GENERAL INSTALLATION, OPERATION, MAINTENANCE AND TROUBLESHOOTING MANUAL FOR THREE SCREW AND CIG SERIES PUMPS WARNING This manual, and the pump specific Product Service Manual, should be read thoroughly prior to pump installation, operation, maintenance or troubleshooting. CAUTION ATTENTION Page 2 of this manual has been added to emphasize the requirements of filling and venting the seal chamber prior to starting pump to prevent seal leakage and failures. Manual No. SRM00046 Rev.
Note: This page was added because of the prevalence of seal damage and leakage caused by not venting the seal chamber before putting a pump in service. Seal Chamber Priming for Pumps with Seal Vents: Fill mechanical seal chamber with liquid to insure seal does not start dry. This can be done by removing seal vent set-screw and pouring fluid into seal vent before opening pump inlet.
READ THIS ENTIRE PAGE BEFORE PROCEEDING FOR SAFETY OF PERSONNEL AND TO PREVENT DAMAGE TO EQUIPMENT, FOLLOWING NOMENCLATURE HAS BEEN USED IN THIS MANUAL: DANGER Failure to observe precautions noted in this box can result in severe bodily injury or loss of life. WARNING Failure to observe precautions noted in this box can cause injury to personnel by accidental contact with equipment or liquids. Protection should be provided by the user to prevent accidental contact.
APPLICATIONS MANUAL FOR IMO PUMPS A. GENERAL Instructions found herein cover general installation, operation, maintenance and troubleshooting of subject equipment. NOTE: Individual contracts may have specific provisions that vary from this manual. Should any questions arise which may not be answered by these instructions, refer to specific pump instruction manual provided with your order.
D.1 TOOLS Procedures described in this manual require common mechanics hand tools, dial indicators for alignment and suitable lifting devices such as slings, straps, spreader bars, etc. D.2 LIFTING OF PUMP AND PUMP/DRIVER ASSEMBLIES All pumps and pump/driver assemblies should be lifted with appropriate devices securely attached to whole unit. Ensure unit’s center-of-gravity is located between lifting points. See Figure 1. This will avoid tipping of pump or pump/driver assembly.
D.5 MOUNTING OF FOOT MOUNTED PUMPS AND DRIVERS Some pumps are shipped on baseplates without drivers. For these units, install and tighten each coupling half on driver and pump shafts. Place driver on baseplate and set proper distance between shafts and coupling hubs (See Figure 2). Locate driver so pump and driver shafts are in axial alignment. See Section D.6 on Alignment.
The objective of any aligning procedure is to align shafts (not align coupling hubs) by using methods that cancel out any surface irregularities, shaft-end float, and eccentricity. At operating temperatures above 175o F (65o C), pumps require “hot alignment” after pump and driver reach normal operating temperatures. Also, re-check final alignment after all piping is connected to pump. D.6.
Dial Indicator Dial Indicator X1 Y θ X2 A. Face Check (Angularity) Rotating both shafts together for one full turn, align pump and driver until shaft centerlines are parallel (θ = 0, X1 = X2) within 0.005 inch (0.13 mm) FIM. B. Face Check (Parallelism) Rotating both shafts together for one full turn, align pump and driver until shaft centerlines coincide (Y - 0)) within 0.005 inch (0.13 mm) FIM. Figure 4 – Coupling and Hub Alignment D.6.
After pump-bracket-driver is installed into system and after piping is connected to pump, shaft alignment should be re-checked and adjusted, if necessary, When a right-angle foot bracket is used, mount pump onto bracket and tighten pump-tobracket mounting bolts. At this point, bracket base, in effect, becomes pump feet. Continue with aligning procedure as if pump were foot mounted. See Section D.6.3.
D.7 PIPING AND VALVES D7.1 General Piping connected to pump MUST be independently supported and not allowed to impose strains on pump casing including allowing for expansion and contraction due to pressure and temperature changes. To prevent foaming and air entrainment, all return lines in recirculating systems should end well below liquid surface in reservoir. Bypass liquid from relief pressure and flow control valves should be returned to source (tank, reservoir, etc.), NOT pump inlet line.
DANGER The Imo pump is a positive displacement type. It will deliver (or attempt to deliver) flow regardless of back-pressure on unit. Failure to provide pump overpressure protection can cause pump or driver malfunction and/or rupture of pump and/or piping. Relief Valve Figure 7– Proper Relief Valve Return Line Arrangement Some low pressure pump models include built-in safety relief valves. They are intended only for emergency operation, NOT for system control.
D.7.4 Suction Line Suction line should be designed so pump inlet pressure, measured at pump inlet flange, is greater than or equal to minimum required pump inlet pressure (also referred to as Net Positive Inlet Pressure Required or NPIPR). Suction line length should be as short as possible and equal to or larger than pump’s inlet size. All joints in suction line must be tight and sealed.
D.7.5 Suction Strainer /Filter Pump life is related to liquid cleanliness. Suction strainers or filters should be installed in all systems to prevent entry of large contaminants into pump. See Figure 9. Purpose of a suction strainer or filter is for basic protection of internal pumping elements. It should be installed immediately ahead of inlet port. This location should provide for easy cleaning or replacement of strainer element.
D.7.6 System Filtration In systems that recirculate pumped liquid, downstream (pressure and/or return side) filtration should be installed. Downstream filters may also be required to protect components such as servo valves in hydraulic systems or high-pressure fuel nozzles and flow dividers in fuel oil supply systems for gas turbines. System’s most contamination-sensitive component determines its liquid cleanliness requirement.
NOTE: Refer to pump or pump/driver outline drawing and/or specific pump’s instruction manual for quench connection size and port locations. D.10 GAGES Pressure and temperature gages are recommended for monitoring pump’s operating conditions. These gages should be easily readable and placed as close as possible to pump’s inlet and outlet flanges. See Figure 10a. D.
E. Startup, Operation and Shutdown CAUTION ATTENTION Operation conditions, such as speed, liquid viscosity, temperature, inlet pressure, discharge pressure, filtration, duty cycle, drive type, mounting, etc., are interrelated. Due to these variable conditions, specific application limits may be different from pump’s operating and structural limits. Equipment must not be operated without verifying system’s operating requirements are within pump’s capabilities.
E.4 PROTECTIVE DEVICES E.4.1 General Automatic shutdowns, emergency switches, and similar controls should be part of pumping system. They are generally supplied by system supplier or user. E.4.2 Covers and Guards Before start-up, insure all protective-covers and guards are in place. WARNING DANGER To protect personnel from accidental contact with rotating couplings, sheaves, belts, shaft keys, keyways, etc., install the following covers or guards over: • Bracket openings on flange mounted pumps.
E.7 QUENCHED SHAFT SEALS When quenching fluid is hot water or steam, apply to seal at least 30 minutes prior to pump start-up to insure seal area is thoroughly heated. When steam is used, it should be saturated at about 4 to 7 psi gage. When quench fluid is ambient temperature nitrogen, it can be applied just prior to pump start-up. E.8 PUMPED LIQUIDS NEVER operate a pump with water. Pump is designed for liquids having general characteristics of oil.
SEAL CHAMBER PRIMING: Fill mechanical seal chamber with liquid to insure seal does not start dry. This can be done by removing seal vent set-screw and pouring fluid into seal vent before opening pump inlet. Alternately, seal chamber can be vented in situations where inlet pressure is above atmospheric by opening inlet and discharge valves and then loosening seal vent plug to allow positive inlet pressure to push air out of seal chamber until oil flows from it. See Figure 13.
E.11 SHAFT PACKING (STUFFING BOX) LEAKAGE Pumps with packing-type seals must be checked to insure packing gland is not too tight. Excessive gland pressure on packing will cause a scored shaft, overheating and rapid breakdown of packing. Keep gland nuts only finger tight. After new packing has been installed, gland nuts should be tightened evenly but only tight enough to seat packing rings properly. Then, loosen gland nuts and re-tighten finger tight.
F.1 FILTERS AND STRAINERS All filter and strainer elements should be periodically checked for cleanliness and cleaned or replaced as necessary. This will protect equipment from damage due to pressure-drop across clogged or dirty elements. F.2 FOUNDATION Foundation and hold-down bolts should be checked for tightness at least every six months. F.3 ALIGNMENT Alignment of pump and its driver should be checked and corrected, if necessary, at least every six months.
NOTE: Make sure any seal leakage is disposed of properly. WARNING Since leakage or seal failure can be expected to eventually occur, be sure installation can withstand this situation. Take appropriate measures if liquid is hazardous. F.7 SPARE PARTS Where pump out-of-service time is of vital concern, and this down time must be minimized, a set of spare parts or repair kits should be retained on-site. F.8 DISASSEMBLY AND REASSEMBLY Various procedures for disassembly and reassembly apply to different pumps.
H.
H.
Imo Pump 1710 Airport Road PO Box 5020 Monroe, NC USA 28111.5020 Tel: +1.704.289.6511 Toll: +1.877.853.7867 Email: cc@colfaxcorp.com Web: colfaxcorp.com © 2012 Colfax Fluid Handling all rights reserved.
