GE OSMONICS TONKAFLO SS Series Installation, Operation And Maintenance Manual Download

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OSMONICS

TONKAFLO



PUMPS

SS SERIES

INSTALLATION, OPERATION, AND

MAINTENANCE MANUAL

For SS5500, SS8500, SS12500, SS23000,

and SS24000 Series High-Pressure

Tonkaflo Centrifugal Pumps

with E-Bearing Frames

GE Infrastructure
Water & Process Technologies

Summary of Contents for OSMONICS TONKAFLO SS Series

Page 1: ...UMPS SS SERIES INSTALLATION OPERATION AND MAINTENANCE MANUAL For SS5500 SS8500 SS12500 SS23000 and SS24000 Series High Pressure Tonkaflo Centrifugal Pumps with E Bearing Frames GE Infrastructure Water Process Technologies ...

Page 2: ...rd Materials of Construction 3 2 5 Special Materials of Construction 4 2 6 Pump Nomenclature 4 2 7 Special Liquids 4 3 0 PUMP INSTALLATION 5 3 1 Check Upon Arrival 5 3 2 Location 5 3 3 Foundation 5 3 4 Bedplate Installation 6 3 5 Motor Pump and Coupling Alignment 7 3 6 Coupling Guard 9 3 7 Piping 9 3 8 Bypass Piping for Multi Stage Pumps 10 3 9 Suction Screen Strainer 11 3 10 Discharge Screen Stra...

Page 3: ...n E Bearing Frame Tonkaflo Pumps 20 6 5 1 Disassembly of Pumps with Type E Bearing Frame 20 6 5 2 Assembly of Pumps with Type E Bearing Frame 22 6 5 3 Install the Liquid End and Remount the Pump 24 6 6 Oil Seal Replacement 24 6 6 1 Replacement of Oil Seal 2 24 6 6 2 Replacement of Oil Seal 1 25 6 6 3 Replacement of Oil Chamber O ring Seal 26 6 7 Lubrication 27 6 7 1 Adding Oil 27 6 7 2 Oil Change ...

Page 4: ...allation 6 3 2 Coupling Alignment 8 3 3 Gap Between Flanges 9 3 4 Suction Lift Piping 10 3 5 Installation of Discharge Screen 11 3 6 Installation of Oiler 13 3 7 Initial Cold Setting for Constant Level Oiler 13 6 8 Separation of Liquid End from Bearing Frame 18 6 9 Removal of Mechanical Seal 19 6 10 Bearing Frame Overhaul 21 6 11 Setting Bearing Frame Shaft End Play 23 9 12 Dimensions Pump Only 30...

Page 5: ...manual is not intended for repair or overhaul of the Tonkaflo pump liquid end Only the factory or those who have successfully completed the Factory Service School and have been certified are authorized to repair service or overhaul Tonkaflo pump liquid ends Your new Tonkaflo multi stage centrifugal pump is designed for quiet smooth running and highly efficient operation The seven series of Tonkafl...

Page 6: ...hieved with optional high pressure construction on the downstream pump With inlet pressures greater than 200 psig 13 8 barg and less than 400 psig 27 6 barg optional high pressure mechanical seals should be used 2 1 Capacities Table 2 1 Tonkaflo Pump Capacities NOTE There must be adequate flow through the pump to prevent excessive heat build up at all times SS Series 5500 8500 12500 23000 24000 35...

Page 7: ...he label on the pump case The temperature stated is for the design flow and pressure 2 4 Standard Materials of Construction SS Wetted castings and pump shaft are 316 Stainless Steel SS The pump casing is 316SS Impellers and diffusers are Noryl except SS23000 and SS24000 Series diffusers which are 316SS The mechanical seal has a carbon rotating face and a ceramic stationary face The secondary seali...

Page 8: ...us solutions at elevated temperatures or corrosive solutes consult the factory for compatibility 4 M o d e l S S 5 5 1 8 E SS Materials of Construction 55 Series 5500 18 Number of Stages E Bearing Frame M o d e l S S 5 5 2 7 E 5 0 H z SS Materials of Construction 55 Series 5500 27 Number of Stages E Bearing Frame 50Hz 50 Hertz Operation Viton and Teflon are trademarks of E I Dupont de Nemours and ...

Page 9: ...sure pump It is ideal for the pump to be fed from a reservoir above the pump or from a supply line under positive pressure 3 3 Foundation The foundation for the bedplate motor and pump must be sufficiently rigid and substantial to prevent any significant vibration of the pump or deflection of the motor and pump shafts when operating the pump The recommended foundation is of reinforced concrete or ...

Page 10: ...6 3 4 Bedplate Installation NOTE The bedplate must be level and securely mounted for proper pump operation Figure 3 1 Bedplate Installation ...

Page 11: ...complete unit slide one coupling flange onto the pump shaft with a snug fitting key With the flange and key flush with the shaft end tighten the set screws Slide the coupling flange onto the motor shaft with shaft key and position the motor on the bedplate Measure horizontal and vertical alignment Figure 3 2 2a 2b using a straight edge and feeler gauges Align the coupling to the accuracy noted in ...

Page 12: ...Figure 3 2 Coupling Alignment 8 ...

Page 13: ...ized so that the pressure available at the pump suction inlet exceeds the Net Positive Suction Head NPSH required by the pump Generally the suction inlet piping should be 4 inches 10 2 cm for flows greater than 170 gpm 38 6 m3 h 3 inches 7 6 cm for 100 gpm 170 gpm 22 7 38 6 m3 h 2 1 2 inches 6 4 cm for 60 gpm 100 gpm 13 6 22 7 m3 h and 2 inches 5 1 cm or greater for 60 gpm 13 6 m3 h or less see fr...

Page 14: ...ubmerged enough so air is not drawn into the suction line from a vortex Increasing the size of the inlet pipe to reduce the velocity will help to prevent the vortex from forming Hot liquids within the temperature range of the pump must have sufficient positive head to prevent vaporization at the impeller inlet Consult the factory for NPSH requirements of the pump for your application The pump must...

Page 15: ...llect any foreign objects or large particles The pump must not be operated with restricted suction line inlet flow Positive gauge pressure must be maintained at the pump inlet downstream from the filter or screen A clogged screen or filter will result in a greater pressure drop A low pressure alarm or shutoff switch located between the screen or filter and the pump should always be used in conjunc...

Page 16: ...0 95 L of oil is provided with each new Tonkaflo oil lubricated pump Additional oil can be purchased from GE Section 10 2 Standard Model Parts List A heavy duty premium hydraulic and lubricating oil anti wear non detergent rust oxidation and foam inhibited should be used such as those listed in Table 3 3 Typical Heavy Duty Hydraulic and Lubricating Oil Types Table 3 3 Typical Heavy Duty Hydraulic ...

Page 17: ...ottle fill allow 15 minutes or more to elapse before measuring the oil level On the final fill the bottle should be approximately 2 3 to 3 4 full and not completely full for best operation of the Trico Oiler Check the oil level according to Figure 3 7 Initial Cold Setting for Constant Level Oiler Adjust as necessary draining excess oil Replenish oil in bottle only when oil is no longer visible in ...

Page 18: ...is suggested that controls to protect the pump be used These controls include pressure switches flow switches and temperature switches 4 2 Pump Rotation When initially connecting to the power source be certain that the motor wiring and available line voltage are the same Connect the wires as shown on the motor wiring diagram located on the inside of the motor junction box cover or on the nameplate...

Page 19: ...d and pump rotation checked your pump is ready to operate Upon start up check to see that the correct boost pressure level is obtained at design flow and that oil droplets form in the oil eye Section 3 12 Lubrication of Pump Bearings If prime was not achieved reprime as necessary 15 ...

Page 20: ...equately primed 2 Air leak in inlet piping 3 Excessive flow 4 Clogged suction line filter or screen 5 Reverse rotation of pump shaft 6 Foot valve operating improperly PUMP LEAKING 1 Mechanical seal needs replacing 2 O rings in pump casing damaged 3 Oil seals need replacing 4 Piping not sealed properly LOW FLOW 1 Restrictions in inlet or discharge 2 Foot valve operating improperly 3 Air leak in inl...

Page 21: ...e mechanical seal or for maintenance work on the pump bearing frame as described in Sections 6 3 6 6 The liquid end may be removed from the bearing frame without removing the bearing frame from the bedplate or other mounting STEPS 1 Remove the four 3 8 inch bolts and lock washers connecting the liquid end assembly to the bearing frame as shown in Figure 6 8 Separation of Liquid End from Bearing Fr...

Page 22: ... and insert the pump shaft such that the key on the pump shaft fits into the key way on the bearing frame shaft Then push until castings come together 4 Fasten together the inlet casting mechanical seal holder and bearing frame assembly with the four 4 3 8 inch bolts and lock washers Reference Figure 6 8 Separation of Liquid End from Bearing Frame and Figure 6 9 Removal of Mechanical Seal for corr...

Page 23: ... Removal of Mechanical Seal 4 When installing a new mechanical seal do not cut the rubber bellows when sliding the seal over the shaft key way One method is to wrap thin plastic tape over the shaft key way to protect the rubber bellows from damage Wrap 1 1 4 turns to cover the end of the key way opposite the shaft end With some overlap wrap a second 1 1 4 turns etc until complete key way is covere...

Page 24: ...bly over the pump shaft 10 Install the liquid end assembly onto the bearing frame Section 6 2 2 6 4 High Pressure Mechanical Seal Replacement High pressure mechanical seals have the same basic design as standard mechanical seals Replace them using the same procedure as denoted in Section 6 3 Mechanical Seal Replacement 6 5 Bearing Frame Maintenance on E Bearing Frame Tonkaflo Pumps 6 5 1 Disassemb...

Page 25: ...ed continue pressing to remove the shaft assembly from the bearing frame Bearing cone 1 will remain on the shaft Removal of bearing cone 1 from the shaft should be done only when replacement is necessary Figure 6 10 Bearing Frame Overhaul 5 Inspect the bearing cups and cones for any rough surface conditions and replace both cup and cone when necessary Pitted and galled rollers and or bearing cap i...

Page 26: ...while starting Press until the bearing cone is fully seated against the bearing cup and there is no end play 4 Reinstall the tanged flat washer lock washer and nut Hand tighten the lock nut and lightly set a tang on the lock washer into a slot on the lock nut If desired a 3 8 16 NC x 3 bolt may be inserted through a side port in the bearing frame and into the set screw hole in the end of the beari...

Page 27: ...h 0 08 mm less end play 9 Repeat Steps 5 and 6 10 When the end play setting is correct set one tang of the lock washer into a slot in the lock nut 11 Inspect and replace the O ring on the oil seal holder and on t h e end cap if damaged Replace the oil seals 12 Reinstall the oil seal holder oil seal and retaining ring Figure 6 10 Bearing Frame Overall making sure the seal and O ring are lubricated ...

Page 28: ...g frame Section 6 2 2 Steps 1 5 2 Mount the pump on the bedplate or other mounting and position and tighten the clamp on the discharge support 3 Align the coupling Section 3 5 Motor Pump Coupling Alignment 4 Lubricate pump bearings Section 3 12 Lubrication of Pump Bearings 6 6 Oil Seal Replacement Oil leaking around the bearing frame shaft means oil seal 2 Figure 6 10 Bearing Frame Overhaul is lea...

Page 29: ... frame Care must be taken to not damage the oil seal lip 10 Reinstall the three bolts and lock washers to fasten the bearing frame cap to the bearing frame 11 Reinstall the coupling flange so it is flush with the end of the shaft and remount the pump or motor as required 12 Install and align the flexible coupling Section 3 5 Installation of Discharge Screen 13 Install the coupling guard 14 Replace...

Page 30: ...ing ring in the bearing frame Make sure the O ring on the outside of the oil seal holder and the oil seal lip are lubricated before installing Replace the O ring if damaged 6 Install the liquid end and remount the pump Section 6 2 2 Steps 1 4 6 6 3 Replacement of Oil Chamber O ring Seal Should the O ring seal for the oil chamber bulkhead Figure 6 10 Bearing Frame Overhaul need replacement remove t...

Page 31: ...brication of Pump Bearings for oil type 6 7 2 Oil Change THE RECOMMENDED OIL CHANGE INTERVAL IS 2000 HOURS OF PUMP OPERATION OR SIX MONTHS WHICHEVER OCCURS FIRST Refer to Section 3 12 Lubrication of Pump Bearings on oil filling The crossbar support for the oiler must be installed do not discard Always add oil into the oiler bottle do not fill directly into the oiler reservoir Before starting check...

Page 32: ...pair replacement and warranty disposition Field service of the liquid end with the exception of mechanical seal replacement is not recommended If a liquid end is damaged by running the pump dry inadequate flow excessive deadheading cavitation or other reasons contact a Tonkaflo distributor certified for service or return it with or without motor to the factory for repair The pump has a oil lubrica...

Page 33: ...ective pump to the factory for repair and return 8 1 Motor Warranty Motors must be sent to the nearest authorized motor service center or repair replacement and warranty consideration 8 2 In Warranty Pump Failure 8 2 1 Return the pump on an RGA for repair on an RGA within 15 days from RGA issue date GE absorbs the cost of repair The repaired pump will be returned and is under warranty for the rema...

Page 34: ...9 0 DIMENSIONAL DRAWING Figure 9 12 Dimensions Pump Only 30 ...

Page 35: ...10 0 REPLACEMENT PARTS 10 1 Pump Cutaway Drawing Figure 10 13 Pump Cutaway Drawing 31 ...

Page 36: ... 1122335 1121278 1121279 1121280 1120599 1120380 1120381 1120382 1120383 1123059 Part Description Screw Cap 5 16 18NC x 1 2 inch Nut Lock Discharge Support Assembly Includes items 10 11 Screw Cap 3 8 16NC x 1 0 inch Plug 1 4 NPT SS 316 Screw Cap 3 8 16NC x 1 1 2inch Oil Sight Gauge Screw Cap 1 4 28NC x 3 4 inch Oil Chamber Bulkhead O ring 4 1 4 inch ID Retaining Ring N5000 433 Lock Washer 5 16 inc...

Page 37: ...5 1122204 1111754 1121978 1122025 1121976 1110202 1114476 Part Description Mechanical Seal Standard Type 21 200 psi 13 8 bar ceramic seat High Pressure Type 1 300 psi 20 7 bar ceramic seat High Pressure Type 1 300 psi 20 7 bar Ni resist seat High Pressure Type 1 400 psi 27 6 bar tungsten carbide seat O ring 1 7 8 ID Seal Holder Set Screw Oil Seal CR18546 Oil Seal Holder Assembly Retaining Ring 510...

Page 38: ...g Grade 100 1 Quart 1 Quart 0 95 L 1 Case 12 Quarts 114 L0 Anti seize thread compound Thrust washers Stage bearing Carbon bearing Center housing tool E Bearing frame pump Discharge housing tool E Bearing frame pump SS5500 SS12500 Series stage parts Mechanical seal kit 200 psi 13 8 bar Type 21 ceramic 300 psi 20 9 bar Type 1 ceramic 300 psi 20 9 bar Type 1 Ni Resist 400 psi 27 6 bar Type 1 tungsten...

Page 39: ...upling 3 inch Style 77 Buna N Victaulic coupling 4 inch Style 77 Buna N Part Number 1120589 1120590 1120586 1120587 1120588 1122066 1122067 1114373 1115161 Part Description Operation and Maintenance Manual for SS5500 SS8500 SS12500 SS23000 SS24000 Series High Pressure Pumps up to 1000 psi 69 bar with Type E Bearing Frames 1 inch Type 21 BF501C1 316SS Mechanical Seal Kit Inlet pressure 200 psig 13 ...

Page 40: ... NPT Bearing frame shaft washer Bearing frame shaft bolt Oil breather Bearing frame shaft set screw cone point Oil sight gauge Oil drain nipple 1 4 inch NPT x 2 inch Oil drain cap 1 4 inch NPT Oil seal holder assembly Without oil seal PN 1113996 Coupling flanges 2 and sleeve 1 Refer to Section 3 5 Motor Cup Coupling Alignment Coupling key bearing frame Pump shaft key Machine bolts 5 16 x 18NC x2 i...

Page 41: ...1 One 3 16 inch Allen hex wrench for removal of bearing frame shaft set screw 2 9 16 inch wrench 10 8 Ordering Parts Order parts through your local distributor or directly from GE Infrastructure Water Process Technologies 5951 Clearwater Drive Minnetonka MN 55343 8995 USA Telephone 952 933 2277 Fax 952 933 0141 Toll Free 800 848 1750 To order parts the following information is necessary 1 Pump mod...

Page 42: ... O B factory of parts or equipment which upon return to GE and upon GE s examination prove to be defective Equipment and accessories not manufactured by GE are warranted only to the extent of and by the original manufacturer s warranty GE shall not be liable for damage or wear to equipment caused by abnormal conditions excessive temperature vibration failure to properly prime or to operate equipme...

Page 43: ... Euro Africa Sales Asia Pacific Sales 5951 Clearwater Drive 230 rue Robert Schurman 1044 8 SOI 44 2 Minnetonka MN ZA des Uselles Sukhumvit Road Parkanog 55343 8995 77350 Le Mée sur Seine Bangkok 10110 USA FRANCE THAILAND 952 933 2277 Phone 33 1 64 10 2000 Phone 66 2 38 14213 Phone 952 933 0141 Fax 33 1 64 10 3747 Fax 66 2 39 18183 Fax GE Infrastructure Water Process Technologies ...

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