Repair manual

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INSTRUCTION, INSTALLATION, MAINTENANCE AND REPAIR MANUAL

3500 SERIES / MODEL 3550 ASME/ANSI B73.1M

FRAMES S, M, L AND XL – INDUSTRIAL PROCESS PUMPS

SECTION 2 ITEM 3550

DATED SEPTEMBER 2010

NOTICE:

Aurora model 3550 pumps MUST be installed only in systems

that have been designed by qualified engineering personnel.

The system MUST conform to all applicable local and national

regulations and safety standards.

This manual is intended to assist in the installation, operation

and maintenance of Aurora model 3550 pumps and MUST be

kept with the pump.

Pump service shall be performed by qualified technicians

ONLY. Service shall confirm to all applicable local and

national regulations and safety standards.

Thoroughly review this manual, all instructions and hazard

warnings BEFORE performing any work on the pump.

Maintain ALL system and pump operation and hazard warning

decals, signs, placards, etc.

This is a SAFETY ALERT SYMBOL.

Read and understand all warnings before installation or

servicing pump. Failure to follow the warnings in this manual

caould cause personal injury, death, or major property damage.

Will cause personal injury or death and major property damage.

Can cause serious injury and major property damage.

Can cause personal injury or property damage.

NOTICE:

Follow special instructions as they are very important and must

be followed.

Danger:

Warning:

CAUTION

Summary of content (28 pages)

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SECTION 2 ITEM 3550 DATED SEPTEMBER 2010 INSTRUCTION, INSTALLATION, MAINTENANCE AND REPAIR MANUAL 3500 SERIES / MODEL 3550 ASME/ANSI B73.1M FRAMES S, M, L AND XL – INDUSTRIAL PROCESS PUMPS 2 NOTICE: This is a SAFETY ALERT SYMBOL. Read and understand all warnings before installation or servicing pump. Failure to follow the warnings in this manual caould cause personal injury, death, or major property damage. Danger: Will cause personal injury or death and major property damage.
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3500 SERIES / MODEL 3550 INDEX: Warnings............................................................................................................................................................... 3 Introduction.......................................................................................................................................................... 4 Installation................................................................................................................................
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500 SERIES / MODEL 3550 MAINTENANCE SAFETY DATA: Warning: Toxic Fluid Handling Hazardous or toxic fluids must be flushed and properly disposed of before performing service to the pump. Check local and national regulations on disposal regulations for your area. Clean all contaminated parts according to local and national regulations. Isolate pump by closing the suction and discharge valves before servicing the pump.
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3500 SERIES / MODEL 3550 INTRODUCTION: RECEIVING SHIPMENT: Upon receiving shipment, check items against packing list. Be sure to inspect entire box for any additional parts and read all special instruction tags attached to the pump. STORAGE: If the unit will not be installed immediately, the unit should be kept dry and in the shipping container until ready for installation. HANDLING: CAUTION Heavy pumps and components.
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3500 SERIES / MODEL 3550 • Operate the pump and driver for an adequate amount of time to achieve maximum operating temperature before the final or hot alignment is performed. • Repeated checks of alignment should be performed to ensure proper, smooth and continuous operation. • If any changes occur in process conditions it is recommended to perform an alignment check.
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3500 SERIES / MODEL 3550 Excess forces and moments on the pump may occur due to: • Thermal expansion and contraction of the piping indicating improper piping design and/or lack of expansion joints or loops. A straight length of suction piping at least five times the diameter of the pipe is recommended directly in front of the suction flange. • Improper pipe support due to use of rod hangers (instead of spring hangers), anchors or restraints used when installing the piping.
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3500 SERIES / MODEL 3550 ORIENTATION: • For suction above centerline: Eccentric – Flat side on bottom. Concentric. SUCTION Install an isolation valve to prevent the pump, at start-up, from running in excess of the pump curve by throttling while the system is being filled. The isolation valve is also used to isolate the pump for maintenance. Undersized valves can cause excessive flow restriction. Install reducers between the check valve and the pump to prevent this.
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3500 SERIES / MODEL 3550 Change oil every 12 months. Oil should be changed more frequently under severe environmental conditions (dust, moisture, corrosive atmospheres, etc.). PROPERTIES OF LUBRICATING OIL: ISO GRADE VG...................................................................... 68 Approximate SSU at 100°F (40°C)........................................ 300 300 Kinematic Viscosity at 100°F (40°C)(cSt)........................
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3500 SERIES / MODEL 3550 a. When making adjustments, unseat the mechanical seal from the shaft. b. Check total clearance. Confirm that it follows the given instructions. c. Set the proper operating clearance on the suction side of the impeller. Increase the clearance on the suction side of the impeller if the pumpage temperature exceeds 100°F (38°C). Consult Appendix I Table I of the manual for proper instructions. 4. Check Rotating Element.
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3500 SERIES / MODEL 3550 Tag valves as standard practice. Warning: When handling hazardous and/or toxic fluids, use personal protection equipment to avoid personal injury. Pumpage must be handled and disposed of in accordance with applicable environmental regulation. DISASSEMBLY: Warning: Pump components can be heavy. Proper methods of lifting must be employed to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.
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3500 SERIES / MODEL 3550 8. Use frame adapter (108) or frame (228) for placing hoisting strap. 9. Remove bearing frame foot hold-down bolts and casing bolts (370). Warning: Never apply heat to remove parts. Use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage. 10. Tighten jack screws (418) evenly then remove back pull-out assembly from casing (100). NOTE: If adapter to casing joint is excessively corroded, penetrating oil can be used.
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3500 SERIES / MODEL 3550 FRAME ADAPTER REMOVAL – M, L, XL: Remove the following components in the order listed below: • Dowel pins (469B) and bolts (370B) • Frame adapter (108) • Gasket (360D) (Discard and replace with new gasket during reassembly) INBOARD LABYRINTH OIL SEAL (333) REMOVAL: NOTE: It is an O-ring fit into bearing frame (228) for STX, frame adapter (108) for M, L & XL models. If necessary, remove O-rings (497H, 497J).
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3500 SERIES / MODEL 3550 • Localized wear or grooving greater than 1/8" (3.2mm) deep • Pitting greater than 1/8" (3.2mm) deep • Check case gasket seat surface for deformities or irregularities REASSEMBLY: Rotating Element and Bearing Frame Assembly S, M Models IMPELLER: Repair or replace the following impeller (101) components if they exceed the following criteria: NOTE: Apply thread sealant to clean pipe threads and fittings. • Impeller vanes grooved deeper than 1/16" (1.
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3500 SERIES / MODEL 3550 8. Install new O-ring (496). 9. Use oil to coat the outside of outboard bearing (112) and bearing housing (134) bore. 4. Note orientation when placing bearing clamp ring (253B) over shaft (122). 5. Install the outboard bearings (112) on shaft (122). CAUTION 10. Place bearing housing (134) onto shaft/bearing assembly. NOTE: DO NOT force assembly together. 11. Place retaining ring (361A) into groove in bearing housing bore (134). Be sure shaft is free turning.
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3500 SERIES / MODEL 3550 NOTE: Consult Appendix V (page 24) for detailed labyrinth seal installation instructions. NOTE: Keyway edges must be free of burrs. NOTE: To protect O-rings, cover keyway lengthwise with a piece of electrical tape before installing labyrinth seal. 14. Use oil to coat outside of bearing housing (134) and all internal surfaces of bearing frame (228). 15. Allowing approximately .125" (3.
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3500 SERIES / MODEL 3550 2. Check shaft end play by moving shaft forward and backward by hand, taking note of indicator movement. If total indicator reading is greater than the values listed in Appendix IV (page 24), disassemble and determine cause. shaft wrench (counterclockwise as viewed from impeller end of shaft) off bench then slam it down (clockwise as viewed from impeller end of shaft). A few sharp raps will properly tighten impeller (101). 3.
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3500 SERIES / MODEL 3550 FOR OUTSIDE MOUNTED SEALS: 11. Install the mechanical seal on shaft (122) or, if applicable, sleeve (126) following the seal manufacturer’s instructions. Install sleeve with seal if applicable. 12. Move gland. Move stationary seat, with gaskets, on shaft or sleeve. 13. Install seal chamber or back plate (184) with hex nuts (370H). Confirm that gland studs line up with holes in gland. 14. Install impeller (101) with new O-ring (412). Place shaft wrench and coupling key on shaft.
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3500 SERIES / MODEL 3550 INSTALLATION TROUBLESHOOTING GUIDE Fault Possible Cause Remedy Excessive shaft end play. Bearing internal clearance too great. • Reduce speed level. Snap ring loose in bearing housing groove. • Reseat. Sleeve worn. • Replace. Shaft bent. • Replace. Excessive bearing frame flange run-out. Shaft bent. • Replace. Bearing frame flange distorted. • Replace. Excessive frame adapter runout. Corrosion. • Replace. Frame gasket adapter not seated correctly.
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3500 SERIES / MODEL 3550 S – PUMP CROSS SECTIONAL 370C 382 134 112 408H 113 228 168 408H 333 126 370 100 503 184 106 353 136 107 105 351 101 355 332 412 400 122 497F 497G 370D 423 496 361A 408H 408M 408L 408A 408J 319 408H 497J 497H 418 250 370H 357K M – PUMP CROSS SECTIONAL 370C 408H 361A 113 228 408H 370B 360D 333 108 370 106 105 382 107 134 353 136 355 332 126 351 360Q 100 184 101 412 400 122 497F 497G 370D 423 496 112 408H 370F 497J 168 497H
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3500 SERIES / MODEL 3550 L – PUMP CROSS SECTIONAL 370C 408H 253B 236A 113 228 408H 370B 360D 333 108 370 105 351 100 184 106 134 101 107 382 355 136 126 332 400 353 412 122 497F 497G 168 497J 497H 370D 496 250 408H 248 408J 423 370F 112 408M 408L 408A 319 408H 469B 370H 357K 360Q 418 241 XL – PUMP CROSS SECTIONAL 136 382 370C 408H 134 228 168 408H 333 355 353 106 107 105 351 100 136 109 184 113 370B 332 101 412 400 122 497F 497G 250 371C 360 20 370D
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3500 SERIES / MODEL 3550 PARTS & MATERIAL COMPOSITION Item Number 100 101 105 106 107 108 112 122 122 126 134 136 168 184 228 241 250 319 332A 333A 351 353 355 357K 358A 360 360A 370 418 469B 496 496A Req’d Per Pump 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 2 1 1 1 3 3 2 1 1 Part Name Casing Impeller Lantern Ring Packing Packing Gland Frame Adapter Outboard (Thrust) Bearing Shaft – Less Sleeve (Optional) Shaft – With Sleeve Shaft Sleeve Bearing Housing Lock Nut / Lock Washer Inboard (Radial) Bearing
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3500 SERIES / MODEL 3550 APPENDIX I: IMPELLER CLEARANCE ADJUSTMENT: FEELER GAUGE METHOD: 1. Lock out power supply to motor. 2. Remove coupling guard and spacer. 3. Loosen jack bolts (370D) and jam nuts (423). 4. Tighten bearing housing bolts (370C) evenly while slowly rotating the shaft. Continue rotating until the impeller begins to rub the casing. 5. Use a feeler gauge to set the gap between the three housing bolts (370C) and bearing housing. Consult the table below for gap settings. 6.
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3500 SERIES / MODEL 3550 3. Once coupling guard half (pump end) is located around end plate, tighten it securely with a bolt, nut and two washers through the round hole at front end of guard half. 4. Spread bottom of coupling guard half (driver end) slightly, then place over coupling guard half (pump end). Check that annular groove in coupling guard half (driver end) faces motor. 5. Place end plate (driver end) over motor shaft.
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3500 SERIES / MODEL 3550 APPENDIX IV Bolt Torque, ft.-lbs. (Nm) Location Frame Casing Bolts (370) or Casing Nuts (425) Frame-to-Adapter Bearing Clamp Ring Bolts (236A) Duplex Bearing Only Bearing End Cover Bolts (371C) Dynamic Seal Capscrews (265) Double Row Duplex S in. (mm) .0011 (.028) .0019 (0.47) .0007 (.018) .0010 (.026) 6" S 5/8" 8" S 1/2" M, L 5/8" XL 5/8" All S, M L XL S, M, L XL Shaft End Play M in. (mm) .0013 (.033) .0021 (.054) .0009 (.022) .0012 (.
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3500 SERIES / MODEL 3550 Maximum Working Pressure Limits APPENDIX VI: PRESSURE – TEMPERATURE RATINGS: Models S, M, L; Class 150 Flanges temperature – degrees Celcius –240 –200 Maximum Working Pressure Limits –160 –120 –80 –40 0 40 60 80 120 160 200 240 Models S, M, L; Class 150 Flanges 280 temperature – degrees Celcius 0 40 60 80 120 22 160 200 240 280 20 316 250 300 18 22 HASTELLOY® B&C 16 20 W-20 14 18 316 MONEL® 200 250 12 16 W-20 150 200 10 14 ® NICKEL MONEL 12 100 150 10 NI
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3500 SERIES / MODEL 3550 APPENDIX VII: PARTS INTERCHANGEABILITY CHART: Impellers and casings are different for each pump size. Stuffing box covers and adapters (except for “S” frames) are shared by casing class. Check interchangeability chart for clarification. POWER END ADAPTER MODEL S MODEL M SEAL CHAMBER IMPELLER CASING SIZE ADAPTER MODEL L 1-3/8" SHAFT DIA. – MAX BHP–40 HP SEAL CHAMBER IMPELLER CASING SIZE 2-1/8" SHAFT DIA. – MAX BHP–200 HP 1 x 1.5 - 6 AA 1 x 2 - 10 A05 1.
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3500 SERIES / MODEL 3550 WARRANTY: Seller warrants equipment (and its component parts) of its own manufacture against defects in materials and workmanship under normal use and service for one (1) year from the date of installation or start-up, or for eighteen (18) months after the date of shipment, whichever occurs first.
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3500 SERIES / MODEL 3550 NOTE: Aurora Pump reserves the right to make revisions to its products and their specifications, this bulletin and related information without notice. 28 Aurora Pump 800 Airport Road North Aurora, IL 60542 phone: 630-859-7000 fax: 630-859-7060 A-03-339 09.