aurora pump maintenance

8/3/2019 Aurora Pump Maintenance

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Aurora PumpsAurora Pumps

Installation & Maintenance Tool

Kit 101


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Installation and MaintenanceInstallation and Maintenance

To ensure proper operation of any pumpingsystem, it is imperative that the pump

should be installed to the pump

manufacturers specifications, operated in

the proper manner and maintained to ensure

continued performance. Above all the pumpshould always be operated or worked on in

a safe manner.


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Maintenance Tool KitMaintenance Tool Kit

Safety Base Installation

Coupling Alignment

Piping Alignment

Grouting

Stuffing Boxes Packing

Mechanical Seals Anti-Friction Bearings

Sleeve Bearings

Checking Rotation

Starting of Pump

Looking for Trouble Conclusion


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SafetySafety

When working on a pump or any piece of rotatingequipment the following safeguards should be put

in place:

Wear safety glasses. Wear a hard hat, (this is important to not only to protect

from falling items, but as a bump hat as well).

Do not wear any loose fitting clothing or jewelry whichcan catch on the equipment.

Long hair should always be tied back.


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Safety ContinuedSafety Continued

System safeguards should also be put in place: Lock out the electrical power to the pump if you are

going to be working on the pump or checking the

alignment.

Notify authorities or building operators that you are

there to do maintenance or operate the pump.

Only operate the pump with coupling guard in placeand with all controller doors in the closed and secured

position.


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Base InstallationBase Installation

Alignment-Base mounted units come fromthe factory with pump and motors on a

common base. These units were properly

aligned at the factory but most likely have

shifted during shipping. To ensure proper

operation of the pumping units the baseshould be mounted on the foundation and

leveled to allow for proper alignment.


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Leveling the BaseLeveling the Base

The pump should be installed on the foundationwith the pump/motor coupling halvesdisconnected. The coupling should not bereconnected until the alignment process has beencompleted.

Wedge type shims should be used to level thebase. These will left in place during the groutingprocedure.

A gap of .5 to .75 should be maintained between

the base and foundation to allow grout to fill inunder the base.


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Typical Base/FoundationTypical Base/Foundation

InstallationInstallation


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Typical Base/FoundationTypical Base/Foundation

InstallationInstallation


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Coupling AlignmentCoupling Alignment

Flexible couplings are not designed to compensatefor misalignment of the pump and motor

combination. Alignment must be checked for the

following: Axial Alignment-Spacing between coupling halves.

Parallel Alignment-Proper side to side, up and down

alignment between coupling halves. Angular Alignment-Face to face alignment of the

coupling halves.


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Aligning the couplingAligning the coupling

In all cases, the coupling should be alignedto the manufacturers specifications.

Failure to comply will not only void the

warranty, but can also create a hazardous

situation.


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Examples of couplingExamples of coupling

misalignmentmisalignment

Parallel

Angular

Axial


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Methods of coupling alignmentMethods of coupling alignment

In many cases, using astraight edge is the

recommended

procedure for aligninga coupling. This

applies mainly to

rough finished, closedcoupled, elastomeric

couplings.


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For angular alignment,

and also axial

alignment, calipers

and feeler gages arethe most popular

methods of alignment.

Again follow themanufacturers

instructions.


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In many cases a dial

indicator is used. This

can be used to check

both parallel andangular adjustment.

This method is used

commonly with allmetallic couplings and

spacer type couplings.


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Example of dial

indicator and ID

calipers or

micrometers for spacercoupling alignment.


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Example of aligning a

metal grid type

coupling. Distance

between the shafts isalways a consideration

when doing coupling

alignment.


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Coupling AlignmentCoupling Alignment After initial installation of the pump, several

factors may disturb the coupling alignment:

Loose nuts or bolts on the pump or driver.

Pipe strain on the pump.

Temperature changes in high temperature applications.

Settling, seasoning, or springing of the foundation.

Shifting of the building or floor.

Alignment verification should be doneperiodically and especially when there is any workdone on the pump or driver.


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Piping AlignmentPiping Alignment

Piping alignment is often overlooked duringthe installation and maintenance of a pumpunit. The pump is not designed to support

the forces and moments of a piping system.In fact just the opposite. All piping, suctionand discharge, should be supported and

restrained near the pump. If an expansionjoint is used there should a pipe anchorbetween the pump and the expansion joint.


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Piping Alignment ContdPiping Alignment Contd

Connections

All connections should use proper mating. E.g. a flat

face flange should use a flat face companion flange and

gasket.

All connections should make up easily. If force is

required to line up bolt holes etc than that force will

be transferred to the pump. Pipe strain can cause the

pump to bind as many of the tolerances are very close.

All connections shall be secure to prevent leakage or

the entrance of air into the system.


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GroutingGrouting

Once the base has been leveled, thecoupling has been aligned, and the piping

has been connected and supported, it is

important to grout the base.

The base should be entirely grouted with

foundation bolts being tightened 48 hoursafter grouting.


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Stuffing BoxesStuffing Boxes Stuffing boxes are designed to be used with

packing, with or without a lantern ring. Thelantern ring assists in lubricating the packing.Make sure that the lantern ring is placed where it

receives the maximum fluid. In externally flushedpumps at the flush line connection, and at theinternal groove on internally flushed pumps.

If the liquid being pump is gritty or dirty, it isusually recommended that a outside source ofclean liquid is used to flush the stuffing box.


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PackingPacking Packing should be the type recommended by the pump

manufacturer. Packing rings are split and should be installed at 90 degree

intervals so that they do not provide a channel for the water

to pass through the stuffing box. Packing should not be overly compressed as this can cause

damage to the shaft sleeve.

Packing should only be compressed with the packinggland, and only when the pump is filled with fluid. A slightadjustment should be made at that time to stop the flow ofwater. In some cases with high suction pressure this may

not be possible.


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PackingPacking When the pump is started the packing gland should be

adjusted to reduce the flow to about 1 drop per second.Tightening of the gland should be done equally to avoid

binding or uneven pressure of the packing on the sleeve.

Packing when replaced should always be replaced as a set. Never add more than specified amount of rings to a pump.

When working on older pumps take caution when

changing out the packing as older pumps may haveasbestos packing in them. Always make sure that any

packing in stock is the non-asbestos type.


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Mechanical SealsMechanical Seals Mechanical seals are the most typical and efficient

way of sealing a pump.

Mechanical seals require no adjustment, butshould be checked periodically for leaks, toprevent a catastrophic seal failure.

In the event of the pump running dry it is

recommended that the seals be changed, as theyare lubricated by the fluid being pumped in mostcases and will more than likely be damaged.

Take great care in keeping the seal faces cleanduring installation to prevent seal failure.


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Sleeve BearingsSleeve Bearings Sleeve bearings are typically used in vertical

pumps.

These pumps are lubricated either by:

Product

Grease

Outside Source, (water or oil)

It is imperative that the bearings are alwayslubricated.

Greasing the bearings should only be done when

the pump is idle, never while the pump isoperating.


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AntiAnti--Friction BearingsFriction Bearings In most cases of failures with anti-friction

bearings, it is too much oil or grease that causesmost failures. Oil and grease should be checked atinstallation and checked periodically thereafter.

For grease lubricated bearings a high grade anti-friction grease should be used and in no casesshould a graphite grease be used.

Oil lubricated bearings should be used in a methodand amount as recommended by the manufacturer.

Record keeping of lubrication of the pump is agood practice.


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Checking RotationChecking Rotation With all electric motor driven pumps it is

imperative to check rotation of the motor driver.

This should be done at start up and anytime that

the motor or controller is re-connected. This should always be done with the coupling

disconnected. On a close coupled pump a mark

should be made on any visible shafting. A qualified electrician should make the changes to

the wiring to ensure proper rotation.


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Starting a PumpStarting a Pump The pump should only be started with the pump

fully primed. If an automatic air release valve isnot furnished the air should be bled out of thepump manually.

In a negative suction application the pump shouldbe primed manually from an outside source orwith a vacuum pump.

The position of all suction and discharge valves inthe system should be noted. It is imperative thatthe suction valve be in the fully open position.


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Starting a Pump ContdStarting a Pump Contd When starting a pump good record keeping should

be maintained. It is a good practice to record all of

the following, where possible, for future reference:

Flow Pressure

Temperature of fluids

Temperature of bearings Pump vibration levels

Pump noise levels


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Looking for TroubleLooking for Trouble No discharge:

Pump not primed or suction closed.

Speed too low.

System head too high. Wrong rotation or impeller on backwards.

Air leak on the suction or through stuffing box.

Broken shaft. Insufficient minimum submergence, (vertical pumps)

Blockage in impeller.


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Looking for TroubleLooking for Trouble Insufficient Discharge:

Wear rings or impeller wear.

Insufficient NPSH.

Impeller installed backwards or wrong rotation. Suction valve not opened completely.

System head is too high.

Speed too low.

Blockage in impeller.


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Looking for TroubleLooking for Trouble

Insufficient Pressure: Speed too low.

System head less than anticipated.

Worn impellers or wear rings.

Impeller diameter smaller than specified.

Wrong rotation or impeller installed backwards. Blockage in impeller.


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Looking for TroubleLooking for Trouble Cavitation can be caused by many things. It

is the point of operation where entrained airis in the pump casing and air can damage

the innards of a pump. Examples of causes: Insufficient NPSH

Open system like a cooling tower with high

suction losses allowing a vortex or suction ofair into the pump.

Blockage in a closed loop system.


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ConclusionConclusion Proper installation and maintenance will

ensure long life performance of your pumpoperating system.

Proper record keeping will help youmaintain your pump and measure yourpumps performance.

Proper safety and maintenance are keys toyour pumps overall successful operation.

aurora pump maintenance

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