are well lubricated. If neccessary, relubricate with the recommended
SUPERBOLT lubricant (see cerficate).
– Firmly tighten tensioner by hand, if neccessary by using a screwdriver stuck between the
jackbolts or the like.
– Afterwards turn back approx. 1/4 turn. Depending on size the gap will be approx.
1 to 3 mm wide.
– The actual tightening occurs in a few steps:

1.4 Tightening:

Step 1: Tighten 4 jackbolts by hand or using a small

1–3 mm

wrench to center the main thread and to eliminate

backlash. Tighten bolts crosswise.

Step 2: Now tighten these 4 jackbolts crosswise with

50% of the recommended jackbolt torque.

Step 3: Tighten the same 4 jackbolts crosswise

with 100%.

Step 4: Now change to circular tightening and tighten all

jackbolts with 100% of the recommended jackbolt
torque.

Step 5: Repeat step 4 until all jackbolts are equally

tightened (less than 20 remaining movement).
Normally 2 to 3 passes are sufficient, with long
bolts accordingly more.

Power tools can save time, see item 3.3.

2. Loosening procedure
Attention: Loosening requires an exact procedure. The jackbolts must be unloaded stepwise!
Under no circumstances unload single screws completely. The remaining screws would have
to carry the entire load and, therefore, would be difficult to loosen. In extreme cases the
jackbolts could mushroom and make loosening impossible!

2.1 Usage at normal temperatures (under 100 C)

Preparation: Before loosening apply penetrating oil, especially with any rust formation.

Step 1: Starting with N 1 loosen every jackbolt in a

circular pattern approx. 1/4 turn (breaking loose
is sufficient). After the first round jackbolt N 1
will be tightened again, however, on a lower level
of loading.
Note: Should several tensioners be loosened,
i.e. on a flange, perform step 1 on all tensioners
before moving to step 2.

Step 2: In a 2nd round repeat step 1, again on all

tensioners.

Step 3: Repeat step 1 in a 3rd round.

Step 4: Relieve jackbolts completely. Now the tensioner

can be removed by hand.

Note: Long screws expand more and, therefore, may require one or two passes more.
Attention: Before re-using follow maintenance instructions!

2.2 Usage at high temperatures (over 100 C)

Preparation: At higher temperatures the petroleum base of the lubricant evaporates, thereby
increasing the effort for loosening.

Step 1: If possible, already apply penetrating oil during

cooling of the installation (at approx. 150 C).
At even higher temperatures use synthetic oil.

Step 2: Starting with N 1 break loose each jackbolt of

one tensioner in a circular pattern.
Note: Do not loosen beyond break loose point,
and break loose all jackbolts of all tensioners of
a joint first.

Step 3: The actual loosening occurs according to the

procedure described under item 2.1 (normal case),
beginning with step 1.

Note: For high temperature applications bolts with bores are often used. Through the use
of heating rods the loosening of SUPERBOLT tensioners can be substancially facilitated.
Five minutes of heating are already sufficient to accelerate loosening.
3. Lubrication and tools
3.1 Lubricant

Jackbolts: The jackbolts are delivered pre-lubricated and are ready for use. Refer to the
cerficate for the lubricant. For jackbolts use only SUPERBOLT lubricants or substitutes
permitted by P&S.

Hardened washers: For the upper side (contact with jackbolts) use the correct SUPERBOLT
lubricant. For the bottom side you may use any suitable anti-seize lubricant.

Main thread: Any suitable anti-seize lubricant including SUPERBOLT lubricants may be
used. Apply with brush or spray.

3.2 Sockets

For tightening the jackbolts only high quality tools in good working order should be used.
Heavy duty sockets for use with impact tools are best suited. Worn sockets are dangerous
and should be disposed of.

3.3 Power tools

Air impact tools have prooven to be most suitable, however, with SUPERBOLT jackbolts
they reach only 30–50% of their rated output (lack of displacement). Therefore, the largest
possible air lines and couplings (i.e. hydraulic couplings from Stäubli) should be used.
Because of the high forces and for repeated usages only heavy duty products should be
chosen (i.e. Ingersoll Rand, Dino Paoli, Atlas Copco). Verifying the torque output of an
air impact tool is easy: Tighten until tool stalls, then measure the torque with a torque
wrench (preferably with electronic gauge).

For regulating the tightening torque simply install a service unit directly in front of the air
impact tool (filter, controller, oiler). Adjust the pressure at the controller and, thereby,
the power of the air impact tool. Tighten a SUPERBOLT jackbolt to the desired torque with
a torque wrench. Then, apply the air impact tool and increase the pressure until the jackbolt
starts turning again. Check the controller if the pressure decreases when starting the air
impact. This indicates an unwanted pressure drop in the air duct. Therefore, use generously
dimensioned air ducts! For regular usage of air impact tools the use of a control unit pays
off (available upon request).

When tightening air impact tools are especially suited for steps 2 through 5 and should
be adjusted to approx. 90 to 100% of the rated torque.

Note: Because of the lower accuracy of power tools, the last tightening round should
always be manually performed with a precision torque wrench.

Note: During loosening caution is mandatory: Use normal air impact tools only for step 4
(complete loosening), but never for steps 1 through 3!
A special air impact tool for loosening SUPERBOLT tensioners is newly available from P&S:
It turns only 1/4 of a turn, and is applicable for steps 1 through 3 .

Notes for the use of air impact tools:

– Network pressure min. 6.5 bar
– up to 70 Nm 3/8" impact tool or air ratchet
– 70–130 Nm 1/2" impact tool, derated (Attention: Do not overshoot!)
– 130–200 Nm 1/2" impact tool
– 200–270 Nm 1/2" impact tool (handy) or 3/4"
– over 270 Nm 3/4" impact tool
4. Maintenance
4.1 Regular checks

SUPERBOLT tensioners do not loose their preload force even after several years in service
provided that they are correctly tightened. During revisons (after several years) the preload
force should be checked nevertheless. Use a torque wrench adjusted to 100% of the
permitted jackbolt torque according to the cerficate or your installation procedure.

Should some jackbolts unexpectedly have lost some of the preload force the following
procedure is recommended:
– Unload tensioner slightly by loosening the jackbolts according to loosening procedure.
However, only 1 turn! Thus, the nut remains tensioned.
– Now retension according to tightening procedure - step 5, meaning:
Tighten in circular pattern with full jackbolt torque, until all jackbolts are tightened.

4.2 Preventive maintenance

i.e. for removal for maintenance purposes:

– Relieve according to loosening procedure.
– Clean thread and end of the SUPERBOLT jackbolts and treat with lubricant according
to cerficate. Do not use molybdenum sulfide (MoS2) unless expressly specified in the
cerficate.
– SUPERBOLT hardened washer may be re-used despite indentations simply by turning
over. Depressions of a few 1/100 mm are normal.
– Retighten according to tightening procedure.

4.3 If you encounter problems

Jackbolts cannot be loosened:

– Try to free at least one jackbolt.
– Remove, lubricate well and tighten with 110% of the recommended jackbolt torque.
– The two neighboring jackbolts should become free.
– Remove also, lubricate and tighten with 110%.
– Again the next two jackbolts should become free.
– And so on.
– Afterwards relieve all jackbolts according to loosening procedure.

Hardened washers are damaged i.e. after a long time in service:

– Exchange against original SUPERBOLT hardened washers.

Jackbolts are damaged or missing:

– Exchange against original SUPERBOLT jackbolts.
Do not use commercially available screws because they are not suitable
for such high loads.

Other problems:
– Please contact your supplier or directly P&S Tensioning Systems Ltd.
5. General notes
5.1 Tensioners with only 4 or 6 jackbolts
Tightening – Step 1: Tighten all jackbolts by hand crosswise.
Step 2: Tighten 2 opposite jackbolts with 50% of recommended torque.
Step 3: Tighten 2 other opposite jackbolts with 100%.
Step 4: Tighten jackbolts in circular pattern with 100% until they are tightend.

5.2 Tightening of long tie rods

To accelerate tightening of long tie rods it pays off to perform step 4 with increased
jackbolt torque (approx. 110–125%).
Attention: In final rounds always check jackbolt torque by hand with 100% to prevent
overloading.

5.3 Gaskets with large elastic displacements

It does not matter if some jackbolts (or tensioners on the circumference) become loose
during tensioning. This is normal, because in the beginning only those bolts carry loads that
are being tightened. Do not spin down loose tensioners, otherwise there will be problems
later during loosing. Preferably adjust jackbolts with power tools.

5.4 Tensioning large flanges or joints

For tensioning large flanges/joints preferably work with 2 men 180 apart or 4 men 90 apart.

5.5 Usage of spacers

Tensioners should be positioned on the outer end of a bolt. This protects the main thread.
It can be tensioned easier (no extensions neccessary) and the expansion is improved. Place
suitable spacer or several heavy washers under the hardened washer. Thereby you can
bridge over areas that have been damaged by other tightening techniques.

5.6 Retensioning for high temperature applications

If tensioned properly it should not become neccessary to retension SUPERBOLT tensioners.
If regular retensioning should nonetheless become necessary, please inform us so that we
can re-examine the joint.

5.7 Recutting of the bolt threads

Recutting of the bolt threads can become neccessary on bolts that have deformed during
years of service, especially at higher temperatures. Likewise on bolts of earlier manufacture
that were manufactured with other tolerances.

5.8 Installation tools

Apart from a variety of standard tools for tensioning of SUPERBOLT tensioners simple special
tools are available, which facilate the installation of large nuts or bolts.

5.9 Protective caps

Protective caps from vinyl, steel or stainless steel are available to protect the tensioners
for different applications. Filled with grease they offer good potection against rust at normal
temperatures.

6. Consultation and exclusion of liability

P&S 5.5-016 GB 10/03

For further information on possible uses, applications and maintenance of SUPERBOLT

pretensioning systems please contact your supplier or directly P&S Tensioning Systems Ltd.
P&S excludes all liability for unsuitable product selection, improper use as well as damage
resulting from disregarding our instructions and directives. Changes due to technical progress
are reserved.
ENCLOSURES

Table of enclosures for operating instruction

PUMP

Performance data-diagram
Performance curve
Pump data sheet

Dimension drawings
Installation plan

Sectional drawing
Centrifugal pump
Parts list - pump
Centrifugal pump
Parts list - pump

Pump special tools

Mechanical seal drawing

Mechanical seal instruction

Seal system API Plan 23

Coupling
Driver

Lube oil system