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PB3 User Instruction

Page 33 of 39

If on vacuum service.

WARNING

Before attempting any maintenance work on pumps in vacuum service, pumps must
be isolated from suction and discharge system then carefully vented to return
pressure in pump casing to atmospheric pressure.

5.1 Maintenance schedule

Although your PUMPIRAN pump has been designed for extended, trouble-free service, certain preventive
maintenance measures should be performed on a regular basis to ensure optimum performance. A well-planned
program of routine maintenance is the best assurance of dependable operation. The following preventive
maintenance (PM) inspections are suggested as a minimum, and may be supplemented by the experience of the
operating personnel.

Preventive Maintenance Item Instructions

Frequency

Suction strainer when used

Check pressure differential between the gauges located on each
side of the strainer.

Daily

Pump Suction And
Discharge Pressure/Flow
Rate

Check suction and discharge pressure/flow rate for proper pump
operation.

Daily

Mechanical Seal

Inspect visually

Daily

Instrumentation

Check all related pressure gauges, temperature and detectors,
etc. to detect any abnormalities.

Daily

Shaft rotation (Down
periods only)

During extended down periods rotate the shaft by hand 1-1/4
times to prevent shaft binding.

Monthly

Auxiliary piping

Check for leakage around connections, etc.

Weekly

Shaft/bearing housing
vibration

Review all vibration data for any abnormalities and/or sudden
changes in levels.

Weekly

Bolting tightness

Check all external bolting for proper torque.

Monthly

Cleanliness

General clean-up soiled areas

Quarterly

Oil system

Refer to Lubrication System section of instruction manual.

Periodically

5.2 Spare parts

5.2.1 Ordering of spares

PUMPIRAN keep records of all pumps that have been supplied. When ordering spares the following information should be
quoted:



Pump serial number



Pump size/type



Order number



Part name – taken from section 7 or pump sectional drawing



Part number – taken from section 7 or pump sectional drawing



Number of parts required – taken from section 7 or pump sectional drawing

The pump size and serial number are shown on the pump nameplate.

To place an order, contact the PUMPIRAN office.

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Summary of Contents for PB3

Page 1: ...ns Contain Fundamental Information Precautionary Notes Please Read The User Instruction Prior To Installation Of Unit Electrical Connection Commissioning It is Imperative to Comply with All Other Operating Instructions Referring to Components of Individual Units Installation Operation Maintenance PB3 User Instruction ...

Page 2: ...ndling 9 2 3 Lifting 9 2 4 Extended storage 11 2 5 Recycling and end of product life 14 3 INSTALLATION 14 3 1 Location 14 3 2 Foundation 14 3 3 Grouting 15 3 4 Initial alignment 16 3 5 Piping 20 3 6 Electrical connections 23 3 7 Final shaft alignment check 24 3 8 Protection systems 24 4 COMMISSIONING START UP OPERATION AND SHUTDOWN 25 4 1 Precommissioning procedure 25 4 2 Pump lubrication 27 4 2 1...

Page 3: ... 7 Running or operation 29 4 8 Stopping and shutdown 30 4 9 Hydraulic mechanical and electrical duty 31 5 MAINTENANCE 32 5 1 Maintenance schedule 33 5 2 Spare parts 33 5 3 Recommended spares and consumable items 34 5 4 Fastener torques 35 6 FAULTS CAUSES AND REMEDIES 36 7 DRAWINGS AND PARTS LIST 38 ...

Page 4: ...Where applicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives and Approvals 1 3 Disclaimer Information in these User Instructions is believed to be reliable In spite of al...

Page 5: ... This symbol indicates is used in safety instructions to remind not to rub non metallic surfaces with a dry cloth ensure cloth is damp It is used where non compliance in the hazardous area would cause the risk of an explosion This sign is not a safety symbol but indicates an important instruction in the assembly process 1 5 2 Personnel qualification and training All personnel involved in the opera...

Page 6: ... vibration Caution Do not run the pump at abnormally high or low flow rates Operating at a flow rate higher than normal or at a flow rate with no backpressure on the pump may overload the motor and cause pump cavitation DANGER Never do maintenance work when the unit is connected to power hazardous substances and toxic fluid When the pump is handling hazardous liquids care must be taken to avoid ex...

Page 7: ...res must be followed to help ensure explosion protection Both electrical and non electrical equipment must meet the requirements of European Directive 94 9 EC 1 6 Noise level Attention must be given to the exposure of personnel to the noise and local legislation will define when guidance to personnel on noise limitation is required and when noise exposure reduction is mandatory This is typically 8...

Page 8: ... may be packed separately with the equipment or attached to side walls of the box or equipment Each product has a unique serial number Checks that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories Brake Horse Power at BEP dBA 3 to 14 Stages 90 to 110 79 110 to 140 80 140 to 180 81 180 to 220 82 220 t...

Page 9: ...ual In general care is to be taken when removing crating coverings and strapping in order not to damage any auxiliary equipment and or the paint finish 2 1 3 Paint rust preventive Internal parts of the pump and bearing housings are protected prior to shipment with a rust preventive such as Dasco guard 2408M This can be removed with petroleum solvents External non machined surfaces are painted with...

Page 10: ...ate before lifting To lift unit sling base plate from all lifting eyes Failure to do this may result in permanent deformation of base plate Damage to base plate caused by mishandling or improper setting prior to grouting is not covered by PUMPIRAN s warranty 2 3 3 To lift driver Refer to driver manufacturer s instructions 2 3 4 To lift pump Install sling from overhead hoist and under bearing housi...

Page 11: ...ended storage NOTE The following information regarding receiving is only offered as a general guideline PUMPIRAN requires that all receiving be conducted in accordance with specifications set forth in Chapter 3 Jobsite Receiving and Protection from API recommended Practices 686 PIP REIE 686 First Edition During extended periods of storage prior to installation and from the time of installation unt...

Page 12: ...tion of the equipment will be proportionate to class type of storage provided b The expense involved in restoring the equipment at time of operation will be proportionate to the class type of storage provided 2 4 3 Storage preferred dry If at all possible the pump and its components should be stored indoors where they will be protected from the elements If it is not possible to store the pump and ...

Page 13: ... Install bearing cover and secure to assure maximum protection Bearings removed for storage should be coated with preservative wrapped in oil wax paper and stored in a warm dry area h Check individually wrapped parts for signs of deterioration If necessary renew preservative and wrapping Caution If storage is over one month Instrumentation Controls Electrical devices Temperature switches should be...

Page 14: ...ic fluids are disposed of safely and that the correct personal protective equipment is used The safety specifications must be in accordance with the current regulations at all times 3 INSTALLATION NOTE The installation commissioning of this equipment must be conducted in according with API Recommended Practicee 686 PIP REIE 686 First Edition 3 1 Location Install the unit close to the source of the...

Page 15: ...e block together with the leveling screws as shown in the General Arrangement Drawing Using a precision level across the machined surfaces of the pump and driver mounting pads adjust leveling screws as necessary to ensure that base plate is leveled in all directions When the base plate is leveled snug the foundation bolts but do not completely tighten Using the previous procedure adjust base plate...

Page 16: ...The shafts must be aligned within the limits given within this section NOTE Adjustment to correct the alignment in one direction may alter the alignment in another direction Always check in all directions after making any adjustment Coupled equipment must be aligned to minimize unnecessary stresses in shafts bearings and coupling Flexible couplings will not compensate for appreciable misalignment ...

Page 17: ... pump and driver shafts in the center of their axial end float Motor with sleeve bearings is to be aligned with rotor at magnetic center Move driver to insure proper gap distance NOTE It is recommended that the pump hold down bolting be torqued before taking any alignment measurements This makes the pump the fixed machine and driver the movable machine In certain cases however it may be impractica...

Page 18: ... many thin shims as this may result in a spongy mounting Recommended shim design 3 4 2 5 Determine misalignment and correct horizontal plane The dial indicators shown below are required to accurately measure the move in the horizontal direction Move the driver by bumping with soft hammer mallet or using the jack screws if provided The amount of horizontal relocation required is calculated in align...

Page 19: ...mperature away from coupling end of pump The units that come under this classification must have the pump support feet dowelled to the pedestal at the coupling end This maintains the coupling gap at the desired amount The pump feet at the opposite end are held from moving vertically by the use of a self locking nut The clearance between the base of the nut and the top of the pump foot should be 0 ...

Page 20: ... 0 051 mm 0 002 in gap between the locknut and the pump foot 3 4 8 Hot alignment check A hot check can only be made after the unit has been in operation a sufficient length of time to assume its NORMAL operating temperature and conditions If the unit has been correctly cold set the offset misalignment will be within 0 076 mm 0 003 in TIR and the angular misalignment will be within 0 0254 mm 0 001 ...

Page 21: ...l prevent the pump from running backward The check valve should be installed between the gate valve and the pump nozzle in order to permit its inspection The gate valve is also useful in priming and starting the pump Keep the suction pipe short and direct Use a suction pipe equal to or one size larger than the pump suction nozzle Keep the suction pipe free of all air pockets A spool piece should b...

Page 22: ...ners consists of conical shaped steel plate with 1 8 in perforations see the below picture The open area of the strainer should be a minimum of three times the area of the pump suction At all times when using suction strainers it is critical that the pressure drop across the strainer be constantly monitored to ensure that the pump suction pressure does not fall below that required to prevent pump ...

Page 23: ...Caution The pressure drop across the strainer is a direct reduction in the NPSH available to the pump NPSH available must always exceed the NPSH required by the pump This requirement may limit the pump flow rate particularly during start up operation Alarms or automatic pump shutdown devices should be installed to minimize the possibility of pump damage It is the responsibility of the pump operato...

Page 24: ...g to the pump rotate the shaft several times by hand to ensure there is no binding and all parts are free Recheck the coupling alignment as previously described to ensure no pipe strain If pipe strain exists correct piping Caution Refer to section entitled shaft coupling alignment and perform a coupling alignment check as outlined This check is recommended to insure the alignment has not been dist...

Page 25: ...erate the pump with suction valve closed b Never operate pump unless it is filled with liquid and vented c Never operate the pump unless a liquid source is available d Never operate the pump without proper lubrication 4 1 1 Pre operational checks At initial start up and after the equipment has been overhauled a Ensure pump and piping are clean Before putting the pump into operation it should be th...

Page 26: ...ng a small amount of hot fluid through the casing by utilizing vents drains or bypass from discharge and suction Preheat pump slowly at a rate not to exceed 55 6 C 100 F per hour d Prime pump and ensure pump suction valve and bypass isolating valve are open Caution Before starting or while operating the pump the casing and suction line must be completely filled with the liquid being pumped The rot...

Page 27: ...180 F Continuous 3 calendar months 3 month intervals are recommended to protect against normal oxidation contamination and deterioration 82 C 180 F Continuous As specified by PUMPIRAN Continuous operation at oil temperatures above 82 C 180 F requires consultation with PUMPIRAN Oil specifications and characteristics Oil Characteristics Operating Oil Temperature 16o C 38o C 60o C 100o F 38o C 82o C ...

Page 28: ...t up temperature of 4 C 40 F For startup when oil temperature is below 4 C 40 F oil preheating is recommended 4 2 4 Cleaning the lubrication system prior to operation Before operating the pump the lubrication system should be thoroughly cleaned to remove any foreign matter that may have accumulated during shipment storage or installation To clean the lubrication system refer to the Sectional drawi...

Page 29: ...d unless coupling guard is bolted in place Failure to observe this could result in injury to operating personnel WARNING When pump is equipped with manifolded vent and drain lines each line must be equipped with an individual valve to prevent any liquid from a high pressure line flowing into a low pressure line These valves must be kept in the closed position during pump operation WARNING Observe ...

Page 30: ...l noises e Check lubrication system f Check for adequate flow of cooling liquids g After unit has been operated a sufficient length of time to reach normal operating temperature and condition the unit is to be shut down and a HOT coupling alignment check must be made Refer to shaft coupling alignment procedure WARNING Operation of the unit without appropriate lubrication can result in overheating ...

Page 31: ...hich the pump was originally designed and or applied the changed conditions should be referred to PUMPIRAN for recommendations 4 9 3 Changing the Pump speed Changing the speed of a centrifugal pump changes the capacity total head and brake Horse Power The capacity will vary in a direct ratio with the speed whereas the total head will vary as the ratio of the speed squared The brake Horse Power wil...

Page 32: ...ing any inspection or repair on the pump the driver controls must be in the off position locked and tagged to prevent injury to personnel performing service on the pump b Isolating Pump WARNING Before attempting to disassemble pump pump must be isolated from system by closing suction and discharge system valves drained of liquid and cooled if pump is handling hot liquid c Draining pump NOTE Pump c...

Page 33: ... operation Daily Mechanical Seal Inspect visually Daily Instrumentation Check all related pressure gauges temperature and detectors etc to detect any abnormalities Daily Shaft rotation Down periods only During extended down periods rotate the shaft by hand 1 1 4 times to prevent shaft binding Monthly Auxiliary piping Check for leakage around connections etc Weekly Shaft bearing housing vibration R...

Page 34: ...res Spares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monthly intervals 5 3 Recommended spares and consumable items A recommended spare parts classification is offered for PUMPIRAN parts furnished on this unit The classification of a required part can be identified by referring to the ...

Page 35: ...er Instruction Page 35 of 39 5 4 Fastener torques The tightening torques indicated for nuts and bolts shall be observed The table below indicates the tightening torques for threads depending on material used ...

Page 36: ...and replace faulty parts CONSULT PUMPIRAN x x x x Inlet of suction pipe insufficiently submerged Check out system design x x x Speed too low CONSULT PUMPIRAN x Speed too high CONSULT PUMPIRAN x x x Total head of system higher than differential head of pump Check system losses Remedy or CONSULT PUMPIRAN x Total head of system lower than pump design head x Specific gravity of liquid different from d...

Page 37: ... If alignment satisfactory check bearings for excessive wear x x x x x Impeller out of balance resulting in vibration Check and CONSULT PUMPIRAN x x x Abrasive solids in liquid pumped x x Mechanical seal was run dry Check mechanical seal condition and source of dry running and repair x x x Excessive thrust caused by a mechanical failure inside the pump Check wear condition of Impeller its clearanc...

Page 38: ...12 441 Crossover Bush 13 269 Suction Ring 14 502 Diffuser Wear Ring 15 171 1 Diffuser A 16 230 Impeller 17 502 4 Wear Ring Impeller 18 171 2 Diffuser B 19 524 Center Bush 20 529 Bearing Sleeve 21 350 Bearing Housing 22 500 Oil Ring 23 321 Angular contact Ball Bearing 24 508 Oil Thrower 25 923 Lock Nut 26 360 Bearing Cover 27 931 Lock Washer 28 524 Spacer Sleeve 29 456 Stuffing Box Bush 30 531 Thro...

Page 39: ...Fax 98 21 88 79 89 42 Factory P O Box 51845 135 Tabriz Iran Tel 98 41 32 89 0644 8 Fax 98 41 32 89 84 46 Marketing Sale Office Tel 98 41 32 89 0707 8 98 41 32 89 0411 Fax 98 41 32 87 22 33 Email Sales pumpiran com Sale Engineering Tel 98 41 32 88 12 86 Fax 98 41 32 87 22 33 Email Sale_eng pumpiran com Website pumpiran com PUMPIRAN WATER OIL ENERGY ...

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