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MANUAL FOR VWS PUMP Instructions on Installations, Operation and Maintenance of Vertical Submersible Pumping System

Varat Pump & Machinery Pvt. Ltd.

KOLKATA 700 001 WEST BENGAL INDIA Ph. No.: 033-2230 1903, 2243 4500 FAX No.: 033-2230 1535/6274 E-Mail : Varat@cal2.vsnl.net.in

Manufactured by :

20, NETAJI SUBHAS ROAD

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MANUAL VWS FOR SEWAGE PUMP

1.0 1.1 GENERAL This book let covers instructions for following Models of VARAT Vertical Centrifugal Wet Pit Non-Clog sump Pump Model : 65VWS-1 65VWS-2 65VWS-3 65VWS-4 65VWS-5 65VWS-6 65VWS-7 65VWS-8 125VWS-1 125VWS-2 150VWS-1 150VWS-2 150VWS-3 150VWS-4 150VWS-6 200VWS-3 250VWS-3 and can be started without

25VWS-1

32VWS-1 32VWS-2 32VWS-3 32VWS-4

50VWS-1 50VWS-2 50VWS-3 50VWS-4

80VWS-1 80VWS-2 80VWS-3 80VWS-4

100VWS-1 100VWS-2 100VWS-3

1.2 1.3 1.4 2.0 2.1

This VWS type Vertical Wet Pit Pumps are designed for submerged operation priming.

When the pumps are received sometime before the use of the pump it should be located in dry place. The coupling should be rotated once in a month to prevent pilling of bearing surfaces. When the pumps kept idle for a period after one use, it should be cleaned properly and overhauling should be made before long storage. INSTALLATION EQUIPMENT REQUIRED FOR THE INSTALLATION A Chain Pulley Block of adequate capacity (about 2 Tons) with Tripod more than 0.5Mtrs. Higher than the total height of the pump or motorised crane. Spirit level/Master level, Pump line, Screw driver, Spanners, Seam, Column pipe holding clamp etc.

2.2

LOCATION The pump should be placed vertically over the liquid source. This will minimise the wearing of line shaft Bearing and pump will give better performance. Ample space should be provided on all the sides so that the pump can be inspected while in operation and can be serviced conveniently whenever required

2.3

FOUNDATION AND LEVELLING The foundation should be sufficiently substantial to absorb any vibration and to form a permanent rigid support for the base plate. Usually pump provided with double base plate. Open the bottom base plate (Part no.27) from the pump and fix it rigidly on the top of the sump. Sometimes, the base plate can be fix up on the channel frame provided on the sump. The base plate also can be fixed up over and above the Petroleum storage tank usually available in Terminals and Refineries. True horizontal leveling of the base plate should be done with the help of spirit (Master) level. The leveling magnitude should be within 0.1mm/ Mtr. This is important in maintaining the alignment of the line shaft Bearings. If concrete foundation on a solid base is permissible as per site condition, foundation bolts of the proper size should be embedded in the concrete by placing the bottom base. A pipe sleeve about two and one-half diameter larger than the bolt should be used to allow movement for the final position of the foundation bolts. The advantage of this pump is

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that of double base plate. A gap of about 25 to 50 mm should be allowed between the base plate and foundation of grouting. Supporting will be such that it will not be distorted or sprung by the uneven distribution of the weight. Adjust the wedges until the Four Corners and machined face of the base are in level. Once the bottom base is fixed, it is not required to remove during maintenance because the top base will be fixed on this bottom base having both the face machined and total assembly will pass through the opening of the bottom plate. So, once master leveling has been made on the bottom base, it is not required to disturb the same and no further master leveling is required during reinstallation after overhauling. 2.4 GROUTING When the leveling is correct, the foundation bolts should be tightened evenly but not too firmly. Working soft concrete under the edges can then grout the unit. Foundation bolts should not be fully tightened until the grout is hardened, usually 48 hours required after pouring.

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2.5

LOWERING OF PUMP Fix the Chain Pulley Block just above the base fitted over the sump. Clamp a small chain on the Motor Stool flange using U-circle and lift the pump gradually by Chain Pulley holding it on the Motor Stool chain. When the pump lifted just above the base of the pump, lower the pump gradually through the hole of the bottom base into the Sump, until its top base (part no.39) fix on the bottom base. Fix up the bases using the bolt (part no.38). Pump should be installed such a manner that the clearance between the bottom of the sump pit & bell mouth of the pump should be minimum 150mm.or more according to the capacity of the pump for successful operation of the pump.

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Verticality of the pump should be checked after installation, with the help of pump line. Provide lubrication pot on the base plate. Pump can be lowered in the sump part by part using a holding clamp above the base and following the reassembling procedure. 2.6 ALIGNMENT Pump supplied by the manufacturers provided with a Motor Stool, which has been designed, for a particular suitable International frame of the motor. After lowering of the pump fix up the Flange mounted Motor on the top flange which will fit with the fitting of the Motor Stool. If the pump and motor are provided with a coupling this will align automatically and no further alignment is required. Just put the Pin Bush of the coupling after free running of Motor (without load) for at least One hour. Check up the direction of the rotation of the motor during free running. Check up the alignment whether correct or not. If alignments found wrong then check up the fitting of Motor Stool flange with the motor flange. Also check the coupling halves of the pump and motor if any misalignment found. FLEXIBLE COUPLING A flexible coupling will not compensate for misalignment of the pump and driver shafts. The purpose of the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts without interference with each other while transmitting power from the driver to the pump. 2.8 MISALIGNMENT There are two types of misalignment between the Pump shaft and the driver shaft: (a) Angular misalignment: Shafts with axis concentric but not parallel. (b) Parallel misalignment: Shafts with axis Parallel but not concentric.

2.7

The faces of the coupling should be spaced for enough apart so that they cannot strike each other when the drive shaft of the rotor is moved over the pump half. Due allowance should be made for wear of the thrust Bearings. A minimum gap of 3 to 4 mm should be maintained. The necessary tools for approximately checking the alignment of the flexible coupling are a straight edge and a taper gauge or a set of feeler gauge. For pin bush coupling disconnect coupling halves before proceeding with alignment. A check for angular alignment is made by inserting the taper gauge or feelers at four points between the coupling faces and comparing the distance between the faces at four points spaced at 90 degree intervals around the coupling, the unit will be in angular alignment when the measurement show that the coupling faces are the same distance apart at all point (FIG 1). A check for parallel alignment is made by placing a straight edge across both coupling ring at the top bottom and at both sides. The unit will be in parallel alignment when the straight edge rests evenly on the coupling ring at all positions. Care must be taken to have the straight edge parallel to the axis of the shaft (FIG-2). It should not be necessary to adjust the shims, if used, under the pump.

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2.9

PIPING Delivery pipe and accessories after special pipe (Part no.47) should be independently supported near the pump so that when the flange bolts are tightened no strain will be transmitted to the special pipe which effect the strain on pump casing. It is usually advisable to increase the size of delivery pipes but not to decrease at the pump nozzles in order to decrease the loss of head from friction and for the same reason piping should be arranged with as minimum bends as possible, as these should be made with a long radius wherever possible. The pipelines should be free from scales, welding residuals etc., and have to be mounted in such way that they can be connected to delivery flanges without any stress on the pump. Adequate supports should be given to pipe lines so that the weight of the pipelines does not fall on the pump. The use of minimum number of the bends and other fittings will minimise the friction losses.

2.10

DELIVERY VALVES AND FITTINGS A check (non-return) valve and a gate or sluice valve (regulating valve) should be installed in the discharge line. The check valve placed between the pump and the gate valve is to protect the pump from excessive pressure and to prevent water running back through the pump in case of failure of the driving machine i.eexcessive back pressure. Discharge piping should be provided with a sluice valve to control the discharge, if required. The valve had to be used in starting and when shutting down the pumps. If enlarger are used on the discharge side to increase the size of discharge piping they should be placed between the check valve and pump. Arrangement for three ways connection of pressure gauge with air-cock should be after delivery flange but before delivery sluice valve is required.

2.11

MECHANICAL SEAL Since mechanical seals are made in a wide variety of designs, the instruction for the specific seal must be carefully studied and followed exactly. A Mechanical Seal is a precision device and must be treated accordingly. It is provided at the Lower Bearing Housing to prevent the entering of liquid inside column pipe of the pump.

2.12

LUBRICATION Pump is usually provided with a special gravity feed oil lubrication pot or screwed type grease lubrication pot. Fix up the pot above the base plate and fill it with oil or grease, if the pump is not self or water lubricated. For self/water lubrication pump, a regulating valve already provided and connected with the base plate. Open the valve before starting of the pump.

2.13 BALL BEARING Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as guide to relubrication periods under normal conditions. Three monthly when on continuous duty. Six monthly when on eight-hour per day duty. The bearings and housings should be completely cleaned and recharged with fresh grease after 2500 hours or the nearest pump overhaul time. 2.14 PRIMING No priming is required for this pump as the pump bowl assembly submerged inside the liquid. 3.0 PREPARATION OF PUMP STARTING: After the pump and the drive are mounted, the plant should be prepared for starting. The following rules should be observed before starting the pump:

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3.1

The pins or pad should be inserted into the coupling not before making sure of the correct rotation of drive. In case of the drive rotating in the wrong direction, the connection of two cable conductors out of the three supplying the current to the motor should be interchange in case of DOL starting. Check presence of grease / oil in bearings and correct location of lubrication line for line shaft bearings, ensure flashing, quenching and lubrication in case of mechanical seal as well as if required as per design. Check the free rotation of pump rotor, turning it by hand to verify any major obstruction or friction with wearing parts. Check the proper order of delivery and pressure pipelines, tightening of flanges, fittings of outlet valve and presence of drain plug (if any). Close the Sluice valve at the delivery side. Making reasonably sure of the proper order of the whole plant and its readiness for operation, you can start
the pump.

3.2 3.3 3.4 3.5 3.6

4.0 4.1

STARTING AND STOPPING OF THE PUMP: Open the stop-cock of pressure gauge .The pump should be loaded gradually, when the drive is engaged. When the prime mover attain full speed, the regulating sluice valve should be smoothly opened. This will avoid overloading of the drive. On the other hand it should be kept in mind that a lengthy operation with completely close sliding valve is likewise to be avoided. Since this causes unnecessary heating of the liquid in the pump.

4.2

By controlling the sliding valve the required flow and head may be obtained. After setting of pressure gauge at required point, check ampere consumption, if found exceed required value, pump should be stopped. During running also check about any abnormal sound from the pump or smooth running of the pump set. For stopping of the pump first close the delivery valve then stop the pump. TECHNICAL INFORMATIONS: DIRECTION OF ROTATION Standard rotation of the pump is clockwise, when viewed from the driving end.

4.3 5.0 5.1

5.2

BEARINGS The pump is supplied with anti-friction ball bearings and angular contact bearing at driving end and usually of SKF/RHP/NBC make. Line shaft bush bearings are made of bronze or cartilage rubber suitable for self-lubrication or oil-lubrication.

5.3

LUBRICATION: Ball bearings are normally greased lubricated. Refilling period is after 1000 hours of running. Bearing temperature is permissible to rise 40 degree Centigrade above ambient temperature. Grades of recommended grease are INDIAN OIL- SERVOGEM-3 or CALTEX-STARFAX-3, H.P.C.L. NATRA-3 or equivalent. In case of oil lubrication bearing for line shaft bushes, oil should be maintained in the oil pot. Servo 30/40 may be used for this purpose. For self-lubrication pumping liquid should be free from any particles.

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5.4

GASKET Compressed asbestos packing gasket for joining of volute casing is used. However, packing gasket suitable to handle corrosive liquid and high temperature fluid is supplied against specific requirements.

5.5

COUPLING Normally pin-bush flexible type or star type spider coupling without spacer (for small size motor) is used. Other type of coupling may be supplied against specific requirements. Pin-bush type coupling is more suitable for this pump because after placement of the motor above the pump, the free rotation of the pump can be possible just not to provide the pin-bush of the coupling and pump may be coupled with the motor just providing the pin bushes after checking of the rotation.

5.6

GUIDE RING / WEARING RING Replaceable ring for protection of suction cover and LBH plate provided in VWS type pumps. If not specified, it is usually of non-sparking (Bronze) material. SHAFT SLEEVES Replaceable sleeve for protection of the shaft at lower bearing housing and sleeve for Mechanical seal are provided.

5.7

5.8

MECHANICAL SEAL The pump is not usually supplied with a mechanical seal. If provided, stationary face (mating ring) is fitted in the seal retainer by press fit providing O ring at the L.B.H. plate. Rotating part is fitted on the pump sleeve.

6.0

SPARE PARTS One set Anti-friction bearing, one bottom shaft, one impeller, one L.B.H plate, one set Wearing Ring, one set Shaft Sleeve, one set Bush Bearings, O Rings, Impeller Lock Bolt, Gasket and one set of mechanical seal kit against each pump must always be kept with the actual users of the pump to ensure uninterrupted service from the pump.

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7.0

SL. NO. 1.

TROUBLE SHOOTING DEFECTS Pump does not deliver liquid. CAUSES (1)Insufficient quantity of water in the sump/water not filled in pump casing (2) Incorrect direction of rotation. (3) Pump is clogged. (4) Pump speed too low. (5) Leakage in Suction Pipe. (6)Valve in Delivery Line not open properly. (7) Delivery liquid too viscous. (8) Incorrect selection of pump for operating condition. (9) Pin & bush of the coupling not provided. (10) Line shaft coupling or shaft broken. (1) Speed too low. (2) Discharge Head too high. (3) Rubber Flap of Non-return Valve clogged. (4) Leakage in the delivery line inside sump. (1) Speed too high. (2) Head less than rating. (3) Shaft Bent (4) Mis-alignment of the set. (1) Prime mover not running at rated speed. (2) Leakage through Discharge pipe inside the sump. (3) Too much clearance between Impeller and Wearing plate. (1) Pump casing not filled with Water/Liquid (it is only possible only when the sump is empty). (2) Misalignment (3) Foundation not rigid (4) Shaft bent (5) Bearing Worn out (6) Lack of Lubrication (7) Pump operating at very low capacity. (1) Mis- alignment (2) Shaft bent (3) Excessive Grease or lack of grease. (4) Dirty particles getting into Bearings. REMEDY (1) Liquid to be checked inside sump. (2) Change the direction of rotation of prime mover. (3) Check up Impeller may clog. Clean the Strainer. (4) Check up speed of prime mover and adjust. (5) Prevent leakage in suc. Pipe. (6) Check up the opening of line valve. (7) Liquid viscosity to be checked & corrected. (8) Replace the pump with a suitable designed capacity. (9) Provide pin & bush. (10) Check & replace the shaft or coupling as required. (1) Check up speed of prime mover and adjust. (2) Check up vertical head and frictional losses. (3) Check up rubber Flap assembly. (4) Check the delivery line inside sump after casing. (1) Check and correct the speed. (2) Provide minimum head. (3) Check and replace the Shaft. (4) Correct the alignment. (1) Check the speed of Prime mover and correct it. (2) Replace Delivery pipe. (3) Measure the clearance between Impeller and Wearing plate and adjust by using proper packings. (1) Allow inflow of liquid in the sump to fill up the pump casing. (2) Correct the alignment. (3) Check up the foundation bolt. (4) Replace the shaft (5) Check & replace Bearing. (6) Lubricate the Bearings. (7) Reduce total head. (1) Correct the alignment. (2) Check the shaft condition. (3) Check up lubrication. (4) Protect bearings neatly.

2.

Not enough liquid delivered.

3.

Pump takes More Power. Not enough pressure.

4.

5.

Pump vibrates and makes more noise.

6.

Bearings have short life.

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8.0

MAINTENANCE Preventative maintenance schedule is the periodical checks and precautions by which possibilities of failures and breakdowns are made very remote.

8.1

Daily Checks 1.1 1.2 1.3 1.4 1.5 Pressure gauge reading Bearing temperature Noise and vibration Voltage and current Constant flow of cooling & lubrication liquid.

8.2

Periodical Maintenance 1.1 Replenish the grease 1.2 Change the stuffing box packing 1.3 Check the alignment of the pump set 1.4 Calibrate the measuring instruments 1.5 Check the sealing and cooling connections for leakage etc. OVERHAULING Normally the pump will be due for overhauling after about 3000 working hours. Pump dismantling and assembling should be done by skilled personal. Special attention should be given to continuous running pumps & advice to keep stand by pump for emergency services.

9.0

10.0

DISMANTLING & REASSEMBLING PROCEDURE

Pump can be dismantled from the driving end side or non-driving end side. When the pump is on the horizontal ground (we refer this as horizontal mode) then it is required to start the dismantling from non-driving end. But when pump has to be removed part by part from the sump due to lack of vertical space above the sump than the pump has to be dismantled starting from driving end of the pump. 10.1 INFORMATION ABOUT DESIGN All VWS type Pumps for sewage application having more than one column pipe assembly are divided into two groups from the design point of view. Design No.1. Pump with screwed type line shaft coupling and with oil seal system having external oil lubrication. Design No.2. Pump with screwed type line shaft coupling and without oil seal for self-liquid lubrication.

Fig. No. 3 explained the design no.1. When part no.54, 55, 56, 58, 59 & 60 are not provided in design no.1 then it is identify as design no.2. In case of pump having single column pipe assembly no intermediate holder or shaft coupling are used and pump having only single combine shaft (fig. No.4).

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10.2.

SPECIAL TOOLS AND TACKLES: Impeller Lock nut opening wrench Column pipe holding clamp for installation Brg. Puller for Motor Stool

Last 2 items required when pump to be installed in the sump or dismantle from the sump part by part due to lack of space. 10.3. 1. DISMANTALLING OF PUMP AT HORIZONTAL MODE: When the pump is on the horizontal ground, it is considered as horizontal mode and to dismantle in this case, remove delivery pipe (part no.70 & 71) unscrewing special pipe in anti-clockwise direction to detach it (part no.72). Remove all lubrication line (part no.53, 61, 62, 63, 64, 65 & 66). Dismantle the strainer (part no.1) by opening the clamp (part no.2) (if applicable) and the suction Bell mouth (part no.3) unscrewing the bolt (part No.5) from volute casing. Unscrew the Grub screw (part no.10) from the impeller lock bolt and after that open the impeller lock bolt (part no.11) from impeller shaft by rotating it in anti-clockwise direction using impeller lock bolt opening wrench (which is a special tool available with the manufacturer) and then pull out the impeller (part No.6) by hand or using puller. Remove impeller key (part no.12). Dismantle volute casing (part no.7) by removing the bolt (part no.9) which are fitted with lower bearing housing directly (as in fig.4) or with the L.B.H plate (as in fig.3). Remove the L.B.H plate (part no.8) if provided. Now remove the lower bearing housing (part No.14) by unscrewing the bolt and nut (part no.16) which is fitted with column pipe. Lower bearing housing fitted with a G.M bush (part no.15) which is press-fitted inside the bearing housing. Bush provided with lubricating channel. If required, remove the bush by pressing it from topside and replace it. Remove oil seal cover (part no.55) and oil seal (part no.54) from both end of the lower bearing housing by unscrewing the bolt (part no.56) ( not applicable for design No.2). Remove the bottom column pipe (part no.17) by unscrewing the bolt and nuts (part no.23) which hold the two column pipes along with intermediate bearing holder (pat no.22). Now remove shaft sleeve (part no.13) and unscrew the sleeve locking grub screw if required (part no.57). Dismantling of Shaft Coupling : Screwed Coupling (applicable for pump having more than one column pipe) Remove 2 nos. shaft coupling lock bolt (part no.21) and then turn the impeller shaft (part no.19) in anticlockwise direction with the help of spanner (slotting space to fit dull wrench provided on the shaft and shaft coupling) holding at shaft and shaft coupling to remove shaft from the threaded coupling (part no.20). After removal of pump shaft remove shaft coupling from other shaft by using spanner. 9. Take out the intermediate bearing holder (part no.22) fitted with a G.M bush (part no.24) 10. having lubricating channel, suitable for self or oil lubrication. Remove oil seal cover (part no.59) and oil seal (part no.58) from both end of the intermediate bearing holder by unscrewing the bolt (part no.60) (not applicable for design no.2) 10. Remove the intermediate column pipe (part no.25) by unscrewing the nut and bolt.

2. 3.

4.

5.

6. 7.

8.

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11. Remove the intermediate bearing holder (part no.22) placed between standard column pipe (it is also part no.17 because it is identical with the bottom column pipe) and intermediate column pipe by removing the bolt. This procedure of removal of column pipes and shafts including shaft coupling will continue until the removal of the top column pipe (part no.28) by unscrewing the bolt (part no.36) from motor stool. For single column pipe pump (fig. No.4), the operation of Sl. No. 7,8,9,10,11 of clause 10.3 does not involve and only single column pipe (part no.28) to be removed. 12. MECHANICAL SEAL Take out the mechanical seal rotary part along with sleeve by unscrewing 4 nos. grub screw (part no.30) provided on the mechanical seal sleeve. Then take out the mechanical seal retainer (part no.34) fitted with mating ring (part no.33) of the seal. Mechanical seal placed over the sleeve and locked with another 4 nos. grub screw, which may be removed to dismantle sleeve from the seal. One no. O ring (part no.31) provided on the shaft may be removed if necessary. 13. DISMANTLING OF MOTOR STOOL & MOTOR (i) Electric motor (part no.76) with half coupling (part No.52) to be removed by unscrewing the bolt (part no.75) from the motor stool (part no.47). This operation may be done at the initial stage of dismantling of pumps.

(ii) Unscrew the grub screw (part No.74) used in pump half coupling and remove it (pat no.49) using puller. Remove key (part no.51) that fastened the coupling with top shaft. Remove the distance piece (part No.48). (iii) Remove the bearing cover (part no.46) by unscrewing the bolt (part no.45). 14. Pull out the top shaft (part no.27) along with the bearings (part no.42 & 43) from the topside Of the motor stool. Remove the bearing lock nut (part no.44) by unscrewing it in the anti-clockwise direction, which is mounted on the shaft and fixed to bearing inner race. Pullout the bearings and the collar Ring (part no.41) from the top shaft by puller. 10.4 DISMANTALLING OF PUMP AT VERTICAL MODE PART BY PART: 1. Pump can be dismantled from the sump pit part by part and in that case dismantling to be started from driving end i.e. the removal of pump coupling bearing cover & bearings. To remove bearings a special puller (available from the manufacturer) is required to be fitted at the place of Motor stool bolt (part no.75).

2.

Bolt for top base (part no.40) to be removed and pump to be lifted a little bit by chain pulley holding it on the motor stool to fix up column pipe holding clamp on the top column pipe to hold the pump assembly and rest it on the base. After detachment of chain pulley block remove bearing nut, fix up the long screw of the puller through the middle hole of the puller plate by screwing it upto the top of top shaft center point. Further tightening of the screw, Motor Stool will come out along with bearings from the shaft. Take it out and remove the bearings from the stool. Remove special pipe (part no.72) by unscrewing it and before that remove lubrication valve & fittings (part no.66) from special pipe & top base. Remove top base (part no.39) unscrewing 6 nos. bolt (part no.38). There after pull out the pump again gradually by chain pulley holding it on the column pipe and fix up the clamp again on the next column pipe and remove the pump part by part by repeating the holding procedure. Procedures for removal of other parts are explained in dismantling of pump in horizontal mode.

3. 4. 5. 6. 7.

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10.5 1.

IMPORTANT INFORMATION When the pump is with single column pipe then the operation of the part no.20 to 27 are not applicable since (this parts are not present in the pump) the pump will be fitted with one combine shaft & single column pipe assembly. When the pump is with two nos column pipes then the operation of intermediate shaft and intermediate column pipe are not applicable considering the point that (they are not present at the pump) there are only two shafts & two column pipes. AFTER REMOVAL OF THE ABOVE PUMP PARTS, IT IS NECESSARY TO CHECK UP PROPERLY FOR ANY WEAR & TEAR AND IF ANY PART IS FOUND TO BE WORN OUT, SAME SHOULD BE RE-PLACED OR RECTIFIED.

2.

10.5

10.7. ASSEMBLING OF PUMP Pump can be assembled from the driving end side or non-driving end side. When the pump is on the horizontal ground (we refer this as horizontal mode) then it is required to start the assembling from driving end. But when pump has to be installed part by part into the sump due to lack of vertical space above the sump than the pump has to be installed starting from non-driving end of the pump.
10.8. ASSEMBLING IN HORIZONTAL MODE :

1. 2. 3.

This is advised to re-assemble this pump from the driving end. First of all clean out all the parts and rub with Mobil oil. Put the collar ring (part no.41) to the top shaft and then press fit ball bearing and angular contact ball bearing (part no.42 & 43) on the top shaft (part no.27). Tighten the bearing lock nut (part no.44). Now push fit the bearing with top shaft in side the motor stool housing (part no.47). Fix bearing cover (part no.46) by tightening bolt (part no.45). Put the distance piece (part no.48) and then provide pump half coupling (part no.49) and key (part no.51) on top shaft. Provide grub screw (part no.74) of the coupling.

4.

MECHANICAL SEAL FITTING: Press fit mechanical seal stationary part (part no.33) (mating ring) after placement of O ring inside the mechanical seal retainer. Care should be taken that if any pin provided inside the retainer that should be placed inside the space provided in the mating ring. Now, the mechanical seal retainer along with the mating ring to be fitted with the motor stool placing through the shaft. Provide two nos.bolt (part no.36) temporarily to hold it in the fittings of the motor stool. Provide O ring (part no.31) on the shaft. The mechanical seal rotary part (part no.32) is to be fitted separately on the half sleeve (part no.29) by 4 nos. grub screw provided on the seal in such a position that about 6mm. Compression may be effected and inside of the seal face (in case of balance seal) does not foul with the sleeve edge. Now, seal along with the sleeve allow to move through the shaft until it reaches the face of the mating ring. With a hand press allow the seal to compress 3mm. and tighten the 4 nos. screws (part no.30) of the sleeve to hold it on the shaft rigidly. Now, remove the 2 nos. bolt (part no.36) temporarily fixed on the motor stool. Hence the fittings of mechanical seal assembly has been completed.

5.

At this stage, if you find the length of the top shaft extension is more than the length of the top column pipe, then top column pipe (part no.28) to be fitted over the mechanical seal retainer (part no.35) with the motor stool (part no.47) by the bolt (part no.36). If the column pipe length is more than the shaft extension, then the joint of the shaft by the shaft coupling is required. See procedure Sl. no.6 clause no. 10.8. After extension of the shaft, top column pipe to be fixed up following the above procedure.

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6.

SHAFT JOINT BY SHAFT COUPLING : Firstly, tighten the threaded coupling (part no.20) in clockwise direction on the intermediate shaft (part no.26) and find that lock bolt for shaft coupling (part no.21) will fit to the shaft (part no.27) and shaft coupling through the tap hole provided on the both. After locking of the side, tighten the other end of the threaded coupling by rotating it in clock-wise direction with the shaft assembly of the pump. Provide lock bolt (part no.21) to lock the shaft coupling with the other the shaft. In case of replacement of the shaft or shaft coupling, trial fit of the shaft & shaft coupling to be made and drill & tap for lock bolt to be provided on the shaft coupling along with shaft before fix it in the assembly. For replacement of the part, this job has to be done before starting of the assembly.

7.

For oil lubrication pump, provide oil seal (part no.58) on the both end of intermediate bearing holder and then fix up seal cover (part no.59) by tightening the screw (part no.60) at both end of bearing holder. Now insert the intermediate bearing holder (part no.22) through the shaft to fit it with the top column pipe. Addition of shaft by shaft coupling and addition of column pipe will continue until fitting of bottom shaft and bottom column pipe. Join pump shaft with intermediate shaft by shaft coupling following the procedure as explained in Sl. No.6 of clause no.10.8 and numbers of joint of shaft coupling will depend on the increase of Nos. of shaft of the pump.

8.

IMPORTANT INFORMATION

SHAFT AND SHAFT COUPLING USUALLY PROVIDED BETWEEN TWO BEARING HOLDERS JOINING BY INTERMEDIATE STANDARD COLUMN PIPE (PART NO.17) WHICH IS ALSO IDENTICAL TO THE BOTTOM COLUMN PIPE. 9. Insert the sleeve (part no.18) so that it aligns with the lock screw (part no.57) provided for it.

10. Provide oil seal (part no.54) at both end of the lower bearing housing (part no.14) and then fix up seal covers (part no.55) by tightening the bolt (part no.56). Fit lower bearing housing (part no.14) placing it through pump shaft with the bottom column pipe by bolt and nut (part no.16). 11. Provide volute casing (part no.4) with the lower bearing housing (fig. No.4) by bolts (part No.9) or placing L.B.H plate between these two parts (fig. No.3) using bolt (part no. 9 & 13). Fit impeller (part no.6) with the step down end of the pump shaft by using key (part no.12) and then tighten the impeller with shaft by lock bolt of impeller (part no.11) in such a manner that it will get tight as well as tap hole provided on the impeller eye and the hole on the lock bolt of the impeller will remain in the same line. Use impeller lock bolt opening wrench for tightening of the impeller. Now tighten the grub screw (part no.10) and thus the locking of impeller is completed. In case of replacement of Impeller, drill & tap to be provided on the impeller by reopen it after necessary marking of the position. 12. Fit suction bell mouth (part no.3) with the volute casing by bolt (part no.5). Fix up strainer (part no.1) with clamp (part no.2) if provided. 13. Fix up delivery bend (part no.68) (not required if integrally caste with the volute-fig. No.4) with the volute delivery flange by bolt (part no.67). Next, add the delivery pipe (part no.70) by bolt, the pipe will come out through the top base plate (part no.39) delivery pocket provided for it. Only threaded portion of the pipe will extend through the pocket. Fix up the special pipe (part no.72) on the thread of the pipe by rotating it in clockwise direction and the same will fix up on the surface of the base plate. Dont forget to provide gaskets (part no.9) between all the delivery flange joint. Now, rotate the coupling of the pump by hand to check up whether pump is rotating freely. The pump assembly is ready to reinstall in the sump pit. Fit all lubrication pots or valve (part no.66) and lubrication pipe with fittings (part no.53, 61, 62, 63, 64, and 65).

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10.9

ASSEMBLING OF PUMP PART BY PART IN THE SUMP: Assembly of the pump part by part inside the sump is required when available height above the sump is less than the total height of the pump. For this purpose, first pump sleeve (part no.18) to be provided on the bottom shaft (part no.19). If pump provided with L.B.H plate (fig. No.2) then the plate (part no.8) should be added with the volute casing (part no.7) by bolt (part no.9). If guide ring is applicable (fig. No.3) that has to be added by press fit with the volute and if lock screw is there, to be provided. Addition of L.B.H (part no.14) is required at this stage by bolt (part no.13). Now the shaft with sleeve to be inserted through the center hole of the L.B.H fitted with casing unit from driving end. From the non-driving end, impeller to be fitted on the shaft and locking to be made as explained in the serial no.11 of clause 10.8. Suction bell mouth and strainer (if applicable) to be fixed up by bolt. Now, rotating assembly will rest on the suction bell when it is in vertical position. At this stage, intermediate shaft to be added with the bottom shaft by shaft coupling following the procedure as explained in serial no.6 of clause 10.8. Next, bottom column pipe (part no.17) to be fixed up by bolt (part no.16) with the lower bearing housing (part no.14). Now, the pump is ready for lowering inside the sump by holding the column pipe with the chain pulley block. After lowering of the casing unit (keeping it in downward direction), a special holding clamp to be fixed up on the column pipe and with a further lowering of the holding clamp to be rest on the bottom base (part no.37) already existing on the top of the sump (the bottom base is not required to be disturbed during lifting of the pump from the sump). Addition of intermediate holder, shaft and shaft coupling will continue as per serial no.6, 7 and 8 of clause no. 10.8 until addition of all the intermediate column pipes, intermediate bearing holders and intermediate shafts. Before fixing of the top shaft, one trial fit of the bearings with the shaft inside the motor stool as per serial no.3 of clause no 10.8 to be made. Providing the mechanical seal retainer with the column pipe, mechanical seal with the sleeve to be placed with a 3mm. compression as per serial no.4 clause no.10.8 to mark the position of the sleeve on the shaft. Now, after dismantling of this trial fit, the top shaft to be added with the intermediate shaft. Insert mechanical seal with sleeve assembly on the shaft from the driving end and fix it at the marked position (instruction as per serial no.4 clause no.10.8 may be followed). Next, bolt up the top column pipe (part no.28) with the intermediate column pipe (part no.17 or 25 as applicable) keeping the intermediate holder (part no.22) in between them. Mechanical seal retainer fitted with mating ring (refer Sl. no.4 clause no.10.8) to be placed on the top column pipe. At this stage with a little press on the retainer towards the column pipe you can fill the compression of seal. Motor stool (part no.47) to be added next on the retainer holding with bolt (part no.36). Before addition of the motor stool, top base plate (part no.39) to be added with the motor stool by bolt (part no.40). With the addition of the column pipe, addition of delivery bend, delivery pipes and lubrication pipes and fittings to be simultaneously carried out. Now, fix up the top base over the bottom base by bolt (part no.38) so that delivery pipe should come out through the hole provided for it on the top base. Now place the collar ring, 2 nos. bearings (part no.42 & 43) and tighten with the bearing nut (part no.44). Place the bearing cover by the bolt (part no.45). After providing distance piece (part no.48), coupling (part no.49) and key (part no.51) as per serial no.13 clause no.10.8, you will find the rotor assembly can be rotate by hand. Fix up special pipe and complete the lowering

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