roto-jet© ro-ft pumps installation, operation ......this manual describes features, installation,...

Document Name: IOM-ROFT-EN Page | 1 Revision 1 Copyright © 2017, Weir Specialty Pumps, All rights reserved

Roto-Jet© RO-FT Pumps Installation, Operation & Maintenance Manual

Roto-Jet© is a registered trademark of Weir. Weir is the owner of the copyright and all confidential information in this document. The document may contain information that is private, confidential and/or privileged. The document must not be copied in whole or in part, in any form or by any means, and the information in it must not be disclosed to any person, or used for any purpose other than the specific purpose for which it has been provided, without the prior written consent of the company.

Excellent

Engineering

Solutions


Roto-Jet© RO-FT Pumps Installation, Operation & Maintenance Manual

Revision Page

Revision Description Reviewed Authorized Date

Rev 0 Initial Release Bryce Neilson Kelly Wardell 4-28-15

Rev 1 RO-FT-F Update Kelly Wardell 1-30-17

Excellent

Engineering

Solutions

Roto-Jet© RO-FT Pump


Table of Contents

1. Introduction .................................................................................................................................. 7

1.1 Scope of the Manual............................................................................................................................ 7

1.2 Intended Audience .............................................................................................................................. 7

1.3 Disclaimer ........................................................................................................................................... 7

1.4 Overview of the Manual ....................................................................................................................... 8

Table 1-1 manual organization ................................................................................................................ 8

1.5 Glossary of Abbreviations ................................................................................................................... 9

2. Safety ........................................................................................................................................... 10

2.1 Symbols ............................................................................................................................................ 10

2.2 Important Information ........................................................................................................................ 10

2.3 Operating Conditions ......................................................................................................................... 12

2.4 General Safety .................................................................................................................................. 12

2.5 Emergency Procedures ..................................................................................................................... 13

3. Technical Data ............................................................................................................................ 14

3.1 Pump Identification ............................................................................................................................ 14

3.1.1 Nameplates ................................................................................................................................ 15

3.1.2 Model Number Description ......................................................................................................... 16

3.2 Torque Tables ................................................................................................................................... 16

3.3 Oil Pans and Gear ratios ................................................................................................................... 18

3.4 Gear and Bearing Lubrication ............................................................................................................ 18

3.5 Materials ............................................................................................................................................ 19

3.6 Dimensional Drawings ....................................................................................................................... 20

3.7 Section Drawings .............................................................................................................................. 22

3.8 Seal Selection Information ................................................................................................................. 29

3.9 General Arrangement Drawings ........................................................................................................ 29

4. Description .................................................................................................................................. 32

4.1 Introduction to RO FT Pump .............................................................................................................. 32

4.2 Component Descriptions ................................................................................................................... 32

5. Transportation and Storage ...................................................................................................... 33

5.1 Transportation Requirements ............................................................................................................ 33

5.1.1 Pre transport Requirements........................................................................................................ 33

5.2 Storage.............................................................................................................................................. 33

5.2.1 Short Term Storage (up to 2 months) ......................................................................................... 33



5.2.2 Rotor Drain Process ........................................................................................................................ 34

5.2.3 Long Term Storage (up to 24 months) ........................................................................................ 35

5.3 Prior to Start-up ................................................................................................................................. 35

6. Installation .................................................................................................................................. 36

6.1 Installation Safety .............................................................................................................................. 36

6.2 Pump Working Envelope ................................................................................................................... 36

6.3 Foundations ...................................................................................................................................... 37

6.4 Grouting and Base Installation ........................................................................................................... 37

6.5 Alignment .......................................................................................................................................... 38

6.5.1 Alignment checks ....................................................................................................................... 39

6.5.2 Alignment measurement guidelines ............................................................................................ 39

6.5.3 Couplings ................................................................................................................................... 40

6.6 Piping ................................................................................................................................................ 40

6.6.1 Bolt Tightening Procedure .......................................................................................................... 41

6.7 Before Start Up .................................................................................................................................. 44

6.8 Guards .............................................................................................................................................. 44

6.9 Bypass/Filtration System ................................................................................................................... 45

6.9.1 Bypass System........................................................................................................................... 45

6.9.2 Filtration ..................................................................................................................................... 46

7. Commissioning .......................................................................................................................... 47

7.1 Safety ................................................................................................................................................ 47

7.2 Motor Setup ....................................................................................................................................... 48

7.3 Mechanical Seal & Support ............................................................................................................... 48

7.3.1 Control Devices .......................................................................................................................... 48

7.4 Commissioning Procedure................................................................................................................ 49

7.5 Commissioning Checklist .................................................................................................................. 50

8. Operation .................................................................................................................................... 51

8.1 Normal Start Up ................................................................................................................................. 51

8.3 Operating Checks .............................................................................................................................. 51

8.4 Pump Shutdown ................................................................................................................................ 51

9. Maintenance ................................................................................................................................ 52

9.1 Maintenance Check Points ................................................................................................................ 52

9.2 Vibration Monitoring........................................................................................................................... 53



9.3 Annual Inspection .............................................................................................................................. 54

10. Decommissioning ................................................................................................................... 55

10.1 Decommissioning Steps .................................................................................................................... 56

10.2 Disposal ............................................................................................................................................ 57

11. Troubleshooting ...................................................................................................................... 58

No liquid delivered at end delivery point or through flow meter ..................................................................... 58

Not enough liquid delivered at end delivery point or through flow meter ....................................................... 59

Not enough pressure on discharge pressure gauge ..................................................................................... 60

Liquid runs from drain hole ........................................................................................................................... 60

Pump overloads driver ................................................................................................................................. 61

Pump works for a while then quits ................................................................................................................ 61

Pump vibration ............................................................................................................................................. 62

Bearings overheat or wear rapidly ................................................................................................................ 63

Pump Noise ................................................................................................................................................. 63

12. Assembly/Disassembly .......................................................................................................... 64

12.1 General ................................................................................................................................................ 64

12.2 Recommended Tools & Parts ............................................................................................................... 64

12.3 Parts and Drawings .............................................................................................................................. 64

12.4 Balancing Procedure ............................................................................................................................ 64

12.5 Gears ................................................................................................................................................... 65

12.5.1 Gear installation ............................................................................................................................. 65

12.5.2 Gear Removal ............................................................................................................................... 66

12.6 Bearings ............................................................................................................................................... 67

12.6.1 Bearing installation ........................................................................................................................ 67

12.6.2 Bearing removal ............................................................................................................................ 68

12.6.3 Bearing Isolator Installation ............................................................................................................ 69

12.7 Seals .................................................................................................................................................... 70

12.7.1.1 Seal Removal ............................................................................................................................. 70

12.7.1.2 Seal Installation .......................................................................................................................... 70

12.7.2 Disengage Seal ............................................................................................................................. 71

12.7.3 Engage Seal .................................................................................................................................. 73

12.8 Pump assembly ................................................................................................................................. 75

12.8.1 Rotating assembly ......................................................................................................................... 83



12.8.2 Drive Shaft Assembly .................................................................................................................... 94

12.8.3 Attach Seal plate............................................................................................................................ 95

12.8.4 Attach Pitot tube to seal plate ........................................................................................................ 96

12.8.5 Attach Discharge Elbow ................................................................................................................. 97

12.8.6 Install suction spool ....................................................................................................................... 97

12.9 Pump Disassembly .............................................................................................................................. 98

12.9.1 Pitot Tube Replacement ................................................................................................................ 98

12.9.2 Remove suction spool ................................................................................................................. 100

12.9.3 Remove discharge elbow ............................................................................................................. 101

12.9.4 Detach Pitot tube from seal plate ................................................................................................. 102

12.9.5 Remove Seal plate ...................................................................................................................... 103

12.9.6 Disassemble/Assemble Rotating Assembly ................................................................................. 104

12.9.7 Suction/Discharge Shaft Removal ............................................................................................... 106

13. Parts ....................................................................................................................................... 107

13.1 Spare Parts ..................................................................................................................................... 107

13.2 Ordering Parts ................................................................................................................................. 109

14. Appendix ................................................................................................................................ 110

Appendix A Lifting Instructions ............................................................................................................ 110

Appendix B Transportation Tie Down Locations .................................................................................. 112



1. Introduction The IOM manual included in the shipment must be read thoroughly before installing or operating the pump. All instructions regarding maintenance must be retained for reference. The Roto-Jet© pump is a simple and reliable pump. The design, material and workmanship incorporated in the construction of Roto Jet© pumps makes them capable of giving long, trouble free service. The life and satisfactory service of any mechanical unit, however, is dependent upon correct application, proper installation, periodic inspection, and careful maintenance.

1.1 Scope of the Manual This manual describes features, installation, operation, and maintenance of the Roto-Jet© RO-FT pump.

1.2 Intended Audience This manual is intended for:

Trained Roto-Jet© pump service personal

Trained recipients with Weir equipment.

1.3 Disclaimer Contact your local Roto-Jet© pump representative for any assistance.

The manual provides basic information about the product. The product purchased may contain variations to this manual.

Operation conditions specified may vary from operating conditions from on site.

Illustrations shown in the manual are for reference only and may not match the specified product



1.4 Overview of the Manual Table 1-1 manual organization

Chapter Description

Introduction Introduction and development of the Roto-Jet© RO-FT pump

Safety Guidelines that must be adhered to while installing, operating and maintaining the pump.

Technical Data Technical data and features of the pump

Description Detailed features of the pump as well as component descriptions.

Transport and Storage Safety guidelines and procedures to follow while delivering the pump to a customer location, movement between locations and storing the pump.

Installation List of installation procedures and guidelines for installation

Commissioning Information on initial checks and settings to be done, before putting pump into operation.

Operation Information to pre- start up procedures, pump start up, problems that may occur during the pump start up, and shut down procedures.

Maintenance Lists of running and rebuild procedures

Decommissioning Guidelines regarding a pump out of service, and disposing or selling it.

Assembly/ Disassembly

Safety guidelines and procedures to be followed during assembly and disassembly. This section also contains outlined ways of proper assembly and disassembly instructions.

Troubleshooting Provides information to fix common pump issues

Tools List of tools required to rebuild pump. Other tools may be required.

Parts List of replacement parts and contact information.

Appendix Additional information



1.5 Glossary of Abbreviations

Abbreviations Description

NPSH Net Positive Suction Head

IOM Installation, Operation & Maintenance

MSDS Material Safety Data Sheets

GA General Arrangement

ISO International Organization and Standardization

COR Chain of Responsibility

MJT Multi Jack Tensioner



2. Safety The instructions in this chapter must be followed for safe and efficient operation.

2.1 Symbols

Signal Warning Description

DANGER Danger Indicates a hazard with a high level of risk which, if not avoided, could result in death or catastrophic equipment damage.

WARNING Warning Indicates a hazard with a medium level of risk which, if not adhered to could result in serious or moderate injury, or serious equipment damage.

CAUTION Caution Indicates a hazard with a low level of risk, which if not adhered to, could result in a moderate or minor injury or moderate equipment damage.

NOTICE Notice Indicates important information

2.2 Important Information

DANGER EXPLOSION

Prolonged operation with blocked suction and discharge could result in extreme heat being generated leading to vaporization of the entrapped liquid. This can result in a life threatening explosion.

DANGER VAPORIZATION

Personnel injury and equipment damage could result from the high temperature and pressures created if the pumping liquid vaporizes.

DANGER OVERPRESSURE IN PUMP

The system design must include suitable pressure relief measures and operation. Excess pressure may damage seals and may damage rotating assembly. Refer to name plate for pressure limits.

Running the pump with the discharge valve closed for a prolonged period produces heat and pressure builds up in the pump. The time between closing the valve and pump shut down must be minimized to reduce the risk of exceeding the pumps temperature and pressure limits.

Suitable pressure relief must be included in the suction pipe work.



DANGER PUMP ISOLATION

Never carry out maintenance work when the unit is connected to power. The pump must be fully isolated before any maintenance work, inspection or troubleshooting. Work includes any work on sections which are potentially pressurized (casing, seals, connected pipework) or involving work on the mechanical drive system (shaft, bearing assembly, and coupling).

Power to the electric motor must be isolated and tagged out.

Ensure that the intake and discharge openings are totally isolated from all potentially pressurized connections.

Remove all forms of energy

Depressurize seal reservoir (If applicable).

DANGER THERMAL SHOCK Do not feed very hot liquid into a cold pump or very cold liquid into a hot pump. Thermal shock may cause damage to the internal components and rupture the pump casing.

DANGER LIFTING DEVICE SAFETY

Use lifting devices to lift heavy or awkward components.

The lifting devices must be in good condition, certified and tagged.

The lifting devices must be of adequate capacity and must be used whenever they are required.

Personnel must never work under suspended loads.

Trained personnel should perform lifting procedures.

DANGER LIFTING POINT SAFETY

Refer to Roto-Jet© pump instructions at all times.

Tapped holes (for eye-bolts) and cast-on lugs (for shackles) on Roto-Jet© pump parts are for lifting individual parts only.

Some heavy parts of the pump have threaded holes for lifting. During assembly, eye bolts are screwed into holes to engage the crane.

DANGER ROTOR INSPECTION

Rotors should be checked for any signs of wear or cracking during routine maintenance.

Rotating assembly should be checked for balance during maintenance.

Rotation of assembly at high speeds can cause cracks and ultimately failure.

DANGER TOXIC VAPORS FROM SEAL Vapors leak past seals. Appropriate risk assessment must be made regarding the nature of the product in the pump and necessary safety precautions put in place to protect from exposure to product vapors.



2.3 Operating Conditions See pump name plates for pump operating limits. If the operating range is outside this contact your local Roto-Jet© pump representative for further information.

WARNING FAILURE DUE TO OPERATING CONDITIONS If the pump is operated outside the recommended temperature range it may cause mechanical failure leading to safety issues.

NOTICE OPERATING RANGES FOR MATERIALS Contact your local Roto-Jet© pump representative for further information on the operating temperature ranges of alloys and elastomers.

2.4 General Safety Legal requirements and local regulations may differ substantially with regard to particular safety

requirements and may be regularly modified by relevant authorities without notice. As a consequence, applicable laws and regulations must be consulted to ensure compliance. The following cannot be guaranteed for its completeness or continuing accuracy.

These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations. It is the responsibility of the purchaser of the product to ensure such regulations are observed by all, including those installing the product. Always coordinate repair activities with operations personnel and follow all plant safety requirements, applicable workplace health and safety laws and regulations.

These instructions must be read prior to installing, operating, using and maintaining the equipment in

any region, worldwide. The equipment must not be put into service, until as a minimum, all the conditions relating to workplace health and safety in the instructions, are met. Information in these user instructions is believed to be reliable. In spite of all the efforts to provide correct and necessary information, the content of this manual may appear insufficient and is not guaranteed as to its completeness or accuracy.

If pump has been in operation, drain the pump and isolate pipework before dismantling the pump. The

appropriate workplace health and safety precautions must be taken where the pumped liquids are hazardous. Mixing of new and worn pump components may increase the incidence of premature pump wear and leakage. All metal mating faces must be cleaned of dirt, rust, paint and other adhering substances prior to pump assembly. Failure to clean parts can affect pump assembly and running clearances and could lead to catastrophic failure of parts.

Avoid contamination:

Burning of elastomer pump components causes emission of toxic fumes and results in air pollution which leads to personnel injury/illness.

Leakage in excess of the seal lubrication requirements from shaft seals and/or leakage from worn pump components or seals, causes water and/or soil contamination.

Liquid waste disposal from servicing of pumps or stagnant water from pumps stored for long periods, causes water and/or soil contamination.



CAUTION SHARP EDGES

Worn pump components can have sharp or jagged edges. When handling worn parts, care must be taken to prevent damage to slings or personnel injury. Assess the components before moving or lifting and use mechanical devices wherever possible.

Extra precaution should be taken when handling the Pitot tube. The edges can be very sharp. Protective gloves should be worn when handling the Pitot tube.

WARNING ROTATING PARTS Personnel injury or illness may result from contact with rotating parts, seal leakage or spray from the rotating shaft.

2.5 Emergency Procedures A number of possible emissions or leakage of hazardous substances may be possible depending of the product being pumped. Ensure you are familiar with site and local procedures and requirements.

NOTICE MSDS Always refer to MSDS of substance before handling.



3. Technical Data This section describes the following,

Nameplate information

Model numbering

Torque tables

Materials of Construction

Pump dimensional drawings

Seal selections

Pump sectional drawings

Pump operating Limits

3.1 Pump Identification

Label List

Item Description Quantity Item #

Nametag #1 Part 1 of machine Description 1 167

Nametag #2 Part 2 of Machine Description 1 167

Motor Rotation Check Motor Rotation 2 171

Check Seals Remove seal tabs before startup 2 177

Rotation direction Pump rotation 1 176

Alignment Align shaft before startup 1 172

Oil Level Double check proper oil level is in place 1 146

Oil Nameplate On side of case to indicate oil level 1 174

Abrasive Pumping Recommended fluid to pump 1 173

Patent Information Indicates patents on pump 1 175



3.1.1 Nameplates Below is a detailed description of the Roto-Jet© RO-FT pump nameplates

Nameplate Label Description Model Indicates pump model from factory

PUT Indicates pitot tube size

Serial No. Serial number generated from factory, used for locating parts

Capacity Flow output at rated point.

S.G. Rated Specific gravity

Head Head development at rated capacity

Speed Rated speed of rotating assembly, not the speed of the input shaft

Gear Ratio Installed gear ratio from drive shaft to rotating assembly

Date Mfg Date pump was built. Used for warranty

Item No. Number from customer indicating pump

Rot Hydro Test Pressure Hydrostatic test pressure rating of the rotating assembly.

Rotor Bearings Part number for angular contact bearings on the rotating assembly

Input Thrust Brg. Part number for the input shaft angular contact bearings

Input Roller Brg. Part number for the input shaft cylindrical roller bearing

Seal Seal manufacturer and cartridge size

Suction MAWP Suction maximum allowable working pressure for the suction portion

Discharge MAWP Discharge maximum allowable working pressure for the discharge portion of pump.



3.1.2 Model Number Description

RO-FT16-1 RO-FT-------Pump Model 16-------------Rotor Size (in) 1---------------Seal Type

-1 Industrial cartridge seals. -2 API 682 cartridge seals

3.2 Torque Tables

General Torque Table 75% Proof Strength

Size Type

B8M SAE Grade 5 B7

Diameter in Inches

Threads Per Inch

mm Ft/lbs N/m Ft/lbs N/m Ft/lbs N/m

1/4 20 6.350 6 8.1 9 12.2 9 12.2

3/8 16 9.525 19 25.8 31 42 31 42

1/2 13 12.700 45 61 75 101.7 75 101.7

5/8 11 15.875 93 126.1 150 203.4 150 203.4

3/4 10 19.050 150 203.4 250 229.0 250 229.0

7/8 9 22.225 202 273.9 378 512.5 378 512.5

1 8 25.400 300 406.7 583 790.4 583 790.4

1 1/8 7 28.575 474 642.7 782 1060.2 782 1060.2

1 1/4 7 31.750 659 893.5 1097 1487.3 1097 1487.3

NOTICE ANTI- SEIZE COMPOUND Use anti-seize compound when assembling all fasteners.



Critical Torque Table Part/ Location Bolting Torque Ft/lbs N/m

Input Shaft Locking Nut

Item # 431

175 237

Rotating Assembly Locking Nut Item # 110

400 542

Rotor Bolts Item # 207

150 271

MJT Tensioner Bolts Item # 142

75 101

Rotor Cover Drain Plug Item # 221

13 17.6



NOTICE TORQUE PROCEDURE

Torque procedures should always be performed with a properly calibrated torque wrench.

Torque procedure should be followed as per torque wrench manufacturer.

The use of air tools should never be used with the assembly of critical torque bolts.

3.3 Oil Pans and Gear ratios

Gear Ratio Components

Gear Ratio Oil Level Tag PN Oil Pan PN Oiler Ring PN Drive Shaft

Tooth Count

0.807 0667638-1 0667308-1 0667275-1 75

0.931 0667638-1 0667308-1 0667275-1 81

1.000 0667638-1 0667308-1 0667275-1 84

1.074 0667638-1 0667308-1 0667275-1 87

1.154 0667638-1 0667308-1 0667275-1 90

1.240 0667638-1 0667308-1 0667275-1 93

1.333 0667638-2 0667309-01 0667275-2 96

1.435 0667638-2 0667309-01 0667275-2 99

1.545 0667638-2 0667309-01 0667275-2 102

1.666 0667638-2 0667309-01 0667275-2 105

1.8 0667638-3 0667310-01 0667275-3 108

2 0667638-3 0667310-01 0667275-3 112

The oil gauge max and minimum value is set according to the Oil Level Tag.

3.4 Gear and Bearing Lubrication This section will describe proper gear and bearing limits as well as requirements.

DANGER FIRE HAZARD

Bearing assemblies may catch fire if bearings are not lubricated.

CAUTION OVER FILLING OIL The pump must be stopped to check the oil level. Over-filling will cause oil to drain out of gear case.



The recommended lubricant for the Roto-Jet© RO-FT pump is per Roto-Jet© pump spec. MP 830 (Mobil SCH 630). This oil is intended to be used with gear drives. The physical and chemical characteristics are shown below. It is formulated from synthesized hydrocarbons based fluids combined with additives to provide enhanced oxidation stability, corrosion protection, and gear load carrying capacity. Other oils can be used if they meet the ISO VG 220 oil specification, however Weir recommends consulting factory if other oils are used. Do not use oils that have detergents as it will cause excessive foaming and may damage the pump.

Characteristic Mobil SCH 630

Gravity, API 34.4

Specific Gravity 60°F (15.6°C) .853

Pour Point -50°F (-45°C)

Flash Point 460°F (238°C)

Viscosity cSt at 40°C cSt at 100°C SUS at 100°F SUS at 210°F

220 26.4 1137 130

Viscosity Index 145

Color, ASTM L 1.0

ISO Viscosity Grade 220

Copper corrosion ASTM D 120 24h at 212°F (100°C)

2A

Change Frequency 3000 hours or 6 Months

NOTICE CHECK OIL

Be sure to check oil level weekly when the unit is not running

Add oil through the Gear Observation plug

3.5 Materials

Materials of Construction S5 S6 S8 C6 A8 D1

Rotor Carbon Steel (A216 WCB)

12% CR (A743 CA6NM)

316 AUS (A351 CF3M)

Duplex (A351 CD4MCu)

Flanges Carbon Steel (A216 WCB)

12% CR (A743 CA6NM)

316 AUS (A351 CF3M)


Shaft Assembly Carbon Steel (A193 4140)

12% CR (A743 CA6NM)

316 AUS (A351 CF3M)


Input Shaft 4140 Carbon Steel (A193)

Pitot Tube 17-4-PH* Stainless Steel (A564) or Inconel* (718)

Gearbox Casing Carbon Steel (A216 WCB)



3.6 Dimensional Drawings

Side View

Front View



Top View

Bottom View



3.7 Section Drawings

Pump Assembly


Item No.

Pump Assembly

100 CASE ASSY

101 O-RING CORD

102 PIPE PLUG

103 NUT, HEX

104 SEAL PLATE,DISCHARGE

105 SEAL PLATE,SUCTION

106 BEARING CAP,ROTATING ASSY

107 EYE BOLT, GEAR CASE

108 BRG ISOLATOR,ROTATING ASSY

109 LOCKWASHER,BEARING

110 LOCKNUT, BEARING

111 SPACER,BRG,DISCHARGE

112 SET SCREW

114 WAVE SPRING

115 O-RING, DRV SHFT BRG CAP

118 DISCHARGE ELBOW,

119 SPACER, BRG SUCTION SHFT

120 SUCTION SPOOL

121 PIPE PLUG,SUCTION SPOOL

122 GASKET, SUCTION SPOOL

123 STUD, SEAL PLATE SUCTION

124 LOCK WASHER,BRG CAP ROT ASSY

125 SCREW,BRG CAP ROT ASSY

126 PIPE PLUG, DISCH ELBOW

127 STUD,SEAL PLATE DISCHARGE

128 CASE,UPPER MACH

129 CASE,LOWER MACH

130 LOCATING PIN,TAPER

131 STUD,CASE ASSY

132 NUT,CASE ASSY

134 PIPE PLUG, CASE

135 O-RING,PUT,DISCHARGE ELBOW

136 NUT,DISCH ELB & SUCT SPOOL

137 STUD,DISCHARGE ELBOW

138 BREATHER,CASE

139 PITOT TUBE

141 SIGHT GLASS, OIL SUMP

142 NUT,TENSIONER

143 O-RING,PUT,DISCH SEAL PLATE

144 STUD,SUCT SPOOL

145 DOWELL PIN, PUT

146 NAMEPLATE, OIL LEVEL

148 PIPE PLUG, TRICO PORT

149 SCREW,CASE FOOT

150 PIPE DRAIN

151 OIL PAN

154 PLANGE, PIPE

155 SPACER,BRG OUTER RACE

156 O-RING,BRG CAP

157 STUD, LONG CASE ASSY

158 SEAL SPACER

159 BALL BEARING

160 SPACER, BRG GEAR DISCH SHFT

161 O-RING, SEAL SPACER

162 KEY,GEAR DRIVEN

164 GUARD, SEAL CHAMBER, SUCT

165 GUARD, SEAL CHAMBER, DISCH

166 SCREW,GUARD

167 NAMEPLATE, PUMP

168 DRIVE SCREW

169 BREATHER, ROTOR CASE

170 BUSHING, REDUCER

171 MOTOR ROTATION TAG

172 ALIGNMENT TAG

173 ABRASIVE WARNING TAG

174 OIL LEVEL TAG

175 PATENT NAMEPLATE

176 ROTATION ARROW LABEL

177 SEAL TAB TAG



Item No.

Drive Assembly

407 BEARING CAP, DRIVE SHAFT

408 O-RING, SPACER

410 KEY, GEAR

411 SHIM- BRG .005”

412 SHIM- BRG .015”

413 SPACER, GEAR

416 DRIVE SHAFT

417 SCREW, BRG CAP

420 BEARING ISOLATOR

421 GEAR & PINION SET

428 BEARING, ANG CNT

429 SPACER,BRG LONG

430 LOCKWASHER, BEARING

431 LOCKNUT, BEARING

435 BEARING,GEAR

457 KEY, DRIVE SHAFT

Item No.

Rotating Assembly

201 ROTOR

202 O-RING, ROTOR

203 ROTOR COVER

204 STUD,ROTOR COVER

205 SUCTION SHAFT

206 DISCHARGE SHAFT

207 SCREW,ROTOR COVER

208 O-RING SUCT/DISCH SHFT

209 OILER RING

211 NUT,HEX

212 O-RING, WSP SEAL SHAFT

213 STUD,ROTOR

220 FLINGER, SUCTION SHAFT

221 DRAIN PLUG,RTR CVR

222 SET SCREW

Item No.

Industrial Seal Assembly

301 SEAL HOUSING,INNER

302 SEAL HOUSING,OUTER

303 SHAFT,EXTENSION

304 O-RING, HOUSING

305 O-RING.SEAL

306 MECHANICAL SEAL

307 SPACER DBL SEAL

308 ANTI ROTATION PIN

309 O-RING, SHAFT EXT ID

310 SNAP RING

311 O-RING,SEAL MATING RING

312 SEAL MATING RING

313 SEAL CLIPS

314 SCREW,SEAL CLIPS

315 SET SCREW

316 SCREW,SEAL HOUSING

317 MECHANICAL SEAL, NDE

318 ANTI ROTATION PIN

324 NUT, SEAL MOUNTING

325 BOLT, SEAL MOUNTING


Rotating Assembly

Drive Assembly



Case Assembly



Industrial Seal Assembly

Seal Plate Assembly



Pump Section

Pump Side View



Pump Front View

3.8 Seal Selection Information See seal manufacturer O&M for specific seal information

3.9 General Arrangement Drawings



Typical Arrangement



4. Description This section provides Features of the Roto-Jet© RO-FT pump Component Descriptions

4.1 Introduction to RO FT Pump The features of the Roto-Jet© RO-FT pump are:

Interchangeable Pitot Tubes

Cartridge Seals

Low flow High head capabilities

Low NPSH capabilities

A selection of many material types

A robust frame

Stable operation over pump curve

4.2 Component Descriptions The Roto-Jet© RO-FT pump is built with for the most part, very similar parts, components and features. However there are some important features between different pump models and configurations. These include the rotating assembly shaft, oil pans, gears, and material differences. Gear Differences

The Roto-Jet© RO-FT pump is an integral geared pump. Different gear ratios are required to accomplish different speeds. Pump speed is always referring to pump rotor speed. Different sized oil pans and oiler rings are required to accommodate different gear sizes. Material Differences Different materials are required for different speeds, pressures, fluid compatibility. Always consult factory for proper material selection. Suction/Discharge Shafts Difference Shafts are identical except for the length. Below is a visual difference between each.

Factory Cartridge Seal Shaft RO-FT16-1

API 682 90mm Cartridge Seal Shaft RO-FT16-2


5. Transportation and Storage

5.1 Transportation Requirements The tie-down instructions indicate the points on the pump and pump baseplate that are safe to use as tie-down points for the bare shaft pump. The other tie-down instructions specific to different regions may be found in Appendix, B if applicable. See APPENDIX B TRANSPORTATION TIE DOWN Locations

DANGER LIFTING POINT FAILURE No other points on the pump or pump baseplate must be used other than those indicated in the tie-down instructions. If other lifting points are used they may be damaged which can lead to a dropped load.

5.1.1 Pre transport Requirements

NOTICE PRE-TRANSPORTATION ACTION

In order for the pump mechanical seals to maintain integrity and before pump can be transported, the seal tabs need to in place as well as disengaging the set screws before transporting the pump.

See seal manufacturers recommendations for additional seal transport requirements.

See seal manufacturer for location and installation of seals. Seal tabs and set screws will vary manufacturer to manufacturer.

WARNING PERSONNEL INJURY WHILE LASHING/UNLASHING The use of over-center load chain binders (dogs) results in the release of the stored energy in the load restraint tools while unlashing. This can cause personnel injury.

5.2 Storage

NOTICE PUMP STORAGE It is possible for operational and storage problems to arise due to environmental conditions the pump is subjected to. These problems must be corrected at the owner’s expense prior to operation. Weir will accept no responsibility for these problems. These provisions are applicable to Roto-Jet© pump proprietary items only. For the appropriate storage procedures for non-Roto-Jet© pump items refer to specific requirements from the manufacturer.

5.2.1 Short Term Storage (up to 2 months) Weir recommends draining the oil filled assemblies; every two weeks remove the Case Cover and

spray the bearings with a light coat of oil ISO VG 220 oil. This procedure helps to prevent the following two risks: Environmental damage from leaking oil, and Corrosion

Protect all exposed, unpainted surfaces from rust.

Plug the ports. If the assembly is stored in an open area with major temperature fluctuations, it is preferable to install a desiccant breather instead of one plug. If the stand-by assemblies/pumps are idle for long periods, it is advisable to turn their shafts a quarter turn by hand, once in a week. In this way, all the bearing rollers are made to carry static loads and external vibration.

Do not store spare bearing or rotating assemblies near vibration or in a damp area.



5.2.2 Rotor Drain Process 1. Isolate Machinery see 10.1 DECOMMISSIONING STEPS 2. Remove the lower drain plug (Item# 134) in gear case.

3. Rotate the pump until one of the rotor cover drain plugs (Item# 221) line up with the hole in the gear

case.

4. Remove the rotor cover drain plug and allow the liquid to completely drain out. 5. Inspect and replace if necessary the O-ring on the drain plug. 6. Reinstall the rotor cover drain plug in the rotor cover. Torque to as required see 3.2 TORQUE

TABLES 7. Reinstall the plug in the gear case.

Seal Storage 8. When storing seals for extended periods of time, be sure to drain internal fluids and keep seals dry. By

keeping seals dry it will keep freezing and crystallization from occurring on the seal faces.

WARNING HAZARDOUS CHEMICALS During disassembly, personnel may come in contact with hazardous chemicals from process. These chemicals must be identified before disassembly, and the correct MSDS must be made available and appropriate safety management precautions put in place.



5.2.3 Long Term Storage (up to 24 months) Long term storage should be in conjunction with short term storage. To store and safely keep the new and stand-by pumps for long-term:

Limit the long-term storage to a maximum of 24 months. Do not stack other pieces of equipment on top of the pumps. Touch up any scratches in paint before storage. Flush and clean the pumps with clean water or desiccant when you remove a pump from service,

for storage to eliminate rust. Follow the motor manufacturer’s instructions for storage.

CAUTION WINTERIZATION To prevent pump from freezing during cold weather, liquid in the rotor assembly must be drained. Failure to remove the liquid during freezing temperatures could result in severe damage to the pump.

5.3 Prior to Start-up Follow commissioning instructions

NOTICE

WARRANTY REQUIREMENT A report must be submitted stating that the storage procedures listed in this section are carried out on a monthly basis. Failure to follow this will void the warranty issued by Weir

NOTICE NON ROTO-JET© PUMP ITEMS These provisions are applicable to Roto-Jet© pump proprietary items only. For the appropriate storage procedures for non Roto-Jet© pump items, refer to specific requirements from the manufacturer.



6. Installation This section describes the:

Factors that affect the installation of the pump

Pre-start procedures

6.1 Installation Safety


Some heavy parts of the pump have threaded holes for lifting. During assembly, eye bolts are screwed into holes to engage the crane. See APPENDIX A LIFTING

INSTRUCTIONS for lifting locations.

WARNING TIPPING OR FALLING

The pump can tip over or fall, if the lifting points are offset from the recommended lifting points.

6.2 Pump Working Envelope The working envelope is a safe working environment for replacing of parts or working on the pump assembly. Recommended X= 6 feet.



6.3 Foundations Installing the pump on adequate foundations provides efficient pump service. Ensure that:

1. The steel and concrete foundations meet local geological requirements. 2. The steel and concrete foundations are designed to withstand all loads from the pump and motor, and

to absorb any vibrations. 3. All hold down bolts are fully tightened. 4. The pump is located such that the straight length of the intake pipe is at least 10 pipe diameters. 5. Adequate space is available to access the pump for installation and disassembly procedures.

A properly mounted base on a rigid foundation is essential for a smooth running pump. The foundation should minimally be a 4” (100 mm) thick concrete slab floor or an 8” (200 mm) thick concrete pad, extending two inches larger in width and length than the pump or unit, and should be steel reinforced according to local building codes.

6.4 Grouting and Base Installation The pump and drive assembly should be placed on the foundation with the coupling halves disconnected. The alignment operation must be completed before the coupling is reassembled. The baseplate should be supported on metal wedges or blocks. The support wedges, or blocks, should be placed close to the anchor bolts.

Fig 6.4A Leveling shims/wedges

Level base with leveling bolts (if provided). Insert metal wedges, or blocks, around base edge near anchor bolts as shown in fig 6.4A. Then suction flanges, discharge flanges and coupling faces should be checked by means of a level. Corrections may be made for flange or coupling level or plumb by shims under the pump or motor.



Fig 6.4B Typical Base Installation

6.5 Alignment

DANGER LOCK OUT PROCEDURE

When checking alignment or performing any work on the pump or additional components,

electrical service must be locked out with an approved lockout and key. Failure to lockout

equipment could result death or serious injury



The pump and driver, if supplied, were not aligned at the factory since the unit can shift during shipment. Couplings are disconnected for shipment. The pump and driver shafts must be checked for angular and parallel alignment. (Realignment is also necessary after the grout has hardened and anchor bolts have been tightened.) The alignment must be finally checked after the piping has been completed and rechecked periodically. Inaccurate alignment results in vibration and excessive wear on bearings, shaft sleeves or mechanical seals.

6.5.1 Alignment checks

Type of check When it is used Initial alignment (cold alignment) check

Prior to operation when the pump and the driver are at ambient temperature.

Final alignment (hot alignment) check

After operation when the pump and the driver are at operating temperature.

Initial alignment (cold alignment) checks

When Why Before baseplate grout This ensures that alignment can be accomplished

After baseplate grout This ensures no changes have occurred during the grouting process

After piping connection This ensures that pipe strains have not altered the alignment. If changes have occurs, you must support or alter the piping to remove pipe strains on the pump flanges.

Final alignment (hot alignment) checks

When Why

After first run This ensures correct alignment when both the pump and the driver are at operating temperature.

Periodically This follows the plant operating procedure

6.5.2 Alignment measurement guidelines

Guideline Explanation Rotate the pump coupling half and the driver coupling half together so that the alignment tool has contact with the same points on the driver coupling half

This prevents incorrect measurement

Move or shim only the driver in order to make the adjustments

This prevents strain on the piping installations

Make sure that the hold-down bolts for the driver feet are tight when you take alignment tool measurements

This keeps the driver stationary since the movement causes incorrect measurement.

Make sure that the hold-down bolts for the driver feet are loose before you make alignment corrections

This makes it possible to move the driver when you make alignment corrections.

Check the alignment again after any mechanical adjustments

This corrects any misalignments that an adjustment may have caused



6.5.3 Couplings Flexible couplings are not intended to permit permanent misalignment. Even slight misalignment will reduce bearing life and cause other problems. Flexible couplings do permit some temporary slight change in alignment or end play to allow for unusual momentary loads or thermal expansion during start-up. The coupling should be installed and aligned according to the manufacturer’s recommendations. The dimensions and tolerances listed below apply only to the couplings furnished by Weir.

NOTICE ALIGNMENT VALUES The specified values are valid only at operating temperature. For cold settings, other values are permitted. You must use correct tolerances. Failure to do so can result in misalignment and reduce pump reliability

Coupling Coupling

Size

Gap

Min

Gap Max Concentricity

Total

Concentricity max

center-line

Face

Parallelism

Thomas

Series 71

225 5 5 1/16 .005” .0025” .005”

6.6 Piping This section describes basic pipe fitting and guidelines

CAUTION INTAKE PIPEWORK

Suitable isolation or valves must be fitted in the intake pipe as near to the pump as possible.

The intake pipe must be a minimum of 10 straight pipe diameters.

CAUTION AIRTIGHTNESS OF PIPEWORK

When the bore of the intake pipe is increased to a size larger than that of the pump intake branch, the form of taper pipe used must not allow the formation of air pockets.

To avoid air pockets, the installation of intake pipework must be arranged with as few bends as possible and the pipework must be completely airtight.

The inlet piping should slope upward to the pump. A horizontal suction line must have a gradual rise to the pump. Any high point in the piping will become filled with air and thus prevent proper operation of the pump. When reducing the piping to the inlet opening diameter, use an eccentric reducer with the eccentric side down (Figure 6-8). Never use a straight taper (concentric) (Figure 6-7) reducer in a horizontal suction line, as it tends to form an air pocket in the top of the reducer and the pipe.



All pipe work must be correctly aligned and independently supported; pump flanges should not be

overloaded. Pipe work restraints must be saddles, rather than stands, such that axial and radial movement can be restrained.

Area must be kept clean to ensure safe working environment and effective use of pump set.

Never tamper with pump construction.

Apply grease, anti-seize, or denso tape for bolts to allow easier removal when required.

6.6.1 Bolt Tightening Procedure Always use cross pattern (180 degrees) for tightening bolts, for even pressure. Repeat sequence two-three times. Use calibrated torque wrench for correct tension. See 3.2 TORQUE TABLES



The Roto-Jet© RO-FT pump has many different configurations of the discharge elbow to allow for different set up configurations.

NOTICE LOADS AND MOMENTS

Allowable loads and moments take into consideration the effects of casing distortion and shaft misalignments.

External loads acting on the pump must be less than the allowable. To minimize pipe strain as much as possible.

Ensure that pipes are aligned with the pump flanges and supported independent of the pump and as close to the pump as practical.



Nozzle Loadings Per API 610 11th edition

Location/ Orientation

Nozzle- loading force as a function of flange size

Force Lbf (N)

Discharge Flange Suction Flange Each Side Nozzle

FX 160 (710) 240 (1070)

FY 200 (890) 300 (1330)

FZ 130 (580) 200(890)

FR 290 (1280) 430(1930)

Moment ft-lbf (Nm)

ft*lbs

Each Nozzle

MX 340 (460) 700 (950)

MY 170 (230) 350 (470)

MZ 260 (350) 530 (720)

MR 460 (620) 950 (1280)



6.7 Before Start Up The following procedures should be used when starting a new unit for the first time or after major maintenance has been performed.

1. Be sure that all installation requirements have been met and that the system has been designed to keep the pump within its operating limits.

2. Rotate unit by hand to be sure that it turns freely. Or shaft wrench and follow safety. 3. Jog driver; check rotation. See 7.2 MOTOR SETUP 4. Be sure pump and drivers are within allowed alignment limits. See 6.5 ALIGNMENT 5. Check for proper lubrication. See 3.4 GEAR AND BEARING LUBRICATION

6. Be sure seals are properly engaged see 12.7.3 ENGAGE SEAL 7. Close discharge valve. (This should be done to reduce the load on the driver during start-up and to

provide a restriction.) 8. If equipped with seal flush, be sure all flush inlet valves are open so that liquid can get to the seal. 9. Be sure all guards are installed see 6.8 GUARDS 10. Prime pump. The Roto-Jet© pump is not a self-priming pump and may be damaged if run dry. It must

always be filled completely with liquid before starting. a. Be sure all valves in the suction line are fully open. b. If the pump is installed with a positive head on the suction, prime by opening the inlet valve

while venting air out of discharge line. c. If equipped with charge pump, prime by starting charge pump while venting the discharge line

until all air is out of the rotor.

DANGER VALVE PROCEDURE

Never operate pump with closed suction valve. On startup, start with closed discharge valve and open slowly to desired head requirement. Do not run pump for an extended period of time with the discharge valve closed.

6.8 Guards

DANGER GUARDS All guards and protective devices must be installed before the pump is started. Contact with unguarded components could result in serious injury

The Roto-Jet© RO-FT pump has guards (Item# 164, 165) in place to protect the user from bodily harm. Below is a picture of the guards on the package assembly.



Seal Guards

6.9 Bypass/Filtration System This section will describe required procedure for pump bypass information and process filtration.

6.9.1 Bypass System Like other centrifugal type pumps, the Roto-Jet© RO-FT Pump loses a certain amount of power in churning the fluid within the pump. This lost power is converted to heat. If the pump is operated at or near shut-off (no flow), the temperature of the fluid within the pump will rise to unacceptable levels, and could cause seal failure or damage and possible injury. If the possibility of no flow condition exists it is necessary to have a fluid bypass to remove this heat and insure adequate seal cooling. The minimum recommended bypass flow should be approximately 10% of the peak efficiency flow of the pump. Listed below are applicable bypass orifice sizes which will meet the bypass flow requirement of the Roto-Jet© pump selected:

Model Orifice Size

RO-FT16 D266 3/32”

RO-FT16 D375 3/32”

RO-FT16 D484 1/8”

RO-FT16 D600 5/32”

We recommend that ½” minimum (13 mm) bypass line be installed (tee-in) with or without pressure relief in the discharge line of the pump, between the pump and the discharge valve. The bypass line should be piped back to the suction reservoir, or to a disposal.

CAUTION BYPASS PIPING

Never pipe the bypass line directly into the intake or suction line of the pump

A vortex breaker, screen, and/or baffle may be required if tank is small or the bypass return line is too close to the pump suction line.



6.9.2 Filtration As a minimum recommendation, install a 100 Mesh (149 Micron) strainer or equivalent filtration device in the suction piping adjacent to the pump to prevent mill scale, rust and other foreign material from damaging the pump.

CAUTION WATER QUALITY PROBLEMS The Roto-Jet© pump is not designed to pump abrasives and is not warranted against damage or wear. It will normally operate satisfactory with up to 100 PPM suspended solids, but wear will depend on the particle size and hardness. Consult factory for filtration and special parts recommendations if this level is exceeded.



7. Commissioning

7.1 Safety

DANGER PERSONAL INJURY

Do not stand near an operating pump during commissioning as pump components or piping may fail during this period

DANGER EXPLOSION Excess loading from the discharge or suction pipe on the pump casing may crack the casting. Pump component exposed to freezing or over pressurization may waken components causing failure.

WARNING HOT SURFACES Pump bearing assembly becomes hot during operation. Do not touch bearing assembly surfaces without taking appropriate precautions to protect against personal injury.

CAUTION THERMAL SHOCK Be aware that thermal shock may damage pump components during priming

CAUTION FLANGE DAMAGE Over torqueing of the flange bolts may cause flange damage and or failure

CAUTION VIBRATION Components may become loose under excessive vibration. Ensure tensioning and locking procedures are followed.

CAUTION PITOT TUBE MJT Check to be sure pitot tube is secured and held in place. Pitot tube MJT needs to be properly torqued. See 3.2 TORQUE TABLES



7.2 Motor Setup Check drive rotation by jogging driver before shaft couplings are connected. The correct pump rotation is indicated by an arrow on the pump casing.

WARNING PERSONAL INJURY Do not touch the rotation elements with hands to establish the direction of rotation.

DANGER PUMP ROTATION DIRECTION

Rotation in the opposite direction indicated by the arrow on the pump could unload bearings and cause premature failure

Head development will be about half required when pump if run in reverse

Rotation of the drive shaft should be counter clockwise if looking down the drive shaft from the coupling end

Perform the following test, before operating the pump after any maintenance. This is to ensure that the direction of rotation of the pump is correct.

1. Isolate the drive unit from the power supply. 2. Remove the coupling guarding. 3. Remove the couplings. 4. Replace the coupling guarding. 5. Reconnect the drive unit to the power supply. 6. Jog motor and check direction. 8. Isolate the drive unit from the power supply. 9. Remove the coupling guarding. 10. Replace the couplings and align them. 11. Replace the coupling guarding. 12. Reconnect drive unit to the power supply.

7.3 Mechanical Seal & Support

CAUTION MECHANICAL SEAL TABS

Ensure that the grub screws are tight before removing the setting tabs.

Always remove the mechanical seal setting tabs prior to starting the pump.

Failure to remove the tabs will result in damage to both the pump and the seal.

Always refer to seal manufacturer and follow manufactures recommendations for seal support systems and control device setup.

7.3.1 Control Devices See seal support documentation for exact manufacturer recommendations.



7.4 Commissioning Procedure 1. Ensure seals are engaged see 12.7.3 ENGAGE SEAL 2. Ensure seal support systems are operational and within operating parameters 3. Priming the pump

Open the inlet valve and allow the pump to flood, or start charge pump if equipped to, bleed off air in system

4. Close the discharge valve before start-up, and then open slowly. 5. Turn the pump ON

a. Check whether pump starts correctly and runs smoothly b. If faults occur, Refer to 11. TROUBLESHOOTING

DANGER OVERPRESSURE IN PUMP

The system design must include suitable pressure relief measures and operation. Excess pressure may damage seals and may damage rotating assembly. Refer to name plate for pressure limits.

Running the pump with the discharge valve closed (while necessary at shut down) produces heat and pressure builds up in the pump. The time between closing the valve and pump shut down must be minimized to reduce the risk of exceeding the pumps temperature and pressure limits.

Suitable pressure relief must be included in the suction pipe work.

6. Monitor performance Check operating parameters are within limits

7. Turn the pump OFF a. Turn OFF pump and allow to completely stop. b. Close the Discharge valve c. Turn OFF seal supply, if applicable



7.5 Commissioning Checklist

Checks Reference Notes

Unit Storage 5.2 STORAGE

Foundation 6.3 FOUNDATIONS

Tighten Fasteners 3.2 TORQUE TABLES

Grout Base 6.4 GROUTING AND BASE

Piping 6.6 PIPING

Motor Rotation 7.2 MOTOR SETUP

Seal Engagement 12.7.3 ENGAGE SEAL

Pre-Startup 6.7 BEFORE START UP

Alignment 6.5 ALIGNMENT

Prime 7.4 COMMISSIONING PROCEDURE

Seal Support 7.3 MECHANICAL SEAL & SUPPORT

Guards 6.8 GUARDS

Bypass/Filtration 6.9 BYPASS/FILTRATION SYSTEM

Startup- Procedure 8.1 NORMAL START UP



8. Operation

8.1 Normal Start Up

1. Check once more that all bolts are tight and that the rotor turns freely for normal run. 2. Be sure seals are engaged and support system is functioning. 3. Open intake valve and check that process is available at the inlet. 4. If a discharge valve is installed, it is common practice to close it or slightly open for start-up. This is

however mandatory only in some cases, where the motor could overload.

DANGER

EXCESS HEAT If the discharge is left closed, heat will build in pump. This heat could build up pressure and damage seals, vaporize process and cause a catastrophic failure.

5. Start pump and run up to speed 6. If faults occur see 11. TROUBLESHOOTING

8.3 Operating Checks The following checks should be performed periodically

1. Check the pump and piping to assure that there are no leaks. 2. Check and record inlet and discharge pressure gauge readings for future reference 3. Check and record voltage, amperage per phase and KW if an indicating wattmeter is available. 4. Note any unusual noise or vibration. 5. Be sure seal support is online and operating.

8.4 Pump Shutdown This section describes proper shutdown for any reason.

1. Stop Pump 2. Close discharge valve 3. Close valves to prevent flow through by-pass. (if installed)

CAUTION WINTERIZATION To prevent pump from freezing during cold weather, liquid in the rotor assembly must be drained. Failure to remove the liquid during freezing temperatures could result in severe damage to the pump.

4. For long-term pump storage in cold temperatures Refer to 5.2.3 LONG TERM STORAGE (UP TO 24

MONTHS)

WARNING LOCK OUT TAG OUT When performing equipment maintenance or if the pump is to remain out of service for a period of time, the equipment electrical service must be locked out with an approved lockout device. Failure to lockout equipment may result in injury.



9. Maintenance

DANGER TOXIC VAPORS FROM SEAL

Vapors can leak past seal guards appropriate risk assessment must be made regarding the

nature of the product in the pump and necessary safety precautions put in place to protect

from exposure to product vapors.

DANGER ROTOR INSPECTION

Rotor should be checked routinely for signs of wear or damage.

Failure to inspect routinely may result in catastrophic failure

WARNING HOT SURFACES Pump bearing assembly becomes hot during operation. Do not touch bearing assembly surfaces without taking appropriate precautions to protect against personnel injury.

9.1 Maintenance Check Points Check the indicated parts of the pump periodically as part of the maintenance process as shown



Parameter Interval Detail of Inspection Remarks

Bearing Assembly Lubrication

See 3.4 GEAR AND

BEARING LUBRICATION See 3.4 GEAR AND

BEARING LUBRICATION Small amounts periodically

Bearing assembly Temperature

Every shift Monitor if > 70 °C Stop pump if > 93 °C

Bearing assembly Vibration

Every shift Take vibration from designated vibration dimples

Normal operation not to exceed .3 ips RMS Shut down if greater than .4 ips RMS

Pump Performance Weekly Measure motor amps, pump speed and discharge pressure.

If pump power changes by more than +/- 15% compared to normal running conditions or if speed control is at maximum speed, stop and find the cause.

Fastening bolts Monthly Check for tightness See 3.2 TORQUE

TABLES

Seal set screws Annually Follow manufacture recommendations

See 7.3 MECHANICAL SEAL

& SUPPORT

Seal support Daily Follow manufacture recommendations

See 7.3 MECHANICAL SEAL

& SUPPORT

Pitot Tube Annually See 9.3 ANNUAL

INSPECTION See 9.3 ANNUAL

INSPECTION

Rotor Cover Annually See 9.3 ANNUAL

INSPECTION See 9.3 ANNUAL

INSPECTION

9.2 Vibration Monitoring Contact factory for vibration specifications.



9.3 Annual Inspection

A. Bearing system Bearings should be inspected for smooth rotation and no signs of pitting, rust or metal bluing. Bearings

should be replaced as a complete set. It is considered good practice to replace the wave spring when replacing the bearings as conditions may have affected the temper of the spring. The bores inside of the gear case should be inspected for scoring, pitting, rust or debris.

The purpose of the drive shaft bearing shims is to reduce the amount of end play. The number of shims may need to be adjusted when the bearings are replaced. See PUMP ASSEMBLY

B. Rotor and Rotor Cover To alleviate vibration damage, the rotor & rotor cover are assembled and balanced at the factory. (SEE 12.4

BALANCING PROCEDURE) Unless otherwise specified, the assembly is balanced for fluid of specific gravity of 1.0. Other applications may require rebalancing of the rotating assembly. Excessive material removal due to erosion, corrosion, or damage may also affect the balance of the rotor. The rotor and rotor cover should be inspected for signs of cavitation damage. If damage is evident, the cause should be identified and eliminated. The flow passages in the rotor cover should be inspected for excessive wear. The flow passages in the rotor and rotor cover should be inspected for blockage.

C. Pitot Tube The condition of the Pitot tube will affect the successful operation of the pump. For optimum operation, the

pick-up tube must be free of blockage and the inlet must be smooth and free of damage due to erosion or mishandling. Some wear at the inlet of pitot tube is normal. Excessive wear can affect pump performance and may be signs of pump mis-operation.

D. Gear Inspection The condition of the gears should show some signs of wear with no discoloration or breakage. Excessive

Wear or pitting should be inspected further before putting back into service. For inspection do not remove gears from shafts. Removal of gears from shafts can cause damage to shaft.

E. Elastomers It is recommended during an annual inspection and tear down to replace elastomers that may compress or leak if not in good condition. See 13.1 SPARE PARTS for complete list of replacement parts.



10. Decommissioning

DANGER LIFTING DEVICE SAFETY

• Use lifting devices to lift heavy or awkward components. • The lifting devices must be in good condition, certified and tagged. • The lifting devices must be of adequate capacity and must be used whenever they are required. • Personnel must never work under suspended loads.


• Tapped holes for eye-bolts are for lifting individual parts only. One exception is the lifting eye on the top half of the gear case; this is designed to lift the assembled pump. • Some heavy parts of the pump have threaded holes for lifting. During assembly, eye bolts are screwed into holes to engage the crane.

WARNING TIPPING OR FALLING During decommissioning, ensure that the pump components are secured properly, so that they do not fall or tip over, or cause injury.

CAUTION SHARP EDGES • Before disassembly, identify work parts that could be hazardous due to sharp edges. All metal components must be considered to have sharp edges. • Worn pump components can have sharp or jagged edges. Handle worn parts carefully, to prevent damage to slings or personnel injury.

WARNING HADARDOUS CHEMICALS During disassembly, personnel may come in contact with hazardous chemicals. These chemicals must be identified before disassembly, and the correct SDS must be made available and appropriate safety management precautions put in place.

CAUTION GLOVES MUST BE WORN Cut proof gloves must be worn while handling parts with sharp edges.

NOTICE TOOLING Only impact type sockets must be used with air or electric impact tools.



NOTICE PPE Correct PPE must be worn when disassembling pumps.

10.1 Decommissioning Steps

1. Confirm the hazards associated with the process fluid pumped and adopt necessary safety precautions. 2. Isolate the pump electrically, hydraulically, and mechanically following proper lock out tag out

procedures. 3. Close suction and discharge valves 4. Depressurize seal reservoir (if applicable) 5. Disconnect the pump from piping and seal support. 6. Remove coupling guard if removing pump from service 7. Uncouple pump from motor 8. Drain pump and decontaminate if necessary. 9. If removing pump for rebuild leave feet in place. This will minimize or eliminate need for realignment.



10.2 Disposal When a pump is sold, all pump documentation and guarding must be supplied with it. To dispose of a complete pump unit, Weir recommends the following steps:

1. Confirm the hazards associated with the process last pumped. 2. Ensure that all lifting points are suitable to use.

DANGER LIFTING POINTS GIVING WAY

Lifting points may be corroded and may not be fit to use by the time of disposal.

3. Remove complete pump unit to a decontamination area. 4. Decontaminate by a static flush and drain.

CAUTION HAZARDOUS CHEMICALS Personnel may come in contact with hazardous chemicals. Adopt necessary safety precautions such as wearing appropriate PPE.

5. Disassemble the main components from the baseplate. 6. Grease, oil, rubber, and urethane must be disposed under applicable waste and environmental

regulations. 7. All metal and alloys can be recycled if they are decontaminated and are not classified as hazardous

material under applicable environmental regulations.



11. Troubleshooting

No liquid delivered at end delivery point or through flow meter

Possible Causes Corrective Action

Inlet or discharge valves closed Be sure all valves are fully opened.

Lack of prime Fill pump and suction completely with liquid. Check for vapor bind.

Obstruction in liquid passages Dismantle pump and inspect passages of pitot tube, rotor cover and manifold. Remove obstruction.

System head too high

Total system head greater than head for which pump designed. Check pipe friction losses. Larger piping may correct condition. Are valves wide open? Increase pump speed to develop greater differential pressure. CAUTION – Brake HP of pump varies with the cube of the speed; therefore, any increase in speed means considerable increase in the power demand.

Suction Lift Too High

If no obstruction at inlet, check for pipe friction losses. However, static lift may be too great. Measure with mercury column or vacuum gauge while pump operates. Check with pump NPSHr at flow. If static lift is too high, liquid to be pumped must be raised or pump lowered.

Air Leak in Suction Line Suction line can be tested by shutting off or plugging inlet and putting line under pressure. A gauge will indicate leak with a drop of pressure.

Speed Too Low Check whether motor is directly across-the-line and receiving full voltage. Frequency may be incorrect, motor may have an open phase.

Wrong Rotation

Check motor rotation with drive shaft rotation. Rotation will be counter clockwise looking down drive shaft from coupling end. Pump operating backwards will produce ½ head development.

Suction or Discharge Line Plugged Unplug line.

Gas or Vapor Pocket in Suction Line Remove all gas from suction line. Re-pipe so air cannot be trapped.



Not enough liquid delivered at end delivery point or through flow meter


Air Leak in Suction Line Suction line can be tested by shutting off or plugging inlet and putting line under pressure. A gauge will indicate a leak with a drop of pressure.

Speed Too Low Check whether motor is directly across-the-line and receiving full voltage. Frequency may be incorrect; motor may have an open phase.

Wrong rotation


Obstruction in Liquid Passages Dismantle pump and inspect passages of pitot tube, rotor cover and manifold. Remove obstruction.

Discharge Head Too High

Total system head greater than head for which pump designed. Check pipe friction losses. Larger piping may correct condition. Are valves wide open? Increase pump speed to develop greater differential pressure. CAUTION – Brake HP of pump varies as the cube of the speed; therefore, any increase in speed means considerable increase in power demand.

Suction Lift Too High

If no obstruction at inlet, check for pipe friction losses. However, static lift may be too great. Measure with mercury column or vacuum gauge while pump operates. Check with pump NPSHr at flow. If static lift is too high, liquid to be pumped must be raised or pump lowered.

Suction or Discharge Line Partially Plugged Unplug line.

Inlet Cavitation

Insufficient NPSH (Net Positive Suction Heat) available. Available NPSH must always equal or exceed the required NPSH of the pump. Depending on installation: A. Increase inlet pressure to pump. B. Reduce inlet pipe friction losses. C. Increase height of fluid in sump. D. Pressurize suction vessel. E. Lower the pump.



Not enough pressure on discharge pressure gauge


No Restriction on Pump Discharge Restrict discharge valve

Speed Too Low Check whether motor is directly across-the-line and receiving full voltage. Frequency may be incorrect; motor may have an open phase.

Wrong rotation



Air Leak in Suction Line Suction line can be tested by shutting off or plugging inlet and putting line under pressure. A gauge will indicate a leak with a drop of pressure.

Air or Gases in Liquid

May be possible to over rate pump to point where it will provide adequate pressure despite condition. Better to provide gas separation chamber on suction line near pump.

Head Lower Than Rating, Pumps Too Much Liquid Pump may be operating at a higher flow rate than suspected. Throttle pump at discharge to reduce flow.

Pitot Tube Damaged Dismantle pump and inspect pitot tube for erosion or damage.

Inlet Cavitation

Insufficient NPSH (Net Positive Suction Heat) available. Available NPSH must always equal or exceed the required NPSH of the pump. Depending on installation: A. Increase inlet pressure to pump. B. Reduce inlet pipe friction losses. C. Increase height of suction vessel. D. Pressurize suction vessel. E. Lower the pump.

Liquid runs from drain hole


Leakage past O-rings Dismantle pump, clean and inspect O-ring grooves. Inspect O-rings. Replace parts as necessary



Pump overloads driver


Speed too high Check driver and verify correct size for required speed and flow conditions.

Specific gravity too high This can cause overloading.

Head lower than rating, pumps too much liquid Pump may be operating at a higher flow rate than suspected. Throttle pump at discharge to reduce flow.

High viscosity This can cause high drag on the rotor, rotor cover and pitot tube.

Electrical defects

The voltage and frequency of the electric motor may be lower than that for which the motor was built. The motor may not be ventilated properly due to a poor location.

Pump works for a while then quits


Incomplete priming Free pump, piping and valves of all air. If high points in suction line prevent this, they need correcting.

Suction lift too high

If no obstruction at inlet, check for pipe friction losses. However, static lift may be too great. Measure with mercury column or vacuum gauge while pump operates. If static lift is too high, liquid to be pumped must be raised or pump lowered.

Air leak in suction line Suction line can be tested by shutting off or plugging inlet and putting line under pressure. A gauge will indicate a leak with a drop of pressure.

Air or gases in liquid

May be possible to over rate pump to point where it will provide adequate pressure despite condition. Better to provide gas separation chamber on suction line near pump.

Mechanical failure of critical pump parts Check bearings and pitot tube for damage.



Pump vibration


Inlet Cavitation


Air or gases in liquid Better to provide gas separation chamber on suction line near pump.

Misalignment Check alignment

Mechanical failure of critical pump parts Check bearings and pitot tube for damage.


Foundation not rigid

The foundation must be rigid enough to support the pump, auxiliary equipment, drive and baseplate, and prevent vibration and misalignment during operation.

Foreign particles in rotor The accumulation of foreign particles in the rotor may create and unbalanced condition. Clean pump rotor.

Unbalance of rotating assembly

Check pump rotor for evidence of erosion. Displacement of metal within rotor could create an unbalanced condition. Rebalance or replace rotor assembly.



Bearings overheat or wear rapidly


Improper lubrication or bearing pre-load A. Make sure bearings are installed properly. B. Remove cover and verify that the oil ring is in the proper location. See 3.7 SECTION DRAWINGS

Vibration See 9.1 MAINTENANCE CHECK POINTS

Dirt or water in bearings Dismantle pump and clean bearing housing. Replace bearings and lubricate.

Pump Noise


Vibration See 9.1 MAINTENANCE CHECK POINTS

Inlet Cavitation


Discharge cavitation Decrease flow requirements; increase pump discharge pressure

Turbulence in discharge piping A. Fully open the discharge valve. B. Increase the pipe diameter. C. Eliminate sharp bends in the piping.

Operating at extremes of pump curve

Operation at extremes of pump cure will cause cavitation noise. Intermittent operation at this point is allowed; however prolonged operation will result in damage of pitot tube.



12. Assembly/Disassembly

12.1 General The following are recommended dismantling and assembly instructions for your Roto-Jet© pump. We urge that the instructions be read thoroughly before attempting to dismantle the unit. The component parts must be handled with care during the dismantling and assembly process. The work area should be clean and be equipped with the required tools. Depending on the accessibility of the pump and the extent of the repair or inspection required, the pump can be dismantled in place on its foundation. The assembly and disassembly of the Roto-Jet© RO-FT pump should be done in a clean and safe environment. When splitting the case, caution needs to be in taken to make sure pump is isolated from dirt, water, and any other foreign contaminants from falling into the bearing case. If removing rotor or drive shaft, there needs to be a clean surface to place the components.

12.2 Recommended Tools & Parts See ERROR! REFERENCE SOURCE NOT FOUND.

12.3 Parts and Drawings See 3.7 SECTION DRAWINGS

12.4 Balancing Procedure Pre balance requirements.

1. Removal of the rotating assembly from case 2. Removal of pitot tube 3. Removal of rotating assembly bearings 4. Assemble rotating assembly with all o-ring’s and rotating assembly bolts 5. Torque bolts to required torque see 3.2 TORQUE TABLES 6. Fill rotor with water and plug off both ends (This allows for a better balance)

Balancing specifications

1. Rotating assembly needs to be balanced to G1.0 2. Run out needs to be verified with rotating assembly spec.

Continue assembly, see 12.8.1 ROTATING ASSEMBLY



12.5 Gears This section will describe inspection and installation procedures critical to proper gear life and operation.

12.5.1 Gear installation a. Make sure gears are proper ratio

a. Refer to nameplate ratio. Count teeth, refer to gear teeth count 3.3 OIL PANS AND GEAR RATIOS b. Orient shaft so shaft is supported and balanced in vertical position as shown. c. Insert keys into shaft. (Item# 162 Rotating assembly, Item# 410 Drive Shaft)

a. Be sure keys slide freely in gear and shaft keyways and are fully seated. Failure to do so may result in incomplete gear installation.

Drive Shaft

Discharge Shaft

Tip: Cool shaft before installation d. Heat gear uniformly to a temperature of 350 deg F (Item# 421) e. Place gear onto shaft making sure not to catch keys in gear slot Tip: While not necessary it is recommended discharge shaft is installed on rotor prior to gear installation


f. Allow gear to cool completely before handling.

12.5.2 Gear Removal

Recommended: If on discharge shaft remove shaft from rotating assembly see 12.9.7

SUCTION/DISCHARGE SHAFT REMOVAL

NOTICE GEAR REMOVAL

Applying heat may make gear removal more difficult.

Inspect shaft for any deep grooving, replace if damaged.

Excessive force may bend shaft.

When pressing gear, fully support gear.

Recommended: Use of hydraulic shop press is the recommended procedure for removal. Using such method will reduce chance of damage and injury. Use of bearing puller not recommended.



12.6 Bearings This section will describe inspection and installation procedures critical to proper bearing life and operation.

12.6.1 Bearing installation Note: Refer to bearing manufacturer and drawings for proper installation

a. Clean shaft and remove any burs if present b. Heat bearings to 250 Deg F c. Installing Drive Shaft Bearings (Item # 428 Angular Contact, Item# 435 Bearing Gear)

Note: Back to back bearings need to be fully seateda. Install spacer (Item# 429) and lock nut

(Item# 431) and tighten to required torque to ensure bearings are seated.

b. Cylindrical roller bearings need to be captured with inner race lip. Install spacer (Item #413) and loose ring first.


d. Installing Suction and Discharge shaft bearings Note: Follow contact angle see 3.7 SECTION DRAWINGS

a. Install spacer on gear side (Item# 160) b. Install bearings on discharge and suction shafts. c. Install spacers (Item# 111 Discharge, Item# 119 Suction) and lock nut (Item# 110) and tighten

to required torque to ensure bearings are seated.

12.6.2 Bearing removal

a. Recommended use of hydraulic shop press to remove bearings. Bearing puller may be used if press is not available.

b. Tip: Removing shaft from rotating assembly makes it easier to fit into press. See 12.9.7

SUCTION/DISCHARGE SHAFT REMOVAL c. Fully support inner race when pulling bearings

d. Inspect shafts after pressing off to make sure tolerances are held and there is no deep scoring in the

shaft surface. Replace shaft as necessary



12.6.3 Bearing Isolator Installation a. Use an arbor press to install the assembly into the bearing cap. Check for proper orientation (verify the

drain port is down). Do not insert past location stop or shoulder. Isolator will have interference with the bearing cap.

b. Lightly lube the bearing cap and O-rings with the supplied lubricant. c. Slide the bearing cap (Item# 106 Rotating Assembly, Item# 407 Drive Shaft) and isolator (Item 108

Rotating Assembly, Item# 420 Drive Shaft) together into the bearing cap and into position. Push on the outboard face of the isolator.

d. Verify the inner race turns freely

NOTICE BEARING ISOLATOR INSTALATION

The Isolator is a one-piece assembly. Don’t try to separate the parts

O-Ring will shear due to tight tolerances.



12.7 Seals This section will describe the removal, inspection and installation procedures critical to proper seal life and operation.

NOTICE SEALS See seal manufacturer instructions for specific recommendations. Seal installation details will differ from seal manufacturer to seal manufacturer.

12.7.1.1 Seal Removal a. Isolate Machinery see 10.1 DECOMMISSIONING STEPS b. Remove suction or discharge spool 12.9.2 REMOVE SUCTION SPOOL 12.9.3 REMOVE DISCHARGE ELBOW c. Disengage seal 12.7.2 DISENGAGE SEAL d. Detach pitot tube (if discharge) 12.9.4 DETACH PITOT TUBE FROM SEAL PLATE e. Remove seal plate 12.9.5 REMOVE SEAL PLATE f. Remove seal off of shaft making sure not to damage seal or shaft

12.7.1.2 Seal Installation g. Be sure shaft and o-ring are clean and lubricated. Also be sure shaft is free of burrs and surface

roughness h. Slide seal onto shaft (Item# 300)

1. Take care to keep sleeve aligned with shaft during installation. 2. Seal needs to be supported during installation to prevent sleeve from becoming wedged on

shaft. 3. If seal becomes wedged, cocked or stuck. Do not force. Free seal by backing it off.

i. Install seal plate 12.8.3 ATTACH SEAL PLATE j. Install seal bolts and nuts k. Attach pitot tube 12.8.4 ATTACH PITOT TUBE TO SEAL PLATE l. Engage seal 12.7.3 ENGAGE SEAL



12.7.2 Disengage Seal

NOTICE SEAL DISENGAGEMANT These are general instructions. Requirements for your seals may vary. Refer to seal manufacturer instructions for your seal.

a. Isolate machinery 10.1 DECOMMISSIONING STEPS b. Remove seal piping and flush port (if installed)

c. Insert seal clip and lock into place



d. Loosen grub screws enough to clear shaft

e. Remove 4 seal gland bolts and nuts.



12.7.3 Engage Seal

NOTICE SEAL DISENGAGEMANT These are general instructions. Requirements for your seals may vary. Refer to seal manufacturer instructions for your seal.

a. Isolate machinery 10.1 DECOMMISSIONING STEPS b. Tighten 4 gland bolts and nuts

c. Tighten grub screws



d. Remove seal clips and make sure they clear the rotation of the seal

e. Attach seal piping and flush port plug

f. Pressurize seal reservoir (if applicable)



12.8 Pump assembly

NOTICE ELASTOMERS To avoid damage to elastomers and for better installation, be sure to lubricate all elastomers before assembly.

a. Place gear case (Item# 100) on level surface b. Install oil pan (Item# 151) into bottom gear case

c. Install completed rotating assembly (Item# 200) into gear case. 12.8.1 ROTATING ASSEMBLY

d. Install completed drive shaft assembly (Item# 400) into gear case. 12.8.2 DRIVE SHAFT ASSEMBLY



e. Install oil sight gauge & oil Nameplate (Item# 141) . Be sure proper oil depth name plate is installed. f. Install drain plug (Item# 102)

g. Install all studs ( X-19 Item# 131 Short Studs, X-2 Item# 157 Long Studs) in bottom gear case.



h. Install o-ring cord (Item# 101) into gear case channels. Cut and fit material. Do not stretch or compress material to fit in channels. Use small amount of RTV at ends of o-ring channel.

i. Fill gear case with recommended oil to proper level. see 3.4 GEAR AND BEARING LUBRICATION j. Install lifting eye (Item# 107) on top half of case



k. Install top half of case

NOTICE O-RING INTERFERENCE Be sure bearing caps do not interfere with top half of case. Pulling bearing caps away from mating surface will allow sufficient clearance to avoid shearing o-rings.



l. Install 4 alignment pins (Item# 130). Drive pins with light blows from hammer.

m. Fasten all 4 bolts (Item# 125) in suction bearing plate (Item# 106). Be sure bearing isolator drain hole is

pointed down.



n. Fasten all 4 bolts (Item# 125) into discharge bearing plate (Item# 106).

o. Fasten all 4 bolts (Item# 417) into drive shaft bearing plate (Item# 407).

a. Use shims to be sure shaft axial end play is at least .003” and no more the .010” b. After shim adjustment be sure to torque down shaft nut and lock in place with lock ring



p. Fasten all 21 nuts starting with bolting around bearings and continuing as shown.

q. Install observation plugs (Item# 134) and drain plug holes



r. Install gear case breathers (Item# 138, Item# 169)

s. Install suction and discharge seals 12.7.1.2 SEAL INSTALLATION t. Install suction and discharge seal plates 12.8.3 ATTACH SEAL PLATE u. Attach pitot tube to seal plate 12.8.4 ATTACH PITOT TUBE TO SEAL PLATE v. Engage both suction and discharge seals 12.7.3 ENGAGE SEAL w. Install discharge elbow 12.8.5 ATTACH DISCHARGE ELBOW x. Install suction spool 12.8.6 INSTALL SUCTION SPOOL



12.8.1 Rotating assembly a. Install suction shaft assembly onto rotor cover

1. Install studs (Item# 204) into rotor cover Item# 203 2. Install drain pugs (Item# 221) into rotor cover and torque as required see 3.2 TORQUE

TABLES

3. Install o-ring (Item# 208) onto shaft



4. Install suction shaft onto rotor cover and tighten nuts (Item# 211) in alternating pattern to required torque see 3.2 TORQUE TABLES

NOTICE INTERFERENCE FIT Shaft has interference fit. Pull shaft into bore with nuts using alternating pattern.

5. Install set screws (Item# 222) into shaft until they touch the rotor cover.

6. Heat oil flinger spacer (Item# 220) to 250°F and install with lip side toward rotor cover.



b. Install discharge shaft onto rotor

1. Install studs (Item# 213) into rotor (Item# 201)

2. Install o-ring (Item# 208) onto shaft



3. Install discharge shaft onto rotor and tighten nuts (Item# 211) in alternating pattern to required torque see 3.2 TORQUE TABLES

NOTICE INTERFERENCE FIT Shaft has interference fit. Pull shaft into bore with nuts using alternating pattern.

4. Install set screws (Item# 222) till they touch rotor

5. Install gear (Item# 421)onto shaft 12.5.1 GEAR INSTALLATION



c. Install o-ring (Item# 202) onto rim of rotor. Be sure to lubricate o-ring

d. Install rotor cover onto rotor and tighten bolts (Item# 207) in alternating pattern and torque as required.

Bolt pattern is non- symmetric. Be sure bolt pattern is aligned before fastening bolts. 1. Refer 6.6.1 BOLT TIGHTENING PROCEDURE 2. Refer 3.2 TORQUE TABLES

****Balance is required at this point 12.4 BALANCING PROCEDURE****



e. Disassemble Rotor and Rotor Cover12.9.6 DISASSEMBLE/ASSEMBLE ROTATING ASSEMBLY f. Suction shaft build

1. Install oiler ring (Item# 209)

2. Install bearing 12.6.1 BEARING installation 3. Install o-ring (Item# 212) onto shaft



4. Install bearing spacer (Item# 119)

5. Put bearing spacer ring into place (Item# 155)



6. Install bearing cap (Item# 106) with bearing isolator (Item# 108) installed 12.6.3 BEARING

ISOLATOR INSTALLATION 7. Put lock ring (Item# 109) and lock nut (Item# 110) onto shaft and torque as required see 3.2

TORQUE TABLES

8. Install O-ring (Item# 156) under bearing cap



g. Discharge shaft build

1. Install spacer (Item# 160) onto shaft

2. Install bearing 12.6.1 BEARING installation 3. Install o-ring (Item# 212) onto shaft



4. Install bearing spacer (Item# 111)

5. Install wave springs (Item# 114)



6. Install bearing cap (Item# 106) with bearing isolator (Item# 108) installed 12.6.3 BEARING

ISOLATOR INSTALLATION 7. Install lock ring (Item# 109) and lock nut (Item# 110) onto shaft and torque as required see 3.2

TORQUE TABLES

8. Install O-Ring (Item# 156) under bearing cap

h. Install Pitot tube (Item# 139) with O-ring (Item# 134) installed. i. Assemble Rotor see 12.8.1 ROTATING ASSEMBLY


12.8.2 Drive Shaft Assembly a. Install gear (Item# 421) 12.5.1 GEAR

INSTALLATION b. Install spacer (Item# 413)

c. Heat on roller bearing 12.6.1 BEARING

installation d. Flip around and install back to back bearings

12.6.1 BEARING installation e. Install o-ring (Item# 408)

f. Install spacer (Item# 429)

g. Install bearing cap (Item# 407) with bearing

Isolator installed (Item# 420) 12.6.3 BEARING

ISOLATOR INSTALLATION

h. Install lock ring (Item# 430) and locknut (Item#

431) onto shaft and hand tight. i. Install o-ring (Item# 115) under bearing cap



12.8.3 Attach Seal plate a. Install 8 studs (Item# 123 Suction & Discharge) in gear case

Warning: Install seal and seal plate separately. If they are installed as an assembly damage to seal may result.

b. Install lifting eyes into seal plate for safe lifting. c. Mount seal plate (Item# 105 Suction, Item# 104 Discharge) with seal spacer (Item# 158) installed.



d. Use 8 nuts (Item# 103) and pull plate into place using alternating pattern. This is an interference fit. Be sure plate is fully seated when done pulling

e. Remove lifting eyes when finished and replace with grub screws (Item# 112). f. Attach seal to seal plate

12.8.4 Attach Pitot tube to seal plate a. Pull pitot tube (Item# 139) into plate (Item# 104)

b. Align pin (Item# 145) with notch in seal plate (Item# 104) at 12 o’clock.



c. Thread on pitot tube MJT (Item# 142) d. Tighten pitot tube MJT jack screws to required torque. Be sure to lube fasteners before installation.

Tighten fasteners in cross pattern with no more than ¼ turn per bolt pass.

12.8.5 Attach Discharge Elbow

a. Install 8 studs (Item# 144) in seal plate

b. Inspect and replace O-ring (Item# 135) on the pitot tube if necessary c. Set elbow (Item# 118) into desired orientation d. Torque 8 nuts (Item# 136) see 3.2 TORQUE TABLES

12.8.6 Install suction spool a. Refer to piping 6.6 PIPING b. Install Studs (Item# 144) c. Center Gasket in place (Item# 122) d. Set spool in place (Item# 120) e. Install nuts (Item# 136) and torque as required see 3.2 TORQUE TABLES



12.9 Pump Disassembly This section will describe pump disassembly

12.9.1 Pitot Tube Replacement a. Isolate machinery 10.1 DECOMMISSIONING STEPS

b. Remove discharge elbow (Item# 118) 12.9.3 REMOVE DISCHARGE ELBOW

c. Remove suction spool (Item# 120) 12.9.2 REMOVE SUCTION SPOOL d. Disengage suction and discharge seals (Item# 300) 12.7.2 DISENGAGE SEAL e. Detach pitot tube from seal plate 12.9.4 DETACH PITOT TUBE FROM SEAL PLATE f. Remove suction and discharge seal plates(Item# 123, 127) 12.9.5 REMOVE SEAL PLATE g. Remove seals from shafts 12.7.1.1 SEAL REMOVAL h. Remove 4 bolts in drive shaft bearing cap (Item# 125)

i. Remove 4 bolts (Item# 130) in each rotating assembly bearing caps



j. Remove 4 alignment pins (Item# 130)

k. Remove 21 nuts from gear case

l. Lift top half of case by lifting eye and set aside. Protect machined surfaces from damage.

m. Remove rotating assembly using lifting strap APPENDIX A LIFTING Instructions n. Remove pitot tube and inspect 12.9.6 DISASSEMBLE/ASSEMBLE ROTATING ASSEMBLY o. Assemble pump PUMP ASSEMBLY



12.9.2 Remove suction spool

a. Remove suction piping from pump b. Remove any accessories from access ports c. Unbolt 8 nuts holding spool to suction seal plate d. Remove gasket and clean surfaces.



12.9.3 Remove discharge elbow

a. Remove any discharge spools or piping attached to the elbow b. Remove any instruments or bypass lines from Accessory Ports c. Remove 8 nuts from elbow



12.9.4 Detach Pitot tube from seal plate a. Remove Discharge Elbow 12.9.3 REMOVE DISCHARGE ELBOW b. Apply oil before removing screws. Loosen smaller bolts in Pitot tube nut to flush with top surface.

Loosen bolts in 180° cross pattern not loosening more than ¼ turn per bolt pass.

c. Unthread pitot tube nut 3 turns

d. Attach discharge elbow

Note: Elbow will push on MJT. If the elbow is not pushing on the MJT, loosen MJT a few turns. a. Tighten elbow nuts enough to relieve taper fit

e. Remove elbow



12.9.5 Remove Seal plate a. Remove discharge elbow or suction pipe spool 12.9.2 REMOVE SUCTION SPOOL 12.9.3 REMOVE DISCHARGE

ELBOW

b. Detach pitot tube from seal plate 12.9.4 DETACH PITOT TUBE FROM SEAL PLATE c. Disengage seal 12.7.2 DISENGAGE SEAL

d. Engage lifting eye e. Remove 8 nuts from seal plate

f. Use jack bolts in lift off holes to drive off seal plate



12.9.6 Disassemble/Assemble Rotating Assembly a. Set rotating assembly on flat surface b. Install lifting eyes into rotating assembly lift off

holes a. Make sure discharge is pointing down

c. Set rotating assembly into fixture or pipe Tip: 12” pipe spool works well

d. Remove rotor bolts and lifting eyes

e. Using 3 jack bolts in lift off ports, thrust rotor

apart in alternating pattern making sure faces stay as parallel as possible.

f. Reengage lifting eyes and lift half of rotor apart


g. Remove pitot tube and inspect as needed or replace

h. Install Pitot tube and replace rotor o-ring. Be sure to clean o-ring grooves in rotor halves

i. Lubricate rotor o-ring and install into place see 12.8.1 ROTATING ASSEMBLY j. Lift rotor cover assembly into place and remove lifting eyes see 12.8.1 ROTATING ASSEMBLY k. Bolt rotating assembly together using alternating pattern to ensure faces remain as parallel as possible

See 12.8.1 ROTATING ASSEMBLY l. Torque bolts as required 3.2 TORQUE TABLES



12.9.7 Suction/Discharge Shaft Removal a. Mark point on rotor and shaft to make sure they align correctly

b. Remove nuts

c. Push shaft off using jack screws.

Once shaft is separated from rotor, inspect o-ring and replace if necessary



13. Parts

13.1 Spare Parts

Spare Parts RO-FT16-1

Quantity Item # Description

10 101 O-RING CORD CASING SPLIT LINE

2 109 LOCKWASHER, 100MM

2 110 LOCKNUT, 100MM

3 114 WAVE SPRING

1 115 O-RING, BRG CAP,DRV SHFT

1 122 PIPE GASKET, 3" 600#

1 135 O-RING, PUT DISCH ELBOW

1 143 O-RING, PUT SEAL PLATE

2 156 O-RING, BRG CAP

2 159 BRG,SPINDLE, 100X180

1 202 O-RING ROTOR

2 208 O-RING, SHAFT

2 212 O-RING, SHFT SLEEVE

2 221 PLUG W/O-RING SST VITON

4 304 O-RING, SEAL HOUSING

4 305 O-RING, SEAL

4 306 SEAL 3-1/2 CARB STAT VIT JC

2 309 O-RING, SHAFT EXT

1 310 HUB / NUT STATIONARY SEAL

2 311 O-RING SMR

2 312 SEAL MATING RING, HUB NUT

1 408 O-RING DRV SHAFT SLEEVE

3 411 SHIM, DRIVE SHAFT, .005


2 428 BEARING,BALL 55MM ANG CNT BRASS CAGE


1 431 LOCKNUT, 55MM

1 435 BEARING,CYL ROLLER 55MM BRASS CAGE



Spare Parts RO-FT16-2

Quantity Item # Description

10 101 O-RING CORD CASING SPLIT LINE


2 110 LOCKNUT, 100MM

3 114 WAVE SPRING


1 122 PIPE GASKET, 3" 600#

1 135 O-RING, PUT DISCH ELBOW

1 143 O-RING, PUT SEAL PALTE


2 159 BRG,SPINDLE, 100X180

2 161 O-RING SEAL SPACER

1 202 O-RING ROTOR

2 208 O-RING, SHAFT

2 212 O-RING, SHFT SLEEVE

2 221 PLUG W/O-RING SST VITON

1 300 DISCHARGE END JOB SEAL CCW ROTATION

1 300 SUCTION END JOB SEAL CW ROTATION

1 408 O-RING SHAFT SLEEVE



2 428 BEARING,BALL 55MM ANG CNT BRASS CAGE


1 431 LOCKNUT, 55MM

1 435 BEARING,CYL ROLLER 55MM BRASS CAGE



13.2 Ordering Parts General – It is Weir’s policy to continually improve its products. Therefore, specifications are subject to change without notice. Parts should be ordered as far in advance or their use as possible since circumstances beyond our control may reduce existing stock. Placing Orders – The satisfactory ordering and receiving of parts is dependent upon specific and correct information supplied by the purchaser. A specification sheet for each unit manufactured is on file at the factory, and in case some special part is needed, it can be provided if the correct model and serial number is given. Many unnecessary errors and delays may be eliminated by observing the following instructions.

Your parts order should state: 1. Model and serial number of pump. 2. Part number, description, and quantity required. 3. Your company name, address and zip code clearly. 4. Specific shipping and billing instructions. 5. Date required.

With this assistance, the time required to expedite your order will be greatly reduced.

Notice

ORIGINAL PARTS Parts will be furnished in original materials unless specified as a material change. All material substitutions should be discussed with the factory.



14. Appendix

Appendix A Lifting Instructions The lifting of the pump or package must be undertaken by a qualified and experienced person who is familiar with lifting safety legislation and practices. This person must be able to assess the load and lift, create a lifting plan and then apply it safely

Notice

LIFTING COMPONENTS Store all lifting equipment in a dry corrosive free environment All lifting points must be routinely inspected and maintained



DANGER

DESIGNATED LIFTING POINTS Lifting components by designated lifting points should be adhered to at all times. Lifting pump components or package by non-designated lifting points could result in serious injury or catastrophic pump damage. Never lift pump by any other component by use of straps, chains or hooks.



Appendix B Transportation Tie Down Locations

Notice

TIE DOWN POINTS Tie down should be across the base plate or on the lifting lugs. The package should never be tied down over motor, coupling guard, pump or seal pots. Doing so may damage components.



For optimum service and technical assistance, please contact our factory for the distributor

or representative nearest to your project:

Weir Specialty Pumps 440 West 800

South Salt Lake City, UT 84101 (P.O. Box 209, 84110-0209)

Tel 801-359-8731

Fax 801-530-7828 [email protected]

www.weirpowerindustrial.com

mailto:[email protected]

roto-jet© ro-ft pumps installation, operation ......this manual describes features, installation,...

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