Mather + Platt

Installation, Operating and Maintenance

Instruction Manual

for

Vertical Pumps

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

MPPL/IM/VP/2006/0

Mather + Platt Table of Content

EC declaration of incorporation (QA02-45) for, pumps without prime mover

EC declaration of conformity (QA02-46) for, pumps with CE prime mover.

1 Preface and Copyright Information 1-1

1-1 Preface 1-1 1-2 Copyright 1-1 1-3 Manufacturer 1-1 1-4 Rights of alteration 1-1

2 General safety information 2-1

2-1 Safety symbols used in the man 2-1

2-2 Guides lines used and CE certification 2-1 2-3 Declaration of Incorporation or conformity 2-1 2-4 Duty conditions 2-2 2-5 Safety & control devices 2-2 2-6 Safety instructions 2-2

2-7 Safety instruction for the operator 2-3 2-8 Electrical connection and electrical work 2-4 2-9 Operation with different pump fluid 2-4

2.10 Sound pressure 2-4 2.11 Prime mover selection 2-5 2-12 Warranty 2-5 2-13 Remarks 2-6

3 Product description 3-1

3-1 General product information 3-1 3-2 Proper use and fields of application 3-1 3-3 Conditions of use 3-1 3-4 Construction 3-2

4 Handling, transportation and storage 4-1

4-1 Handling 4-1 4-2 Delivery 4-1 4.3 Transport 4-2 4.4 Storage 4-2 4-5 Returning to supplier 4-2

5 Installation 5-1

5.1 Introduction 5-1

5.2 Requirements for the operating area 5-1

5.3 Cleaning 5-1 5.4 Foundations 5-2 5.5 Soleplate installation & pump assembly/installation 5-3 5.6 Alignment of pump and driving unit 5-6 5.7 Pipe work 5-8 5.8 Use of diesel engine as prime mover 5-9

MPPL/IM/VP/2006/0

Table of Content Mather + Platt 6 Start up 6-1

6-1 Introduction 6-1 6-2 Pipe work flushing 6-1

6-3 Cleaning of bearing 6-1

6-4 Direction of rotation 6-1

6-5 Availability of liquid 6-1

6-6 Pre-starting checks 6-2

6-7 Normal starting checks 6-2 6-8 Running checks 6-3 6-9 Normal shut down 6-3

6-10 Emergency shut down 6-3

7 Maintenance 7-1

7.1 Routine maintenance & frequency of inspection 7-1 7.2 Overhaul maintenance 7-2 7.3 Spares 7-5 7.4 Lubrication 7-6

8 Troubleshooting 8-1

A Lists, Tables & Type Plates A-1

A1 List of machine operators A-1 A2 Maintenance and inspection log A-2 A3 Type plates A-3 A4 Leveling Records A-4 A5 Alignment Protocol A-5 A6 Pre-Starting checks A-6 A7 Pump commissioning report A-7 A8 Issue & Feedback report A-8

B Machine data sheet B-1

B1 Performance B-1 B2 Pressure limits B-1 B3 Flange loads B-1 B4 Bearing lubrication & gland packing data B-3 B5 Recommended bolting & screw torques B-4

MPPL/IM/VP/2006/0

Mather + Platt EC declaration of incorporation

EC declaration of incorporation According to annexure V of machinery directive 98 /37 /EC, We hereby state that this product (Pump without prime mover)

Product designation : Vertical pump Type designation : Refer section B5 serial No 1 to 43 of the

manual & the name plate on the pump Pump serial no : Refer the name plate on the pump Prime mover designation : Not applicable. Type designation : Not applicable. Prime mover (CE) serial no : Not applicable.

fulfills the following relevant legal requirements:

EC Machinery directive 98 / 37 / EC Harmonized standards used, in particular:

EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050

Manufacturer : Mather and Platt Pumps Ltd., Address : Mumbai Pune Road, Chinchwad, Pune-

411019, India. Telephone : +91 (0)20 27442100. Fax : +91 (0)20 27442211. e-mail : headoffice@pun.matherplatt.co.in

Representative (within EEA) : WILO AG, Address : NortkirchenstraBe 100, 44263 Dortmund,

Germany Telephone : +49 231 4102-0 Fax : +49 231 4102-363 e-mail : info@wilo.de

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune

A. V. Joshi

Deputy General Manager - Quality Assurance

QA02-45 REV 0

Mather + Platt EC declaration of conformity

EC declaration of conformity According to annexure V of machinery directive 98 /37 /EC, We hereby state that the Mather & Platt product (Pump with prime mover), refer prime mover manual name plate, instruction manual & CE declaration of conformity

Product designation : Vertical pump Type designation : Refer Section B5 Serial No 1 to 43 of the

manual & the name plate on the pump Pump serial no : Refer the name plate on the pump Prime mover designation : Refer the name plate on the prime mover Type designation : Refer the name plate on the prime mover Prime mover (CE) serial no : Refer the name plate on the prime mover

fulfills the following relevant legal requirements:

EC Machinery directive 98 / 37 / EC Harmonized standards used, in particular:

EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050

Manufacturer : Mather and Platt Pumps Ltd Address : Mumbai Pune Road, Chinchwad, Pune-

411019, India. Telephone : +91 (0)20 27442100 Fax : +91 (0)20 27442211 e-mail : headoffice@pun.matherplatt.co.in

Representative (within EEA) : WILO AG, Address : NortkirchenstraBe 100, 44263 Dortmund,

Germany Telephone : +49 231 4102-0 Fax : +49 231 4102-363 e-mail : info@wilo.de

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune

A. V. Joshi

Deputy General Manager - Quality Assurance

QA02-46 REV 0

Mather + Platt Preface and Copyright Information

1 Preface and Copyright Information

1.1 Preface Dear Customer Thank you for purchasing one of our company's products. This operating and maintenance manual must be read carefully before installation & initial start-up to ensure safe and efficient use. This documentation contains all the necessary information for the product, allowing you to use it properly. In addition, you will also find helpful information, which will enable you to recognize potential dangers, reduce repair costs, down times and increase the reliability and working life of the product The operating company is responsible for ensuring that all persons working with or on this product are at least 18 years of age and have read and understood this manual. Only qualified and trained personnel should be assigned to work on the product. All safety requirements and specific manufacturer's requirements must be fulfilled before the product is put into operation. This operating and maintenance manual supplements any existing national regulations on industrial safety and accident prevention. This manual must be made accessible to personnel working at all times and also be made available where the product is used. In a case where there is any doubt as to the functioning or adjustment of any parts of the equipment, or in the event of any trouble which cannot be remedied by reference to the information contained in this manual, MATHER & PLATT PUMPS LTD. should be consulted immediately at their Pune address mentioned below. In communicating with the Company, the Pump Serial Number should always be quoted.

1.2 Copyright This operation and maintenance manual has been copyrighted by, the manufacturer. The operation and maintenance handbook is intended for, the use by assembly, operating and maintenance personnel. It contains technical information and diagrams which may not be reproduced or distributed, either completely or in part, or used for any other purpose without the expressed consent of the manufacturer.

1.3 Manufacturer Mather and Platt Pumps Ltd., Mumbai-pune Road, Chinchwad, Pune-411019, India. Tel.: +91 (0) 20 27442100 Fax: +91 (0) 20 27442111 Internet: www.matherplatt.com e-Mail: headoffice@pun.matherplatt.co.in

1.4 Rights of alteration The manufacturer reserves the right to make technical alterations to systems or components and contents of manual.

This operating and maintenance manual refers to the product indicated on the title page.

MPPL/IM/VP/2006/0 1-1

Mather + Platt General Safety Information

2 General Safety Information This operation and maintenance manual contains basic information, which must be strictly observed during operation and maintenance. Not only the safety instructions listed in this chapter must be followed but also those contained in other chapters, which refer to specific parts and procedures. The operator is responsible for ensuring that personnel follow these instructions and guidelines.

2.1 Safety symbols used in the Instruction manual

This symbol indicates danger from general causes where non-compliance with safety instructions would affect personnel safety.

This symbol indicates danger from electrical causes where non-compliance with electrical safety instructions will involve a high risk to personnel safety or loss of life. This note symbol refers to safety requirements or notes that are of critical importance to the user where non-compliance could damage the pump or installation or cause it to malfunction.

2.2 Guidelines used and CE certification Our products conform to the following EU guidelines:

- Machinery directive 98 / 37 / EC. In addition, several harmonized standards have been applied, e.g. EN 809, ISO 2100-1, ISO 12100-2 & EN 1050 (Risk assessment). Please consult the EU Declaration of Conformity for the precise information and the guidelines in effect The EU Declaration of Conformity is issued in accordance with EU Directive 98/37/EC, Appendix II A. The CE symbol is found on the pump nameplate and motor & electrical panel nameplate when in M&Ps scope of supply.

2.3 Declaration of Incorporation or conformity. Since Mather & Platt does not manufacture prime mover, following conditions will apply. It is recommended that customers should opt for CE marked prime mover. When customer takes only bare pump, or pump with accessories without prime mover, Declaration of Incorporation will be applicable. For unitized pumps with CE prime mover, Declaration of Conformity will be applicable. Where customer opts for pumps with prime mover without CE, or supplies his prime mover for unitization, which is not CE, Declaration of incorporation will be applicable.

MPPL/IM/VP/2006/0 2-1

General Safety Information Mather + Platt 2.4 Duty conditions This product has been supplied as per specifications in your purchase order/ approved data sheet & drawings. A copy of these specifications / approved data sheet should be kept with these instructions.

The product must not be operated beyond the parameters specified for the application. In case of any doubts, contact Mather & Platt for advice, quoting Pump serial number.

If the duty conditions of pump are going to be different than the specifications in purchase order / approve data sheet (e.g. liquid pumped, temperature or duty) it is requested the user seeks the written agreement of Mather & Platt pumps Ltd., before start up.

2.5 Safety & control devices Direct controls are applicable when pump is supplied along with motor/panels. When motor/panel are in end users scope, it is advised to go for CE approved motors/panels.

These devices whether on pump/motor/electrical panels must never be dismantled or disabled. They must be checked by, an authorized technician for proper functioning before start-up. Refer to motor & Electrical panel instruction manuals for electrical safety & control devices information.

2.6 Safety instructions

- Installation & service should be done by, qualified personnel only.

- The installation / removal of the product must not be performed by one person alone.

- Failure to comply with safety precautions could result in personnel injury or damage to the equipment or installation. Failure to comply with safety precautions could also invalidate any claim for warranty.

- The operator is required to know mechanical/electrical specifications of the machine and how to cut off the supply.

- The operator must inform his/her superior immediately should any defects or irregularities occur. This applies to both the electrical and mechanical devices.

- If fastening devices are separated from the pump after use, they should be expressly marked as fastening devices. Otherwise they should be carefully stored.

- It is of vital importance that the system is shut down immediately by the operator if any problems arise which may endanger the safety of personnel and/or plant. Problems of this kind include:

- Failure of the safety and/or control devices. - Damage to critical parts. - Damage to electric installations, cables and insulation.

- Main controls for the pumps should be located for easy view of the operator from the control position.

- The removable and/or mobile equipment for lifting loads should be used in a manner that ensures the stability of -the equipment during operation.

- Measures should be taken to bar persons from standing beneath a suspended load. Furthermore, it is also prohibited to move suspended loads over exposed workplaces where people are present.

MPPL/IM/VP/2006/0 2-2

Mather + Platt General Safety Information - The fastening devices should be adapted to the conditions at hand (weather, hooking

system, load, etc.) If these are separated from the pump after use, they should be expressly marked as fastening devices. Otherwise they should be carefully stored.

- Only fastening devices, which are legally designated as such and officially approved, may be used.

- When using mobile working equipment for lifting non-guided loads, measures should be

taken to prevent them from tipping, sliding, slipping etc. - If mobile working equipment is used for lifting loads, a second person should be present

to coordinate the procedure if needed (for example, if the operator's field of vision is blocked).

- While unloading the pump from the truck lift the pump by passing wire rope beneath the

box containing the pump or pump assembly. - The load to be lifted must be transported in such a way that there is no danger of injury in

the event of a power failure. Additionally, when working outdoors, such procedures must be interrupted immediately if weather conditions worsen.

- When working in enclosed spaces care should be taken to provide sufficient fresh air.

Provide sufficient ventilation. - When welding or working with electronic devices, ensure that there is no danger of

explosion.

- When working with pumps using hot liquid appropriate care should be taken. It is advised to use PPE irrespective of warning signs on pump/insulation provided depending upon the temperature of liquid handled.

- Environmental safety: Disposal of any unwanted/scrap material should be disposed in

appropriate way so as not to cause any harm to the environment. No hazardous material is used in M & P pumps.

These instructions must be strictly observed. Non- compliance can lead to serious personal injury and/or damage to the machine.

2.7 Safety instructions for the operator

- Local regulations for the prevention of accidents must be observed. Dangers resulting from electrical energy are to be prevented. National/local energy supply company regulations must be followed.

- Guards for moving parts (e.g. coupling) must not be removed from the machine while in

operation.

For safety reasons, safety and control devices must not be removed without authorization. Personnel must have the requisite specialist knowledge.

Use Standard Personnel protective equipments against sharp corners for protection of hands, for eyes when using grinders, Special PPE against electrical shocks, against sound (Cl 2.8) etc.

MPPL/IM/VP/2006/0 2-3

General Safety Information Mather + Platt

2.8 Electrical connection and electrical work Refer to the instruction manual for motor and panels at the time of installation and connection. Motors or electrical control panels are operated with alternating or industrial high-voltage current. It is recommended to use CE marked motor and / or electrical panel if they are not in M&Ps scope of supply. The local regulations must be adhered to. The "Electrical connection" data sheet in the respective motor and panel instruction manual must be followed when connecting the product. The technical specifications on the nameplate and in the machine data sheet must be strictly observed. Ensure that there is a provision for isolation of all energy sources and locking. If the machine has been switched off by, a protective device, it must not be switched on again until the error has been corrected. The electrical system (machine including protective devices and operating position) must always be grounded. Refer pump GA drawing & respective manuals of motor/electrical control panel for connecting earthing suitable as per motor rating and relevant regulations and standards including proper earthing lug size and fasteners.. If there is a possibility that people can come into contact with the machine and the pumped liquid (e.g. at construction sites), the grounded connection must be additionally equipped with a fault current protection device.

Electrical work (connection, maintenance and repair work) may only, be carried out by a qualified electrician. Any unused wires must be dis-connected! The cable ends must never be immersed in the pumped liquid!

Refer instruction manual of respective equipments like motor, panels etc for safety instruction to be followed when connecting these equipments to the pump and power supply and for the operation.

2.9 Operation with different pumped fluids The pump supplied is intended for specific fluid. Refer pump data sheet and order confirmation. For any change in pumped fluid refer M&P before hand. 2.10 Sound pressure Depending on the size and capacity (kW), the products produce a sound pressure of approximately 75dB (A) to 110dB (A). The actual sound pressure, however, depends on several factors. These include, for example, the installation type, fastening of accessories and pipeline, operating site condition, background noise, etc. Once the product has been installed, we recommend that the operator makes additional measurements under all operating conditions.

In accordance with the laws in effect, guidelines, standards and regu-lations, ear protection must be worn if the sound pressure is greater than 85dB (A). The operator is responsible for ensuring that this is observed!

For actual values on sound level & vibration at the time of pump testing on test bed refer to the Pump performance test certificate submitted along with other certificates.

MPPL/IM/VP/2006/0 2-4

Mather + Platt General Safety Information

2.11 Prime mover selection When prime mover is in M&Ps scope of supply, Electrical motors/diesel engines/steam turbines etc. are selected mutually with the customer/end user depending upon his requirements & absorbed power by the pump at duty point. Prime mover will be with CE marking. When pump is supplied along with prime mover and/or with control panel when in M&Ps scope, manufacturers instruction manual for respective equipment will be provided to the customer/end user along with the pump instruction manual.

2.12 Warranty This chapter contains the general information on the warranty. Contractual agreements have the highest priority and are not superseded by the information in this chapter! The manufacturer is obliged to correct any defects found in the products it sells, provided that the following requirements have been fulfilled: General information

- The materials used caused the defects or the way the product was manufactured or designed.

- The defects were reported in writing immediately to the manufacturer within the agreed warranty period.

- The product was used only as prescribed.

- All safety and control devices were connected and inspected by authorized personnel.

Warranty period

If no other provisions have been made, the warranty period applies to the first 12 months from the date of delivery / installation or 18 months from the date of dispatch from the works whichever is earlier. For details refer the warranty certificate provided. Other agreements must be made in writing in the order confirmation. Spare parts, add-ons and conversions

Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, add-ons and conversions. Only these parts guarantee a long working life and the highest level of safety. These parts have been specially designed for our products. Self-made add-ons and conversions or the use of non-original spare parts can seriously damage the product and/or injure personnel. Maintenance

The prescribed maintenance and inspection work should be carried out regularly. This work may only, be carried out by, qualified, trained and authorized personnel. The maintenance and inspection log supplied must be properly updated. This enables you to monitor the status of inspections and maintenance work. Quick repairs not listed in this operation and maintenance manual and all types of repair work may only be performed by the manufacturer and its authorized service centers. List of machine operators

The machine operator list must be filled out completely by signing this list, all persons working on or with the product confirms that they have received, read and understood this operating & maintenance manual. Damage to the product

Damage as well as malfunctions that endanger safety must be eliminated immediately by, authorized personnel. The product should only be operated if it is in proper working order. During the agreed warranty period, the product may only be repaired by, the manufacturer or an authorized service workshop. The manufacturer reserves the right to recall the damaged product to the factory for inspection.

MPPL/IM/VP/2006/0 2-5

General Safety Information Mather + Platt

Exclusion from liability No liability will be assumed for product damage if one or more of the following points apply:

- Incorrect design on our part due to faulty and/or incorrect information provided by the customer.

- Operation of product different/beyond the parameters specified in purchase order/approved data sheet.

- Non-compliance with the safety instructions, the regulations and the requirements and this operating and maintenance manual.

- Improper installation & pipe work.

- Faulty construction site and/or construction work.

- Chemical, electrochemical and electrical influences.

- Improper assembly/dismantling.

- Improper maintenance.

- Unqualified repairs.

- Wear.

This means the manufacturers liability excludes all liability for personal, material or financial injury.

2.13 REMARKS To avoid ambiguity in the use of the word `replace' the words `replace' and renew' are used in this manual in the following context: Replace - To put back, in its existing state, a part or component that has previously been removed. Renew - To substitute a new part of component for a worn or damaged one.

MPPL/IM/VP/2006/0 2-6

Mather + Platt Product description

3 Product description

3.1 General product information The machine is manufactured with great care and is subject to constant quality controls. Trouble-free operation is guaranteed if it is installed and maintained correctly.

3.2 Proper use and fields of application Vertical pumps are used in cooling tower condensate circulation, condensate extraction for thermal and nuclear power plants, irrigation & water supply, fire fighting, general industrial water supply and low NPSH requirements etc.

Precise information about this can be found on the order confirmation and on the pump data sheet.

3.3 Conditions of use

All vertical pump models are for use in non-hazardous area. For precise details about the model of the pump and design operating conditions, see Pump nameplate, motor nameplate & panel name plate when in supply scope and the pump data sheet. Do not operate the pump away from specified operating range. Operating beyond duty point may not pose a risk to the operator but will reduce the efficiency of the pump or damage the pump itself. Operation more than 5 minutes at close valve condition is not recommended. For hot liquids this is not recommended at all.

A dry run must be avoided at all cost. Ensure that always site NPSH-A is more than NPSH-R. Minimum submergence should be sufficient for vortices free operation.

MPPL/IM/VP/2006/0 3-1

Product description Mather + Platt

3.4 Construction 3.4.1 General description The pump is a vertical end suction pump. The unit is divided into three basic elements:

a. The pumping stages including bowl assembly. b. Intermediate piping works and extension shafting. c. Delivery bend & motor stool assembly.

The pumping stages are freely suspended from the delivery bend by intermediate pipe-work, depending upon the site conditions. In surface discharge installation, the delivery bend & motor stool are placed above floor level. The thrust bearing situated in the motor stool assembly supports the static-weight of the rotating assembly and also absorbs any axial thrust that is developed within the unit during operation. In sub-surface installation, delivery branch is located below operating floor. When expansion joint is installed between pump delivery branch and discharge line, a thrust block is provided opposite to delivery branch to take hydraulic thrust caused by delivery bend. When the pump is in operation fluid is directed by a suction bell-mouth into the impeller inlet. Rotation of the impeller vanes imparts energy to the fluid. This kinetic energy is converted into pressure energy as the liquid flows through diffuser vanes. 3.4.2 Detailed description 3.4.2.1 Suction bell mouth The suction bell mouth forms the inlet to the pump assembly and it is secured to the pump casing by studs and nuts. The bell mouth is designed specifically to stabilize and direct the flow of the incoming fluid into the eye of the impeller. 3.4.2.2 Diffuser casing The pump casing and diffuser are combined into a single unit and are in the form of a semispherical casting, which also incorporates delivery guide vanes. The guide vanes structure is centrally disposed within the casting and is bored to accommodate a bearing bush for the pump shaft. A spigoted flange is provided on the casting for the purpose of connecting it to rising main pipe. O-ring is provided between two flanges. When the head is not obtained by single stage, multistage pump is used. Number of Diffuser Casings & impellers are assembled in series to obtain desired head. 3.4.2.3 Rising main pipe Rising main pipes have flanged connections. Spigot joints are provided in flanges to ensure concentricity. The top rising column is connected to delivery bend. 3.4.2.4 Rotating element The rotating element consists of the pump shaft, impellers, intermediate extension shafting and solid muff couplings. Impellers are keyed to the pump shaft and axially located by pump bearing Sleeve. The complete impeller and sleeve assembly is end tightened against step on the shaft by an impeller nose cap which is locked in position by a locking screw. Intermediate shafts are coupled by solid muff coupling. 3.4.2.5 Impellers Impellers may be of axial flow or mixed flow (open or close). Refer specifications / datasheet / General arrangement drawing / cross sectional drawing for details. The impeller varies in size according to capacity of the individual pump. Close type impellers are hydraulically balanced to reduce axial thrust.

MPPL/IM/VP/2006/0 3-2

Mather + Platt Product description 3.4.2.6 Neck rings / throat liner The impellers necks are accurately machined to provide a close running fit in the neck rings that surround them. The close clearance between the neck rings and impeller necks minimize the leakage of fluid from the high-pressure areas to the low-pressure areas of the pump. To enable this close clearance to be restored periodically as wear takes place, the neck rings are renewable. Semi-open impeller has 0.8 to 1.0 mm gap between throat liner and impeller vanes. 3.4.2.7 Delivery bend / Delivery tee Delivery bend, which forms discharge branch of the pump unit is a fabricated component and situated above operating floor level. The bottom flange of the delivery bend supports rising main pipe and pump bowl assembly. It accommodates the stuffing box and split gland assembly for sealing the top shaft. In sub-surface discharge configuration, delivery tee is located below operating floor. If space permits, delivery tee accommodates the stuffing box and split gland assembly for sealing the top shaft. Alternatively stuffing box is provided in bottom flange of motor stool. Thrust block, if provided, is located opposite to delivery branch. Tapping is provided in outlet flange of delivery pipe to accommodate pressure gauge.

Refer general arrangement drawing for the position of delivery branch, stuffing box and thrust block.

3.4.2.8 Motor stool It is a fabricated structure. In surface discharge installation, bottom flange of motor stool rests on the top of delivery bend. In sub-surface discharge configuration, motor stool rests on sole plate. The top flange of motor stool supports the drive motor. Pump thrust bearing assembly, non-reverse ratchet assembly (when provided) and coupling between pump and motor are mounted in the motor stool. Openings are provided to access the parts housed in motor stool. When hollow shaft motor is provided with combined thrust bearing for pump and motor, motor stool and coupling to connect pump - motor shafts are not provided.

Refer cross sectional drawing for the configuration of motor stool. 3.4.2.9 Thrust bearing assembly It consists of thrust bearing to take up axial and radial thrust. Small verticals pumps have grease lubricated bearings while medium to large verticals have oil lubricated bearings. Pump may have white metal lined bearing as customer requirement. Refer Fig. 7, which is a general indicative figure of the assembly.

Refer to general arrangement drawing/cross sectional drawing / thrust-bearing assembly drawing supplied along with the pump for exact configuration and details.

3.4.2.10 Non reverse ratchet (Optional)

Non Reverse Ratchet is mechanical device to prevent the reverse rotation of pump motor during flow reversal condition. It consists of a fixed ratchet and rotating pins as shown in typical cross sectional drawing. The ratchet plate teeth allow pins to slide up during normal direction of rotation. However during reversal the pins engage with the teeth and prevent reverse rotation.

MPPL/IM/VP/2006/0 3-3

Mather + Platt Transport & storage

4 Lifting, Transport and storage

4.1 Handling In order to prevent damage or serious injury when lifting & transporting the product, the following points must be observed:

- Lifting transport work may only be carried out by, qualified personnel. The safety instructions must be followed at all times.

- Only suitable lifting gear and load carrying equipment with valid test certificates and adequate lifting capacity for the loads involved (such as belts/wire ropes/slings) should be used for lifting & transporting the product. If chains are used, they should be secured against slipping along with protective cover to prevent damage to the product, paint and/or injury to personnel.

- See also "General Safety Information", section 2.

Fig. 1

Lifting diagram

While handling care should be taken so that pump flanges, shaft extensions, suction bell mouth etc. are not damaged

Safe working load of wire ropes reduces with increase in included angle of wire ropes.

Reduction of lifting Capacity with increase in included angle between legs

Included angle

0 30 60 90 120

Lifting Capacity

100% 95% 75% 70% 50%

MPPL/IM/VP/2006/0 4-1

Transport & storage Mather + Platt

4.2 Delivery On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of delivery. Any claim made at a later date will be deemed invalid. Damage to parts must be noted on the delivery or freight documentation.

4.3 Transport Only the appropriate and approved fastening devices, transportation means and lifting equipment may be used. These must have sufficient load bearing capacity to ensure that the product can be transported safely. The product is delivered by the manufacturer / shipping agency in suitable packaging. This normally precludes the possibility of damage occurring during transport and storage. The packaging should be stored in a safe place if the location used is changed frequently.

4.4 Storage Short-term storage The equipments as shipped have adequate protection for short-term storage in a covered, dry and ventilated location at the job site prior to installation. Long-term storage

If the equipment will be subject to extended storage condition prior to installation, then the manufacturer must be informed about storage duration, so that special protection can be recommended.

The following should be taken into consideration for storage

- Place the product on firm foundation and secure it against falling. HSC pumps, End suction pumps and multistage pumps should be stored horizontally and Vertical pump assemblies vertically.

Never put down or pick up the product when it is not secured. Bending the product should be avoided at all costs. It can cause major damage to the product and/or serious injury to persons.

- Any suction or delivery pressure connections on products should be closed tightly before storage to

prevent impurities.

- The machine must be protected from direct sunlight, heat, dust, and frost.

- The rotors or propellers must be turned at regular intervals. This prevents the bearing from locking and the film of lubricant on the mechanical shaft seal is renewed.

If product is to be stored for a longer period, contact M&P for preservation measures to be taken.

4.5 Returning to the supplier Products, which are delivered to the plant, must be clean and correctly packaged. In this context, clean means that impurities have been removed and decontaminated if it has been used with materials, which are hazardous to health. The packaging must protect the product against damage. If you should have any questions please contact M&P.

Products, which are not suitably packaged on delivery, are no longer covered by guarantee!

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Mather + Platt Installation

5 Installation In order to prevent damage to the machine or serious injury during installation the following points must be observed:

- Installation work assembly and installation of the machine may only be carried out by, qualified persons. Any errors in fitting or refitting will not pose risks to persons but pump will malfunction or performance of pump will be affected or internals will be affected. The safety instructions must be followed at all times.

- Before any installation work is carried out, the machine should be inspected for damage that may have occurred during handling, transport & storage.

- See also General Safety information, Section 2.

5.1 Introduction This section provides instructions on the recommended methods of installing vertically suspended mixed flow pumps. Careful attention must be paid to the customer and contractors installation drawings during the installation procedures to ensure that the pumping set is accurately positioned on the correct datum levels. The installation of the pump set may be divided into five stages, namely preparing the foundations, installing the pump, installing the drive unit, alignment, connecting the pipe work and coupling the drive.

5.2 Requirements for the operating area

Pumping machinery should have adequate access and working room for maintenance operations. Adequate overhead space for lifting devices and working clearance must be provided.

5.3 Cleaning Clean any anticorrosive protection from the mounting surfaces using a rag moistened with white spirit.

Do not use any chlorinated solvents such as carbon tetrachloride and trichloroethylene. Bearings, shafts etc should be cleaned and coated with lubricant till such time they are actually taken for installation.

MPPL/IM/VP/2006/0 5-1

Installation Mather + Platt

5.4 Foundations Installation of the pump cannot be done in continuous sequence because two time periods are required to permit to grout to set. The first period occurs after soleplate has been leveled and foundation bolts half grouted. The second time lag occurs after full grouting of soleplate, which is after final alignment of pump and driving unit after piping. A suitable foundation for the pump must be prepared with pockets to accommodate the foundation bolts. The strength of the foundations must be adequate for the static & dynamic loads imposed and depend upon the local soil conditions. The top surface over which the soleplate rests must be left rough to assist in keying of the final grout and sufficient allowance must be made for the thickness of the steel packing and leveling shims beneath the soleplate, the requirement being approximately 25 mm. Foundation work is usually completed before the pump arrives on site but it is mentioned here because it is logical to begin the installation procedure sequentially.

Indicative drawing for foundation.

For details & dimensions refer general assembly drawing.

Fig. 2

MPPL/IM/VP/2006/0 5-2

Mather + Platt Installation 5.5 Soleplate & pump installation

5.5.1 Soleplate installation The sole plate has machined surfaces on both top and bottom; therefore no distortion of mounting plate can be caused due to weight of the unit when supported on a leveled surface of sole plate. To avoid the distortion of sole plate if mounted directly on the uneven surface of foundation, initially the top surface of foundation over which the sole plate rests must be left rough to assist in keying the final grout, after the sole has been leveled by positioning steel packer plates at suitable intervals on the foundation surface as described in 5.5.2. Ensure that the surface beneath each packing plate is solid by crushing any protrusion or alternatively each packer plate may be placed on a thin screen of cement.

5.5.2 Leveling of sole plate 5.5.2.1 Provide suitable packer plate (25 mm to 30 mm thick) or taper wedges on the foundation one each

of either side of foundation bolt and in-between around 250 mm center to center. It is advisable to provide thin layer of cement below the packer plate.

5.5.2.2 Lift the soleplate and lower it on the foundation. Insert the foundation bolts through the holes in the soleplate and screw a nut on to each bolt until the bolt protrudes through the nut by a length, which is sufficient to accommodate a lock nut.

5.5.2.3 Level the soleplate as follows.

a. Use I beam straight edge and an engineers master level (with accuracy of 0.02 mm / meter) for leveling the soleplate. I-beam should rest on the machined surfaces of the soleplate.

These machined surfaces where level is being checked must be clean and free from paint, burrs etc.

b. Adjust the level of the soleplate by inserting shims between the soleplate and the packer plate until

the soleplate is leveled. and supported on all the packing blocks at the height as shown in the general arrangement drawing. For checking the levels & straightness, I-beam type straight edge should be used extensively in conjunctions with engineers master level. Level should be achieved within 0.05 mm per 250 mm. Also ensure that elevation of bedplate is adjusted suitably as shown in General Arrangement Drawing.

5.5.2.4 When the soleplate is leveled, grout the foundation bolts only. Care should be taken so as not to disturb the verticality of foundation bolts. For grouting use rich mix of 1: 1:2 of cement, sand and gravel below 12 mm. Alternatively quick setting grout mix can be used.

5.5.2.5 When the grout has set, gently but firmly tighten the foundation bolts. Care must be taken not to distort the soleplate or loosen the foundation bolts in the grout by excessive tightening.

5.5.2.6 Carefully re-check the level of the soleplate and make adjustments that are necessary by fine shimming. Ensure that the sole plate is leveled, as per the site datum level, various centerlines etc.

5.5.3 Installation/assembly of pump Depending upon column length of the pump it may not be possible to dispatch the pump in fully assembled condition and pump needs to be assembled at site in sequential manner. For installation and assembly purpose suitable beams are required to be placed across the opening over the sole plate. Following sequence should be followed while erection of pump:

5.5.3.1 Lower the pump assembly, comprising of suction bell mouth with suction strainer, casing & diffuser and rising main pipe (bottom) in the sump with the help of sling and EOT crane. Support the assembly on Beams placed across the opening over the soleplate, (If necessary supporting channels must be held together with help of tie rods).

5.5.3.2 Couple first intermediate shafts with pump shaft by solid muff coupling.

Where SS components are fitted, contact surfaces should be dusted with molybdenum disulphide paste to prevent galling.

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Installation Mather + Platt 5.5.3.3 Lift bottom shaft protection tube, if provided, and lower on to the pump assembly. Lift first

intermediate rising main pipe and lower on to the top flange of bottom rising main pipe. Ensure that the O rings have been placed between the flanges. Insert screws & nuts to tighten them.

5.5.3.4 Take first intermediate bearing bracket and lower it on to first intermediate shaft till it is located in groove of top flange of bottom rising main pipe. Ensure that 'O' ring are fitted on both sides of bearing bracket.

5.5.3.5 Slowly raise the whole assembly slightly, comprising of the bottom rising main pipe and pump assembly, remove channels and lower the assembly further into the sump till supporting flanges or lugs of bottom pipe are rested on channels across the sole plate opening.

5.5.3.6 Assemble 2nd intermediate shaft to 1st intermediate shaft through muff coupling.

5.5.3.7 Take 2nd rising main pipe & lower its slowly with the help of slings and crane on the bottom rising main pipe. Ensure that intermediate bearing bracket is located correctly.

Insert bolts and nuts and tighten them properly and evenly.

Rubber O ring should be inserted on both sides of intermediate bearing bracket.

5.5.3.8 Assembly of remaining shaft tubes, if provided, rising main pipes and intermediate shaft is done in same way as explained in seq. earlier.

5.5.3.9 Lift delivery bend and lower on to the top flange of rising main pipe. Tighten the fasteners. Care must be taken to have a O ring between two flanges.

Raise entire assembly, remove temporary support beams and lower down till bottom flange of delivery bend rests on sole plate & fix it with soleplate.

Lift delivery bend and lower on to the top flange of rising main pipe. Tighten the fasteners. Care must be taken to have a O ring between two flanges.

Raise entire assembly, remove temporary support beams and lower down till bottom flange of delivery bend rests on sole plate & fix it with soleplate.

5.5.3.10 Stuffing box assembly: The packing supplied with pumps by Mather & Platt Ltd. is packed in a separate box and should be fitted at site as under:

a. The stuffing box and gland sleeve should be thoroughly cleaned and full entry of gland into stuffing box must be checked.

b. Insert three rings of gland packing into stuffing box. c. Check if each ring of packing length passes round the shaft and meets end to end, theends being cut

square.

Insert logging ring in the stuffing box.

Insert remaining three rings of gland packing into stuffing box.

The packing ring should be inserted into the stuffing box. Each ring should be pushed into position individually using the gland.

d. The joint of each ring must be positioned at 180 deg from joint of its neighbor.

e. Fit gland square with stuffing box and gland nuts should be screwed up to little more than finger tightness.

While re-packing, if packing is available in complete coil from or rope form, then the quantity required for immediate use only should be taken. Each ring of requisite length should be cut so that it passes once round the shaft and meets end to end, the ends being cut square.

Packing should be handled with care and it should not be allowed to pick-up dust or abrasive foreign matter by coming into contact with floors or dirty benches. It is bad practice to hammer packing to facilitate the insertion.

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Mather + Platt Installation 5.5.3.11 Thrust bearing assembly:

(Please refer the typical cross section of thrust bearing assembly)

Thrust Bearing: Thrust bearing assembly provided on this pump comprises of bearing housing, cover, thrust block, locknut, Oil lubricated spherical roller thrust bearing or Grease lubricated deep groove ball bearing as Guide bearing, angular contact ball bearing as Thrust bearing. The outer race of bearing is fitted in the housing where as the inner race is fitted on the thrust block.

For grease lubricated bearing the top surface of thrust block is provided with 6 or 8 equi-spaced holes into which the locking screw can be engaged. The rotating element is set at desired position by engaging the locking screw in the nearest hole, after rotating the lock nut through requisite number of turns.

This thrust bearing assembly requires very little maintenance other than occasional feeding up of lubricating Oil/Grease. The thrust bearing assembly should be completely dismantled, cleaned and reassembled after 8000 hours approximately (Grease lubricated bearings) and 2000 hrs approximately or as required by site conditions (Oil lubricated bearings).

For oil-lubricated bearings when level of oil goes down below required level, the fresh lubricating oil should be filled up to the required quantity.

For Grease lubricated bearings the fresh lubricating grease should be filled up to the required quantity with help of grease gun after every 2000 hrs. running of pump. Before greasing, the grease drain plug should be opened so that while filling the fresh grease, the deteriorated grease drains out.

During assembly of thrust bearing (oil lubricated) follow the following procedure:

Fit oil retaining bush to bearing housing.

Fit inner race of thrust bearing on thrust block & outer race in bearing housing.

Fit bearing housing to motor stool.

Fit thrust block on top shaft so that inside diameter of thrust bearing fits on thrust block.

Fit bearing cover to bearing housing.

During tightening of the lock nut, measure the total float of the rotating element and maintain it at half position from bottom for closed type impeller or to get 0.8 to 1.0 mm front clearance for semi-open impeller. Lock the lock nut on thrust block with the help of locking screw.

5.5.3.12 Fit mounting plate and then ratchet plate at their respective position. 5.5.3.13 Fit pump half coupling on top shaft. An adjusting ring is provided below pump half coupling. This

ring can be machined to maintain the gap of 5 mm 2 mm between pump half and motor half coupling.

5.5.3.14 Place the motor on top flange of motor stool and complete the alignment as given in 5.6. 5.6 Alignment of pump and driving units: The following procedures outline recommended practice given in BS-3170 in 1972 (Appendix A) for checking shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected by canted coupling faces or eccentricity of the outside diameter of the coupling. Before commencing the alignment, rotate each shaft independently to check that the bearings run freely and that the shaft is true to 0.1mm or better. Check that no damage can be caused when the shaft of the driven unit is turned. Coupling should be loosely coupled and the halves must be free to move relative to each other, otherwise gauge Indicators can be incorrect. Where, tightly fitting pins or spring prevent loose coupling, the springs or pins should be removed, a line scribed across both half couplings and readings taken only when the two marks are aligned.

MPPL/IM/VP/2006/0 5-5

Installation Mather + Platt

Before proceeding for alignment please ensure

a. Bearings are properly lubricated.

b. Pumps with stainless steel internals shaft should be rotated only after taking pump liquid inside the casing. Any dry rotation may cause severe damages to pump internals.

5.6.1 Radial alignment Clamp a dial gauge on one of the couplings or to the shaft as shown in figure 4. with the plunger resting on the rim of the other half coupling. Set the dial zero. Rotate the coupling and note the reading at each quarter revolution. Any variation in the readings indicates the deviation from alignment and the position of one of the units must be adjusted until the readings at each quarter revolution are identical or within the tolerances given below.

If fitment of dial gauge is not feasible use small straight edge across the two coupling half flanges.

5.6.2 Angular alignment Angular alignment for vertical pumps is totally dependent on the accuracy of leveling of sole plate and motor stool, since any adjustment at later stage is practically not feasible. How ever one can check the angular alignment as follows After isolating the driven unit from its power supply, clamp two dial indicators are dramatically opposite points on one half coupling or to the shaft behind it with the plunger resting on the back of the other half coupling as shown in figure3. Rotate the coupling unit the gauges are in line vertically and set the dial to read zero. Rotate the coupling by 180 and record the readings on each gauge. The readings should be identical, though not necessarily zero. Either positive or negative readings are acceptable provided they are equally positive or negative. Adjust the position of one of the units if necessary. Rotate the couplings unit the gauges are in the line horizontally and adjust the dial to zero. Repeat the operation outlined above by rotating the coupling by 180. In case where fitment of dial gauge is not feasible check gap between two coupling half with the help of filler gauge.

5.6.3 Alignment tolerances Pump speed Angular alignment Radial alignment a < 1000 rpm 0.15 mm TIR 0.15 mm TIR b > 1000 rpm to 1800 rpm 0.1 mm TIR 0.15 mm TIR c 1800 rpm to 3000 rpm 0.1 mm TIR 0.1 mm TIR

TIR- Total indicated reading The above tolerances are general guidelines since it may very with different types of coupling and its manufacturers standards. However it is recommended that for higher speeds greater degree of accuracy must be observed. All the alignments (angular as well as radial) have to be carried out by using 3 dial indicators, simultaneously.

MPPL/IM/VP/2006/0 5-6

Mather + Platt Installation

Couplings

Fig. 2

Fig. 3

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Installation Mather + Platt

5.7 Pipe work No stress must be imposed on the pump casing by the pipe work; either by the weight of the pipes or by the tightening of badly fitting pipes. Experience has showed that such stress can seriously affect the alignment of the pump unit. All pipe worked attached to the pump must be fully supported and the mating faces of the pipe flanges must be parallel and all bolt holes coinciding with each other. It is important therefore that alignment of the pump and motor should be re-checked after the pipes are finally fitted. Resetting or supporting the pipes must correct any deviations in the alignment.

Fig. 4

5.7.1 Suction condition Intake design Pump intake by way of sump should supply evenly distributed vortices free flow with adequate submergence of pump. Use of strainer If strainer is used it should have opening area which is three times the area of the upstream pipe. Differential pressure gauge / switch should be fitted across strainer to monitor any chocking and resultant pressure drop. It is advisable to connect this to operation logic of pump. Sump Design The design of sump has great influence on trouble free & smooth operation of pump. The special attention must be paid to sump design When two or more no. of pumps are operated in combinations of working + standby conditions. It is recommended that when space & site constraints do not allow the suction sump design as per recommendation of HIS the suction sump design should be verified by a model study. Whenever model study has been carried out previously for optimizing sump design, its recommendation regarding corrective structures should be fully implemented.

MPPL/IM/VP/2006/0 5-8

Mather + Platt Installation

5.7.2 Delivery conditions

A suitable sluice valve should be fitted in the delivery pipe as near to the pump as possible, along with non-return valve. Pump casings have sometimes been cracked by pressure surges imposed on them through the absence a non-return valve. It is often an advantage to provide these valves with by-pass connections, although these are not always required.

5.7.3 Stuffing box packing Pumps are dispatched from our Works with the stuffing boxes unpacked; otherwise, packing will be aged. The packing is packed with greaseproof paper and dispatched with the pump. The softest possible packing i.e. plaited cotton impregnated with oil and colloidal graphite is recommended for most duties. Required number of lengths of packing should be cut off so that each length will pass once round the shaft sleeve line and meet to end. The ends of packing must be cut square. After cleaning the stuffing box and shaft sleeves the packing should be inserted into the stuffing box. Each ring should be pushed into position individually using the glands joint of each ring must be positioned 180 from joints of its neighbor. if a logging ring is included in them arrangement should be inserted into the stuffing box at the appropriate time during the packing sequence so that it is aligned with the cooling water connection. The gland should now be fitted square with the pump casing and the nut should be screwed up to little more than finger tightness.

5.8 Use of diesel engine as prime mover

The location of installation of installation should have facility for disposal of exhaust gases and supply of continuous air. Pump house should have acoustic design.

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Mather + Platt Start-up

6 Start-up

6.1 Introduction This chapter covers the commissioning and operation of pump only. For commissioning of motor, engine, turbine & electrical panels respective instruction manuals should be referred. This procedure also should be adapted after each major overhaul. See also General Safety information, Section 2.

6.2 Pipe work flushing Before the pumps are brought into service, either on initial commissioning or on re-commissioning after overhaul, the pipe work associated with the pumps must be flushed through. This will clear deposits or scales which may have accumulated in the pipes, and which could damage the internal components of the pumps.

6.3 Cleaning of bearings Where possible, especially if the unit has been in store for a long period before commissioning, the bearings should be cleaned and flushed out with clean white spirit or good quality paraffin. Waste should not be used for this purpose, as particles of foreign matter may be left behind which would cause damage when the bearing is in service. Bearings should be then filled with recommended grade and quality of fresh lubricant to the level. Refer list of lubricants at the end of this manual. Ball and roller bearings are given an initial charge of grease before leaving Mather & Platt Works and do not require any attention beyond the normal greasing routine before the first servicing period. Only greases selected from the table at the end of the manual or their equivalent should be used. Bearings should never be over greased.

6.4 Direction of rotation Disconnect the drive coupling and run the motor to check its direction of rotation. A directional arrow is provided on the pump unit.

6.5 Availability of liquid

Efficient operation of the pump depends upon fine running clearance that is lubricated by the pumped fluid. Sufficient fluid must be available to ensure that the pump is flooded at all times to prevent seizure of the internal components. Wherever external flushing/lubrication is provided it should be available before starting the pump.

If on starting, a pump fails to generate at least its rated delivery head, as indicated on the pump nameplate, it must be stopped immediately, the cause ascertained and rectified, before re-starting.

Ensure that minimum submergence is available as recommended.

Open all ancillary inlet and outlet isolating valves such as, bearing cooling systems, gland sealing, or cooling systems, air vents, leak-off connections etc.

The efficient operation of a centrifugal pump depends upon fine running clearances, which are lubricated by the pumped liquid. Any attempt to run the pump dry or partially full may result in seizure of the rotating internal components. These pumps must therefore be properly primed before starting, with venting of all the air, gases, vapor etc.

Any attempt to run the pump dry or partially full may result in seizure of the rotating internal components.

MPPL/IM/VP/2006/0 6-1

Start-up Mather + Platt

6.6 Pre-starting checks 6.6.1 Ensure that sufficient fluid is available at the pump suction for satisfactory operation of the pump.

Efficient operation of the pump depends upon the running clearance, which are lubricated by pumped liquid. Any attempt to run the pumps dry or partially full will result in seizure of internal rotating components.

6.6.2 Normally centrifugal pumps are started with delivery valve closed. How ever for mixed flow as well

as axial flow pumps where power consumption at closed valve is higher it is recommended to start the pump with delivery valve in suitably open / throttle condition. It is also advisable to provide non return valve in the delivery line.

6.6.3 Ensure that bearings have been filled with proper grade of lubricant. 6.6.4 Check that there is no blockage in the strainer at the end of pump. 6.6.5 Check for free rotation of the unit when coupled. 6.6.6 Check that delivery pressure gauges are connected. Test and make available any alarm, signals,

interlock systems and any of the protective devices incorporated in the auxiliary and main pumping control system.

6.6.7 Ensure that all electrical checks on motor, relay setting in panel etc have been carried out in

accordance with the instructions of motor manufacturer. 6.6.8 Ensure that stuffing box sealing water seal connection is provided as shown in GA Drawing.

Refer checklist A.6 for recording the data.

6.7 Normal Starting checks 6.7.1 When all the foregoing pre-start checks are satisfactory, depress the appropriate `START' button on

the control panel and run the pump at its rated speed. 6.7.2 Check that the pump is rotating in the correct direction. This is indicated by a direction arrow on the

motor stool / delivery bend. 6.7.3 Check the ammeter reading to ensure that the motor is not being overloaded. 6.7.4 Check that the pumping unit is generating not less than its rated delivery pressure indicated in the

data sheet/name plate.

If the pumping unit fails to generate at least its rated delivery pressure it must be stopped immediately, the cause ascertained, the fault rectified before restarting.

6.7.5 Ensure that the stuffing box is not overheating and that there is slight leakage from the gland. There

may be at first a tendency for the stuffing boxes to run warm because of the high viscosity lubricant in the packing. During the first few minutes of running with new packing, a small quantity of very viscous fluid will be extruded, but the flow should cease when the packing has settled down.

6.7.6 Check that the bearing is not overheating. The ideal running temperature of bearings is 40 C to 60

C for ball bearings and 40 C to 55 C for bush bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 C for all bearings and 75 C for bush bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

MPPL/IM/VP/2006/0 6-2

Mather + Platt Start-up

If the bearings are overheating its cause should be investigated immediately.

6.7.7 If the foregoing checks are satisfactory, open the delivery valve slowly and bring the pump gradually

up-to its rated parameters based on pressure gauge and ammeter readings. Unless the pump is fitted with a special leak-off device, it should not be run for a long period against a closed delivery valve.

6.7.8 Check that the driving unit is not being overloaded during valve opening.

Overloading may occur if the pump is discharging into an empty system when the delivery head will be temporarily lower than that for which the pump is designed. Careful regulation of the discharge valve until the system is fully charged will prevent this.

6.7.9 Check vibration of pump set and ensure that vibration level is within limits specified in Hydraulic

Institute Standard of America. Check that noise level is within stipulated limits. 6.7.10 Check the pump and motor for overheating, excessive vibration and noise. Report any faults. During

first commissioning, the pumps may be run for 8 hours trial operation and all the parameters like delivery pressure, current, bearing temperature, etc. Be recorded periodically.

6.8 Running Checks: Once the pump is started and duty conditions are set, operator intervention is not required except running checks and unless pump is to be stopped. Make the following checks at regular intervals. It is recommended that they be made at every change of shift. 6.8.1 Check the suction and discharge pressure gauge for normal operating pressure, if there is

significant drop in the suction or discharge pressure the pump may have lost its supply. In the event of this fault occurring, the pump must be stopped immediately and the cause of liquid loss eliminated.

6.8.2 Check the stuffing box assembly for overheating.

6.9 Normal Shutdown 6.9.1 Depress the appropriate STOP button on the control panel. 6.9.2 When the pump has come to rest, close the pump delivery valve. 6.9.3 Isolate any ancillary supplies.

6.10 Emergency Shutdown In the event of any malfunction of the equipment, trip the pump set. When the pump has come to rest, close discharge valves, isolate the driving unit power supply & rectify the fault.

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Start-up Mather + Platt

Fig. 5 Vertical Pump-Axial Flow

MPPL/IM/VP/2006/0 6-4

Mather + Platt Start-up

Fig.6 Vertical Pump-Mix Flow MPPL/IM/VP/2006/0 6-5

Start-up Mather + Platt Ref Description Qty

4130 Grease shield 1

3280 Key (thrust block) 1

3012 Lock nut 2

3020 Locking washer 1

2883 Thrust block 1

2882 Thrust bearing housing 1

2601 Angular contact ball bearing 1

2600 Deep groove ball bearing 1

2007 Ratchet holder plate 1

2004 Ratchet pin 6

2001 Ratchet bush 6

2000 Ratchet plate 1 4890 Sole Plate 1

4830 Flexible coupling (PH) 1

4680 Motor stool 1

4660 Flexible coupling (MH) 1

4600 Erection packers (pairs) 4

4580 Coupling guard 1

4221 Anti rotation pin (Gland sleeve)

1

3250 Key (Flexible coupling) 1

3032 Sleeve nut 2

2410 Gland packing --

2318 Leak off bush 1

2311 Gland 1

2106 Gland sleeve 1

1822 Adjusting ring 1

1804 Top shaft 1

1152 Rising main pipe (Top) 1

1040 Delivery bend 1

Fig. 7A Typical Cross section of vertical pump (Part 1) MPPL/IM/VP/2006/0 6-6

Mather + Platt Start-up 4910 Suction bell mouth 1

4900 Suction strainer 1

4250-1 O ring 5

4250 O ring (Casing & diffuser) 3

3260 Key (Solid muff coupling) 4

3210 Key (Impeller) 2

2834 Intermediate brg. sleeve 2

2832 Impeller sleeve 2

2830 Bearing bush (Pump) 2

2801 Bearing bush (Intermediate)

2

2800 Intermediate bearing bracket

2

2060 Split collar 2

2050 Solid muff coupling 2

1805 Intermediate shaft 1

1802 Pump shaft 1

1704 Impeller distance piece 1

1651 Impeller nose cap 1

1504 Impeller 2

1181 Neck ring 4

1151 Rising main pipe (Intermediate)

1

1150 Rising main pipe (Bottom) 1

1030 Casing & diffuser 2

Fig. 7b Typical Cross section of vertical pump (Part 2) MPPL/IM/VP/2006/0 6-7

Mather + Platt Maintenance

7 Maintenance See also General Safety information, Section 2.

7.1 Routine maintenance & frequency of inspection Vertical pump requires very little routine maintenance beyond periodic replenishing of grease/oil in the bearing assemblies. However, serious troubles can be often avoided by regular observation and analysis of various working parameters. Some of the routine maintenance checks for this purpose are as under:

7.1.1 To keep daily logbook records of working parameters like suction and discharge pressure, flow rate, current drawn, bearing temperature, etc. These parameters should be recorded twice a shift. Any sudden change should be a signal for investigation. Refer Section A.2 for Maintenance & Inspection log.

7.1.2 Bearings will normally run at a temperature of 30C -35C above ambient temp. The ideal running temperature of bearings is 40 C to 60 C for ball bearings / roller bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 C for all bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

7.1.3 Vibration & sound level readings should be taken once in a fortnight and values compared with that of previous records.

7.1.4 Check that there is sufficient leakage from the gland packing to ensure proper cooling and lubrication.

7.1.5 Pump bearings should be replenished with correct grade of grease/oil after every 1000 Hrs. Grease should be changed completely after every 3000 hours or as required by site condition. Recommended type and grade of grease is indicated in section 7.4

7.1.6 Fault Finding - Many of the common faults which occur on centrifugal pumps and which can be diagnosed by observations are given in the chart under section 8.

In case fault can not be diagnosed, please fill up the Issue/Feed back report no SR01-02 and send to service department at Mather & Platt headquarters at Pune / nearby regional office or the representative within EEA.

After a long period of service, wear will occur in parts of the pump, necessitating the renewal of a few components. Parts, those are most likely to be affected are impeller/ wearing ring, bearing, neck rings, bearing sleeves and bearing bushes. Logbook records will indicate wear as gradual deterioration of performance is noticed. Once this is known, pumps should be taken for overhaul. It is recommended that yearly stripping & checking of wear & tear and clearances should be done and overhauling where required.

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Maintenance Mather + Platt

7.2 Overhaul maintenance 7.2.1 General information It is inevitable after long service that certain components will become worn. Frequently it is more economical to renew the worn components completely, but where site machining and engineering facilities are available most components can be restored if wear is not too far advanced. It is impossible to be mandatory regarding the periods at which major overhauls should be undertaken as this will be dependent upon the fluid being pumped, the site operating conditions, and the length of operational availability required. The determination of when major overhaul should be carried out will depend upon the performance of the pump, i.e. its rate of deterioration by reference to instrumentation, during the current operational period. If the hydraulic or mechanical performance has deteriorated to such an extent that no further deterioration can be tolerated during the next operational period, wearable components should be renewed. If related pair of components show a marked degree of wear in relation to the rest of the unit, then it may be sufficient to renew only the heavily worn components. If the wear is uniform throughout the pump, then all wearable components may require renewal. Measurements should be taken and recorded of all wearable components at the first, and every subsequent overhaul period. Reference to these records will enable an accurate assessment of the rate of wear to be made, and a reasonably accurate forecast regarding when a particular component may require renewal can be made. Information regarding original design dimensions and clearances is furnished in data sheet. Any other information if needed can be obtained on application from Service Department, Mather & Platt Pumps Ltd., Chinchwad, Pune 19 India. Such request must quote nameplate number and type of the pump in question. The parts most likely to be affected are:

1. Impeller / wearing rings. 2. Neck Rings. 3. Bearing bush. 4. Bearing sleeves. 5. Bearings.

Before commencing dismantling operations, ensure that the following tools and tackles are available

1. A crane / chain pulley block suitable for handling the weight of pumping unit.

2. A selection of ring and open-ended spanners in British, American, and Metric sizes.

3. Eye-bolts in British and Metric sizes.

4. Cotton rope, wire rope and slings.

5. Hardwood and metal packing blocks.

6. Miscellaneous tools including a set of Allen keys, drills, pin drivers, files etc.

7. Extractor / puller for bearing and coupling.

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Mather + Platt Maintenance

7.2.2 Removing the top motor

a. Isolate the pump motor electrically.

b. Isolate the pump system hydraulically.

c. Clear the area of any equipment that might impede the free lifting of the pump.

d. Disconnect and remove the driving coupling.

e. Disconnect the electrical supply cables from the motor terminal block.

f. Attach slings and lifting apparatus to the motor lifting attachments.

Refer to motor instruction manual and follow the instructions for lifting the motor.

g. Remove the screws / bolts, or nuts, from the motor flange and lift the motor off the combined delivery bend & motor stool. Support the motor on timber packing blocks with the coupling hub clear off the ground.

7.2.3 Dismantling the intermediate assembly The intermediate assembly consists of delivery bend, motor stool, rising main pipes, intermediate shafts, muff coupling etc. Dismantling of intermediate assembly is done in reverse sequence as explained in (Installation of pump).

Unnecessary removal of the bearings should be avoided because removal of the bearing can damage it and cause deterioration of the interference fit. Except where removal is necessary to give access to the other parts, bearing should be removed only if they need close inspection. Symptoms, which will indicate the state of bearing, are the condition of the lubricant, the bearing running temperature, noise level and vibration during operation.

7.2.4 Dismantling the pumping stages Pumping stages assembly consists of suction bell mouth, diffuser casing, impeller pump shaft, rising main pipe, etc. Dismantling is done in following sequence:

a. Remove the fasteners securing to diffuser casing & rising main pipe and lift the rising main pipe off the pump shaft.

b. Dismantle the suction bell mouth from diffuser casing.

c. Remove the locking screw and unscrew the impeller nose cap. d. Remove the impeller. It may be necessary to apply heat to the impeller for removal. Apply heat

uniformly from the shrouds inwards towards the hub. Before removing the impeller put a reference

mark on the shaft for ease of re-assembly at correct center position. e. Remove the retainer ring, bearing bush from pump bearing bracket.

MPPL/IM/VP/2006/0 7-3

Maintenance Mather + Platt 7.2.5 Examination Of Internal Components With the bell mouth, diffuser casing, impeller and shaft dismantled, the internal components and clearances can be checked.

7.2.6 Neck rings / throat liner Examine the neck rings / Throat liners, for wear or grooving. Light scoring will not be detrimental to the hydraulic performance of the pump, but deep or profuse grooving, coupled with extensive wear will impair the efficiency of the machine. Use an internal micrometer to measure the bore of casing ring, taking measurements at intervals around the circumference to check for uneven wear. A comparison between this dimension and that of the impeller neck will indicate the amount of diametrical clearance between the casing neck ring and the impeller neck. If this clearance is 150% or more than the original design clearance, or if the deterioration in hydraulic performances has been such that no further deterioration can be tolerated during the next operation period, The impeller-wearing ring to casing neck ring clearance must be restored to the original design value by fitting small- in-bore neck rings, bored out to suit the diameter of the impeller.

7.2.7 Shaft Sleeves The shaft sleeve should be examined to see if it is grooved, scored or generally worn. The outside diameter of the each sleeve should be measured and a comparison made with the bore of the bush bearing through which the sleeve passes. The amount of clearance between the two can thus be checked to determine whether or not it is within acceptable limits.

7.2.8 Impeller and wearing ring

a. Inspect the impeller as follows:

i. Examine the impeller for damage. ii. For corrosive /erosion pitting. iii. Cavitations pitting. iv. Bent or cracked vanes, inlet and outlet vane end wear.

Any of the above may be repaired, or cause the impeller to be scrapped. Further information should be sought from M + P, Service Dept. Chinchwad, Pune before any decision on repair work is taken.

b. Around the eye, wearing rings protects the impeller. Examine around the eye at neck portion for grooving in alignment with spindle axis; slight grooving is acceptable but deep or profuse grooving must be remedied by machining the impeller by taking a polish cut on wearing ring. Spare wear rings are supplied with excess outside diameter to facilitate machining after fitting. The wear rings are shrink fitted on impeller neck and are screwed.

c. To check wear, around the impeller neck, use precision instruments such as out side micrometer to

accurately measure the outside diameter. Measurements should be taken at intervals around the circumference to check the uneven wear. Differences between the neck OD and the neck ring ID measured will give us the clearance between the two. Clearance thus obtained should not be more than 150% of maximum designed clearance.

7.2.9 Shaft & Keys Shaft should be checked for the trueness, or any other mechanical damage and corrosion. If the shaft is not true within 0.1 mm TIR, it should be replaced / repaired. Examine the shaft keys and key ways. Remove damaged or worn out keys.

MPPL/IM/VP/2006/0 7-4

Mather + Platt Maintenance

7.2.10 Bearings Examine the thrust and guide bearings for wear or damage.

7.2.11 Reassembly of pumping stages

a. Before commencing to re-assemble the pump, thoroughly clean and de-burr all flanges and mating surfaces, making sure that all traces of jointing material are removed.

b. Fit all casing, neck rings and bearing bush in their respective positions. Slide impeller over pump shaft and lock it against bearing bush carrier by impeller nose cap.

c. Lift the assembly and assemble suction bell mouth.

d. Lift rising main pipe (bottom) and pass it over pump shaft and connect with casing. Ensure that `O ring is fitted between them.

e. Assembly of remaining part is done exactly as described in Installation of pump.

While assembling stainless steel component, molybdenum-disulphide paste should be applied to prevent galling / seizure and also to facilitate easy removal in future.

7.3 Spares We recommended the following spares for various periods normally desired by pump users:

a. For two years operation: Gland packing and bearings. b. For three years operation: Gland packing, bearings, neck rings, Gland sleeve, intermediate bearing

sleeves. c. For five years operation: One rotating element.

MPPL/IM/VP/2006/0 7-5

Maintenance Mather + Platt

7.4 Lubrication RECOMMENDATIONS FOR CENTRIFUGAL PUMPS ARE GIVEN BELOW: International Manufacturers Where pumps are fitted with stainless shafts, we recommend that a colloidal graphite lubricant, e.g. Oil Dag (Achesons) be added by an amount corresponding to 1 % to 2% by volume of lubricating oil as shown in the schedule. MANUFACTURER OIL

Ring oil Bush type Bearings

GREASE

Ball & Roller Bearings

GREASE

For use with Mechanical Grease pumps

Alexander Duckham Co. Ltd.

Duckhams H2 Duckhams LB 15 Duckhams, LB 10

Esso Petroleum Co. Ltd. Thresso 47 T.S.D. 807, (U.K.)

Esoo multi Purpose

Grease H. (0verseas)

Firmax 1

Germ Lubricants Ltd Normal shafts,

Crem Dyno bear MH

Germac Neo Astra Germ Gun Grease

Mobile Companies throughout the world

Mobil' DTE oil Medium Mobil Grease No.3 Mobil Grease No 2

National Benzole Co. Ltd TCC-2 MPG - 1 MO- 1

Power Petroleum Co. Ltd BP Energol TH 80HB /

BP Energol TH 100 HB

BP Energrease LS3 BP Energrease

PR 3 OR LS 3

Regent Oil Co. Ltd. Caltex Regal OIL B (R&O) Caltex Multifac 2 Caltex Multifac 2

Shell Companies throughout the world

Shell Tube, Oil 29 / or Vltrea 31

Shell Nerita Grease 3 / or Shell Alvania Grease 3

Shell Unedo Grease 1

Sternol Ltd Deotoyl M Stemoline LHT Sternoline T

Valvoline Oil Co Valvoline No 1 or No.2 Turbine Oil

Volvine No. G.LI. Ball & Roller Bearing grease

Valvoline F.V 18

Wakefield-Dick Industrial Oils Ltd

Perfecto Light

Perfecto Special X

Hyspin 70

Spheerol A.P. 3 Spheerol A.P. 2 OR impervia T

MPPL/IM/VP/2006/0 7-6

Mather + Platt Maintenance Indian Manufacturers MANUFACTURER

Ring oil/Bush type Bearings

Grease

Grease Lubricated Bearing

Indian Oil Corporation Servo System-46 Servogem-2/3

Hindustan Petroleum Enclo-46 Lithon-2/3

Bharat Petroleum Hydral-46 Multipurpose Grease-3

For oil Lubrication:

1. ISO Grade 46 oil.

2. All above oils are compatible with each other when fresh.

3. It is unsafe to mix oil of two or more grades for use in Bearings.

4. Number 46 is Viscosity at 40 degree centigrade in centistokes.

For Grease Lubrication:

1. Only lithium base Grease to be used.

2. Numbers mentioned stands for consistency.

3. Grease of two different grades should not be used.

MPPL/IM/VP/2006/0 7-7

Mather + Platt Trouble shooting

8 Trouble shooting Chart

Sl No

Symptoms Possible cause of trouble and remedies(Each number is defined in the list below)

-- Pump does not deliver water. 1,2,3,4,6,11,14,16,17,22,23 I -- Insufficient capacity delivered. 2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31

-- Insufficient pressure developed 5,14,16,17,20,22,29,30,31

-- Pump loses prime after starting. 2,3,5,6,7,8,11,12,13

-- Pump requires excessive power. 15,16,17,18,19,20,23,24.26,27,29,33,34,37

-- Stuffing box leaks excessively. 12,13,24,26,32,33,34,35,36,38.39,40

-- Pump vibrates or it is noisy. 2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43, 44, 45,46,47

-- Bearings have short life. 24,26,27,28,35,36,41,42,43,44,45,46,47

-- Pump overheats and seizes. 1,4,21,22,24.27,28,35,36,41

Suction troubles Remedies

1 Pump not primed Ensure that casing is fully filled and water comes out from air-cock.

2 Pump or suction pipe not completely filled with liquid

Check leaking foot valve in case of negative suction

3 Suction lift too high. Reduce by lowering pump elevation or increase

Water level.

4 Insufficient margin between pressure and vapor pressure.

Check that NPSH available is at least 1 meter more 1 meter more than NPSH required.

5 Excessive amount of air in liquid. Check the reasons and eliminate. Gas gets entrapped in liquid. Air may be entering through suction joints.

6 Air pocket in suction line. Ensure pipe fully filled and there is no

bend for negative suction.

7 Air leaks into suction line Tighten pipe joints with solution.

8 Air leaks into pump through stuffing boxes. Ensure stuffing box sealing.

9 Foot valve too small or leaking. Replace I Attend.

10 Foot valve partially clogged. Clean

11 Inlet of suction pipe insufficiently submerged. Ensure adequate submergence such that foot valve is not exposed.

12 Water seal pipe clogged. Clean or change.

13 Logging ring is improperly located

in stuff