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Xylem e-XC, Instruction Manual

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5.2  Pump priming

CAUTION:

Do not run the pump dry.

When to prime the pump

You must prime the pump before startup. When it is possible, locate the pump below the
fluid level in order to facilitate priming and to ensure a steady flow of liquid. This condition
provides a positive suction head on the pump. It is also possible to prime the pump by
pressurizing the suction vessel.

Methods for pump priming

Pump installation

Priming method

Positive head on the suction

Open the suction valve and loosen the vent plug on top of the casing.

This allows air to be purged from the casing. While you vent the air

from the pump body, always rotate the pump shaft a few times by

hand.

Suction lift

Priming must be done by other methods such as foot valves, ejectors,

or by manually filling the casing and suction line.

5.3  Fill the system

1. Locate the vents at the highest point so that trapped gases and air can escape.

However, if the gases are flammable, toxic, or corrosive, then vent them to an
appropriate place in order to prevent harm to personnel or to other parts of the
system.

2. Check the pipe hangers and anchors to make sure that they are properly set to take

the additional weight of the pumped fluid.

3. Close all of the drains.
4. Fill the system slowly so that excessive velocities do not cause rotation of the pumping

elements.
Rotation of the pumping elements can cause damage to the pump or its driver.

5. Check the adequacy of the anchors and hangers:

a) Mount a dial indicator off of any rigid structure not tied to the piping.
b) Set the indicator button on the pump flange in the axial direction of the nozzle.

If the indicator moves as the filling proceeds, then the anchors and supports are not
adequate or are not set properly. Take corrective measures.

5.4  Start the pump

NOTICE:

If the pump loses its prime during start-up, shut it down and correct the condition before
you repeat this procedure.

1. Close the drain valves and the valve in the discharge line.
2. Fully open all valves in the suction line.
3. Prime the pump.
4. Start the pump driver.

You might need to warm up the turbines and engines. Consult the instructions
provided by the manufacturer.

5. When the pump is operating at full speed, slowly open the discharge valve.

5  Commissioning, Startup, Operation, and Shutdown

34

e-XC INSTRUCTION MANUAL

Summary of Contents for e-XC

Page 1: ...INSTRUCTION MANUAL P6019152 e XC Single Stage Double Suction Centrifugal Pumps ...

Page 2: ......

Page 3: ...Pump location guidelines 17 4 1 2 Foundation requirements 18 4 1 3 Requirements for setting the baseplate 20 4 2 Level the base on a concrete foundation 21 4 3 Coupling alignment 21 4 3 1 Prepare for alignment 22 4 3 2 Align the pump using a straight edge and calipers 22 4 3 3 Align the pump using a dial indicator 23 4 3 4 Maximum allowable coupling misalignment 24 4 3 5 Final alignment 26 4 4 Pip...

Page 4: ...1 6 5 8 Pump disassembly for pumps with integrated stuffing box design 64 6 6 Reassembly 65 6 6 1 Pump assembly 65 6 6 2 Pump assembly for pumps with drop in stuffing box and sleeve over shaft dry shaft design 65 6 6 3 Pump assembly for pumps with drop in stuffing box and sleeveless shaft wet shaft design 84 6 6 4 Oil lubrication for bearings assembly 91 6 6 5 Pump assembly for pumps with integrat...

Page 5: ...n to the equipment or use of parts not provided by Xylem If there is a question regarding the intended use of the equipment please contact a Xylem representative before proceeding Do not change the service application without the approval of an authorized Xylem representative CAUTION You must observe the instructions contained in this manual Failure to do so could result in physical injury damage ...

Page 6: ... symbol means that failure to follow the instructions may result in a safety hazard Decals Make sure your pump has these safety instruction decals and that they are located as this figure shows If the decals are missing or illegible contact your local sales and service representative for a replacement 1 2 3 4 5 6 1 WARNING Eyebolts or lifting lugs if provided are for lifting only the components to...

Page 7: ...ay attention to the risks presented by gas and vapors in the work area Avoid all electrical dangers Pay attention to the risks of electric shock or arc flash hazards Always bear in mind the risk of drowning electrical accidents and burn injuries Safety equipment Use safety equipment according to the company regulations Use this safety equipment within the work area Hard hat Safety goggles preferab...

Page 8: ... sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump remove plugs or disconnect piping Never operate a pump without a properly installed coupling guard 1 3 1 Wash the skin and eyes Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin Condition Action Chemicals or hazardous fluids i...

Page 9: ...n occur if you attempt this If the driver was mounted on the baseplate at the factory it is safe to lift the entire assembly If the driver was not mounted at the factory do not lift the entire assembly which consists of the pump base and driver Instead lift the pump and baseplate to its final location without the driver Then mount the driver The pump unit should be unloaded and handled by lifting ...

Page 10: ...uch that they will not slip while lifting Notes Size lifting equipment appropriately for unbalanced loading Motors may or may not be mounted at the factory Pump base and driver assemblies where the base length exceeds 100 in 2540 mm may not be safe to lift as a complete assembly Damage to the baseplate may occur If the driver has been mounted on the baseplate at the factory it is safe to lift the ...

Page 11: ...brations Rotate the shaft by hand several times at least every three months Make sure that any changes in ambient temperature are slow and moderate Treat bearing and machined surfaces so that they are well preserved Refer to drive unit and coupling manufacturers for their long term storage procedures 2 Transportation and Storage e XC INSTRUCTION MANUAL 9 ...

Page 12: ...th these liquids Groundwater Process water Gray water Sea water Brackish water Industrial fluids Heat transfer fluids Produced water Solvents Oil Boiler feeder water Condensate Benign liquids Note Pumps must be tailored for their intended application Contact a sales representative before attempting to change your pump application Verify whether or not your current pump configuration meets the requ...

Page 13: ...uid Due to the diversity of operating conditions it is not possible to provide a definitive guarantee of seal life In clean water applications typical mechanical seal life spans two to three years Table 1 Operating limits Seal Name Description Max Pressure psi bar Max Temperature F C MR1 Metric metal pusher 450 31 250 121 MR2 Metric rubber bellow 232 16 MR3 Imperial metal pusher 450 31 MR4 Imperia...

Page 14: ...ing Box Design Drop in Seal Chamber The drop in stuffing box design utilizes a removable stuffing box Seal gland cartridge seals and packing glands are affixed to the stuffing box in this design variant Flush lines connect to seal gland or stuffing box ports for all sealing configurations Integrated Stuffing Box Design Integrated Seal Chamber The integrated stuffing box design omits the need for a...

Page 15: ...ron 175 PSI Ductile Iron 175 PSI Ductile Iron 400 PSI Ductile Iron 450 PSI 1 3X5X8 5 3X5X8 Drop in Single 2 3X5X11 3X5X10 5 Drop in Single 3 3X5X12 5 3X5X12 Drop in Single 4 3X5X13 5 3X5X13 Drop in Single 5 4X5X6 5 4X5X6 Drop in Single 6 4X5X6 4X6X9 5 Drop in Single 7 4X6X13 4X6X12 Drop in Single 8 4X6X14 5 4X6X13 5 Drop in Single 9 4X6X16 4X6X15 5 Drop in Single 10 5X6X7 5 5X6X7 Drop in Single 11...

Page 16: ... 12X16X27 Drop in Dual 40 14X14X12 14X14X11 Drop in Dual 41 14X16X15 14X16X14 5 Drop in Single 42 14X16X27 5 14X16X26 Drop in Dual 43 14X16X30 5 14X16X29 Integrated Dual 44 14X18X18 14X18X17 Drop in Dual 45 14X18X21 14X18X20 Drop in Dual 46 14X20X26 5 14X20X25 5 Integrated Dual 47 14X20X33 14X20X31 5 Integrated Dual 48 16X16X13 5 16X16X13 Drop in Dual 49 16X20X20 5 16X20X19 5 Drop in Dual 50 16X20...

Page 17: ...n Single 6 100 260 100 250 Drop in Single 7 100 325 100 310 Drop in Single 8 100 365 100 350 Drop in Single 9 100 410 100 390 Drop in Single 10 125 195 125 185 Drop in Single 11 125 225 125 215 Drop in Single 12 125 245 125 235 Drop in Single 13 125 300 125 285 Drop in Single 14 125 355 125 335 Drop in Single 15 125 390 125 370 Drop in Single 16 125 475 125 450 Drop in Single 17 150 170 150 160 Dr...

Page 18: ... Dual 49 400 525 400 500 Drop in Dual 50 400 535 400 510 Drop in Single 51 400 580 400 550 Drop in Dual 52 400 800 400 76 Integrated Dual 53 400 970 400 9254 Integrated Dual 54 450 390 450 370 Drop in Dual 55 500 450 500 430 Drop in Dual 56 500 525 500 500 Integrated Dual 57 500 625 500 605 Integrated Dual 58 500 715 500 690 Integrated Dual 59 500 920 500 875 Integrated Dual 60 600 575 600 540 Int...

Page 19: ...ose to the liquid source as practically possible This minimizes the friction loss and keeps the suction piping as short as possible Make sure that the space around the pump is sufficient This facilitates ventilation inspection maintenance and service If you require lifting equipment such as a hoist or tackle make sure that there is enough space above the pump This makes it easier to properly use t...

Page 20: ...ufficient width to cover a 30 degree rule Pump Foundation construction minimum requirements 3000 psi 200 bar concrete with steel re enforcement Pump Foundations should be a min of 1 25 mm above the floor to prevent water collection around the pump base plate Foundation recommendations for 300 hp 220 kW and larger pumps and motors Floor weight can be included in the Pump Foundation weight calculati...

Page 21: ...spring mounts attached to it These isolation bases are welded structural steel with reinforcing and are filled with concrete or grout The design requirements and installation of these isolation bases are the responsibility of the installing contractor Use flexible piping on both suction and discharge sides with an isolation base Flexible piping decreases the strain on the flanges Anchor bolts Foun...

Page 22: ...This pump was properly aligned if furnished with a motor at the factory However since all pump bases are flexible they may spring and twist during shipment Do not pipe the pump until it is realigned After piping is completed and after the pump is installed and bolted down align it again It may be necessary to re adjust the alignment from time to time while the unit and foundation are new This pump...

Page 23: ...sides of each anchor bolt in order to support the pump This also provides a means of leveling the base 4 1 5 2 3 6 7 1 Locate the shims to allow removal after grouting 2 Grout only to top of base rail 3 Pump base rail 4 Grout 5 Concrete foundation 6 1 25 40 mm Gap 7 Allow 1 for shims Place on both sides of anchor bolts 4 3 Coupling alignment WARNING Always disconnect and lock out power to the driv...

Page 24: ...he values shown in Maximum allowable coupling misalignment Alignment may be performed with lasers dial indicators or with a straight edge and calipers 4 3 2 Align the pump using a straight edge and calipers 1 Check the angular misalignment Tool Procedure Calipers 1 Gauge the distance between the two hubs at various points around the circumference Do not rotate the shafts 2 Reposition the equipment...

Page 25: ... between the two arrows is the degree of angular misalignment between the hubs The difference between measurements L1 and L2 correlates to the degree of misalignment Figure 6 Check the alignment using calipers 4 3 3 Align the pump using a dial indicator 1 Check the angular misalignment a Mount the dial indicator base to one coupling half or shaft b Position the dial indicator button on the front f...

Page 26: ...e opposite coupling half c Set the dial to zero d Rotate both coupling halves together and make sure that the index lines remain matched e Reposition the equipment until the offset is within the permissible value 4 3 4 Maximum allowable coupling misalignment TB Wood s Dura Flex Couplings TB Wood s Dura Flex elastomeric coupling alignment guidelines shown are also listed in the coupling service man...

Page 27: ... 10 2 4 0 19 4 8 0 28 7 2 N A WE40 0 12 2 9 0 23 5 9 0 35 8 8 N A WE50 0 14 3 6 0 28 7 2 0 43 10 8 N A WE60 0 15 3 9 0 31 7 7 N A N A WE70 0 16 4 1 0 32 8 2 N A N A WE80 0 20 5 0 0 39 10 0 N A N A Falk Steelflex Couplings Falk Steelflex T10 grid coupling alignment guidelines shown are also listed in the coupling service manual published by Rexnord Falk Refer to the service manual for more detailed...

Page 28: ... shafts However the amount of the offset and or misalignment depends on the style of the applied flexible coupling If you do not correct this coupling misalignment there is a significant impact on the overall life of the mechanical seals and the bearings of the pump 4 4 Piping checklists 4 4 1 General piping checklist CAUTION Never draw piping into place by using force at the flanged connections o...

Page 29: ... 3540 4713 6390 20 500 1479 6580 1641 7300 1331 5920 2576 11460 3784 5130 2699 3660 3109 4215 5598 7590 22 550 1614 7180 1789 7960 1448 6440 2810 12500 4470 6060 3186 4320 3673 4980 6616 8970 24 600 1879 8360 2095 9320 1691 7520 3282 14600 3430 4650 2434 3300 2810 3810 5045 6840 28 700 2149 9560 2392 10640 1933 8600 3750 16680 4293 5820 3076 4170 3518 4770 6328 8580 32 800 2419 10760 2689 11960 21...

Page 30: ...me size as the suction opening If longer suction piping is required pipes should be one or two sizes larger than the opening depending on piping length Check that the elbows in the suction piping for horizontal double suction pumps are installed per the Hydraulics Institute Standards since there is always an uneven turbulent flow around an elbow When there is an elbow in a position other than the ...

Page 31: ...a greater flow to one side of the impeller Figure 10 Unbalanced loading of double suction impeller Examples 1 Level centerline of pipe 2 Check valve 3 Gate valve 4 Increaser Figure 11 Suction pipe installed with a gradual rise to the pump correct 1 1 Air pocket Figure 12 Suction pipe installed with a gradual rise to the pump incorrect 1 1 Air pocket Figure 13 Suction pipe installed with a reducer ...

Page 32: ...tions Make sure that the suction piping valves are placed right before the run of recommended straight pipe Never throttle the pump with the use of a valve on the suction side of the pump Only use suction valves to isolate the pump for maintenance purposes Always install the valve in a position that avoids the formation of air pockets Foot valves If the pump operates under static suction lift cond...

Page 33: ... per second 4 6 m s If a check valve is present in the outlet piping this value must be reduced Discharge piping and fitting sizes System losses life cycle costs and process considerations usually determine the size of discharge piping and fittings Some high energy pumps are sensitive to flow disturbing devices mounted close to the pump outlet Consult Xylem when in doubt about the minimum required...

Page 34: ...oper pump insulation You should not insulate the bearing housings shown in dark gray as this may cause overheating of bearings You may insulate all other portions of the pump shown in light gray 4 Installation 32 e XC INSTRUCTION MANUAL ...

Page 35: ...eeves Pre operation inspections Perform these inspections before you start the pump Check the alignment between the pump and motor See Coupling alignment in the Installation chapter for alignment requirements Check all connections to the motor and starting device against the wiring diagram Check the voltage phase and frequency on the motor nameplate against the line circuit Check the suction and d...

Page 36: ...parts of the system 2 Check the pipe hangers and anchors to make sure that they are properly set to take the additional weight of the pumped fluid 3 Close all of the drains 4 Fill the system slowly so that excessive velocities do not cause rotation of the pumping elements Rotation of the pumping elements can cause damage to the pump or its driver 5 Check the adequacy of the anchors and hangers a M...

Page 37: ...sure gauge readings for future reference Also record voltage amperage per phase and pump speed You can also record the kilowatts if you have an available indicating wattmeter Temperature Check and record bearing temperatures using a thermometer Make sure that temperatures do not exceed 250 F 121 C Vibration The acceptable vibration level of a centrifugal pump depends on the rigidity of the pump an...

Page 38: ...spections Perform these tasks every three months Check that the foundation and the hold down bolts are tight Annual inspections Perform these inspections one time each year Check the pump capacity Check the pump pressure Check the pump power If the pump performance does not satisfy your process requirements and the process requirements have not changed then perform these steps 1 Disassemble the pu...

Page 39: ...iagram below for the following instructions 1 Impeller 2 Casing Wear Ring 3 Impeller Wear Ring Before replacing impeller wear rings ensure the replacement wear rings are of the same material as the impeller and new set screws are on hand for installation Never reuse set screws from the previous wear ring installation Thread locker such as Loctite 243 will be required for installation To replace th...

Page 40: ...or installation instructions and lubrication guidelines WARNING Do not attempt to run the pump without first lubricating the bearings Doing so will cause serious property damage Lubrication schedule Grease Periodic refilling of grease is not required Regrease the bearings if the bearing housings are removed for maintenance reasons It is recommended to hand pack grease onto the bearings before pres...

Page 41: ...les when obtaining measurements Note Hand held infrared thermometers are not recommended for accurate temperature measurements of bearings or the bearing housing IR measurements are highly sensitive to surface properties measurement distance humidity and proper emissivity calibration Furthermore IR thermometers will only provide the surface temperature of the bearing housing Conditions inside the ...

Page 42: ...e bearing housing 3 Insert the grease cup into the top of the bearing housing 4 Using a grease gun inject Exxon Polyrex EM grease into the grease cup Stop adding grease when it exits the drain plug located underneath the bearing housing 5 Run the pump for 30 60 minutes to remove excess grease from the bearing cavity 6 Insert the drain plug beneath the bearing housing WARNING Do not over grease the...

Page 43: ...read the pipe nipple connection into the smaller diameter port along the side of the bearing housing 2 Thread the sight glass into the larger diameter port along the side of the bearing housing 3 Plug unused pipe connection and sight glass ports located on the other side of the bearing housing Ensure any unused monitoring equipment ports are plugged 1 Note It is important to properly seal the bear...

Page 44: ...osity at 100 F 37 8 C 215 SSU 240 SSU Saybolt viscosity at 210 F 99 C 49 SSU Viscosity index minimum 95 API gravity 28 33 Pour point maximum 20 F 6 7 C Flash point minimum 400 F 204 C Additives Rust and oxidation inhibitors ISO viscosity 46 1 Disassemble the oiler by unfastening the thumb screw on the side Separate the upper housing and bulb from the lower housing Remove the level adjuster from th...

Page 45: ...anical seal If you run a mechanical seal dry even for a few seconds this can cause seal damage Physical injury can occur if a mechanical seal fails Mechanical seal life The life of a mechanical seal depends on the cleanliness of the pumped fluid Due to the diversity of operating conditions it is not possible to give definite indications as to the life of a mechanical seal In clean water applicatio...

Page 46: ... and wear steel toed shoes at all times NOTICE Make sure that all replacement parts are available before you disassemble the pump for overhaul 6 5 2 Drain the pump CAUTION Allow all system and pump components to cool before you handle them to prevent physical injury 1 Close the isolation valves on the suction and discharge sides of the pump You must drain the system if no valves are installed 2 Op...

Page 47: ...or guards with vertical supports Figure 25 Fully assembled coupling guard 1 Identify the parts of the coupling guard The following instructions will reference items in the following figure and table 6 Maintenance e XC INSTRUCTION MANUAL 45 ...

Page 48: ...ex Nut 13 Stiffener Clip 2 Unfasten the hex bolts 9 that secure the stiffener clips 13 to the inner coupler guard assembly 1 3 Uncouple the upper halves of the outer 2 and inner 1 guard assemblies by removing the two hex bolts 9 located on the top two faces of the hex guard assembly 4 Remove the upper halves of the outer 2 and inner 1 guard assemblies by unfastening the hex head bolts 9 that faste...

Page 49: ...er of the hex guard assembly Note Not all coupling guard assemblies require pedestal pieces 8 or two guard support sets 3 6 7 If desired the stiffener clips 13 may be removed from the inboard bearing gland of the pump by removing the bearing gland bolts which secure the clips in place Figure 27 Coupling guard exploded view 6 5 4 Remove the hex coupling guard for floating guards Figure 28 Fully ass...

Page 50: ...gardless of which size mounting bracket is used Figure 30 Coupling guard exploded view Legend Part Name 1 Coupler Guard Assembly Inner 2 Coupler Guard Assembly Outer 3 Clip 4 Square Spacer 5 Mounting Bracket 6 Hex Bolt 7 Self Retaining Washer 8 Bearing Gland Bolt 9 Washer 10 Threadless Spacer 6 Maintenance 48 e XC INSTRUCTION MANUAL ...

Page 51: ... be attached to the mounting bracket 5 Coupling maintenance may be performed without further disassembly of the guard 4 Uncouple the lower halves of the outer 2 and inner 1 guard assemblies by removing the two hex head bolts 6 located on the bottom two faces of the hex guard assembly 5 Detach the bottom half of the inner guard 1 from the mounting bracket 5 by unfastening the two hex bolts 6 locate...

Page 52: ...document WARNING Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks Failure to disconnect and lock out driver power will result in serious physical injury Extreme temperature hazard Allow pump temperatures to reach acceptable levels before proceeding Open drain valve do not proceed until liquid stops coming out of the drain valve If liquid d...

Page 53: ...o Pump lifting guidelines on page 7 As a general rule only use lifting lugs or eyebolts to lift the component they are attached to Do not lift the entire pump by its lifting lugs 7 Unfasten shaft guard bolts and remove both shaft guards 8 If using oil for bearing lubrication drain oil from bearing housing by unfastening plugs located on the undersides of both bearing housings 6 Maintenance e XC IN...

Page 54: ...housings from the lower casing 1 Remove the rotating assembly by first unfastening the four bolts which secure each bearing housing to the lower casing 2 Once the bearing housings are no longer fixed to the lower casing lift and remove the rotating assembly using proper lifting equipment Do not lift the rotating assembly by the eyebolts located on each bearing housing Place the rotating assembly o...

Page 55: ...ring gland and bearing seal ring away from the bearing housing 12 Prepare the outboard bearing housing for lifting and movement Support the bearing housing from below or attach lifting equipment to the eye bolts located on top of the bearing housing 13 Remove screws that attach the bearing housing to the lower casing 14 Separate bearing housing from lower casing using the jacking screws located on...

Page 56: ...ing off the shaft Ensure coupling key is removed from the shaft 20 Remove bearing gland screws from inboard side of pump then slide bearing gland and gasket off the shaft 21 Repeat steps 10 18 to remove the remaining components along the inboard side of the pump Note bearing locknut tab washer and shoulder ring only exist on the outboard side of the pump 22 Break the seal between lower casing and ...

Page 57: ...oosen and remove the sleeve locknut using a spanner wrench 5 Remove the shaft sleeve key and then remove the shaft sleeve with the drive ring fastened to it If the shaft sleeve does not slide off easily apply heat to expand the metal and loosen any grease or anti seizing agent underneath the sleeve 6 Separate the drive ring from the shaft sleeve by unfastening the set screws in the drive ring 7 Re...

Page 58: ... Remove impeller assembly from shaft Heat the impeller and slide it off of the shaft Alternatively press the impeller off of the shaft if a suitable press is available Wear insulated gloves when handling hot components 12 Remove the impeller key 13 Remove pins and O rings from each casing wear ring 6 Maintenance 56 e XC INSTRUCTION MANUAL ...

Page 59: ... sleeve nut 5 Pull the shaft sleeve with the rotating element off of the shaft 6 Unfasten the set screws located on the rotating element of the seal and separate the rotating element from the shaft sleeve 7 Repeat steps 1 6 for the inboard side of the pump 8 Remove the stuffing box from the shaft Remove stuffing box O rings from their respective grooves 9 Remove the shaft sleeve O ring if it is st...

Page 60: ...2 Remove impeller assembly from shaft Heat the impeller and slide it off of the shaft Alternatively press the impeller off of the shaft if a suitable press is available Wear insulated gloves when handling hot components 13 Remove the impeller key 14 Remove pins and O rings from each casing wear ring 6 Maintenance 58 e XC INSTRUCTION MANUAL ...

Page 61: ...taneously and decoupled thereafter 4 Repeat steps 1 3 for the inboard side of the pump 5 Continue the disassembly process by following the instructions outlined in Shaft Sleeve and Impeller Disassembly on page 60 Packing on Sleeve 1 Remove packing gland screws which thread into the stuffing box 2 Remove screws which hold the packing gland halves together 3 Remove packing gland halves 4 Remove stuf...

Page 62: ...e shaft sleeve and O ring If the shaft sleeve does not slide off easily then heat up the sleeve to expand the metal and loosen any grease or anti seizing agent 4 Remove impeller hub sleeve and gasket 5 Repeat steps 1 4 for the inboard side of the pump 6 Remove impeller assembly from shaft Heat the impeller and slide it off of the shaft Alternatively press the impeller off of the shaft if a suitabl...

Page 63: ... The term inboard refers to the drive end or coupling end of the pump shaft The term stuffing box may be interchangeable with seal body The following disassembly instructions depend on your specific pump s sealing configuration Choose the instructions suited to your pump MR1 MR2 MR3 and MR4 Mechanical Seal on Shaft 1 Remove seal gland screws 2 Remove seal gland The static face of the mechanical se...

Page 64: ...or the inboard side of pump 8 Remove impeller assembly from shaft Heat the impeller and slide it off of the shaft Alternatively press the impeller off of the shaft if a suitable press is available Wear insulated gloves when handling hot components 9 Remove the impeller key 10 Remove pins and O rings from each casing wear ring 6 Maintenance 62 e XC INSTRUCTION MANUAL ...

Page 65: ...together and decoupled thereafter Loosen the cartridge seal set screws before attempting to pull the entire assembly from the shaft 4 Repeat steps 1 3 for the inboard side of the pump 5 Remove snap ring adjacent to outboard end of the impeller hub 6 Remove impeller assembly from shaft Heat the impeller and slide it off of the shaft Alternatively press the impeller off of the shaft if a suitable pr...

Page 66: ...umps with drop in stuffing box and sleeve over shaft dry shaft design on page 50 and Pump disassembly for pumps with drop in stuffing box and sleeveless shaft wet shaft design on page 61 Follow all safety procedures outlined in Pump disassembly on page 50 1 Before separating the upper and lower casing remove both pump shaft guards all flush lines and remove the top two seal gland bolts from the up...

Page 67: ...ffing box design incorporates the seal chamber into the upper and lower casing halves Therefore sealing components fasten directly to the pump casing 4Row is only applicable for either mechanical or cartridge seal configurations For more information on the MR series mechanical seals see the e XC Performance Curves and Technical Data document WARNING Always disconnect and lock out power to the driv...

Page 68: ...e 4 Check the impeller and casing to determine the correct rotational relationship Insert the outboard non driving end of the shaft into the impeller bore horizontally using a rubber mallet to gently tap the shaft in until the impeller is centered along the impeller key length 5 Lightly grease casing wear ring O rings and roll them into their respective grooves Insert two steel pins into each casi...

Page 69: ...ub sleeve 4 Lightly grease the stuffing box O rings and place them into their respective grooves along the outer diameter of the stuffing box Thread in the plug at the top of the stuffing box 5 Slide the stuffing box onto the shaft until it rests against the impeller hub sleeve 6 Place the mechanical seal s drive ring on the shaft sleeve Tighten the set screws on the drive ring at the inscribed lo...

Page 70: ...he mechanical seal onto the shaft until it sits flush against the drive ring 15 Slide the seal gland and stationary mechanical seal element assembly onto the shaft Secure the seal gland to the stuffing box using with correctly sized hex head bolts and lockwashers 16 Thread the external flush line fitting into the top of the seal gland 17 Repeat for the inboard side of the pump 18 Install stuffing ...

Page 71: ...and lower the entire rotating assembly including bearing housings into the pump Once lowered into the pump fasten the bearing housing to the pump casing See the next two images for rotating assembly installation with bearing housings 20 Lift the rotating assembly and install it within the lower casing Ensure all pins rest within their respective grooves 6 Maintenance e XC INSTRUCTION MANUAL 69 ...

Page 72: ...ong the outer diameter of the stuffing box Thread in the plug at the top of the stuffing box 5 Slide the stuffing box onto the shaft until it rests against the impeller hub sleeve 6 Place the mechanical seal s rotating element on the shaft sleeve Tighten the set screws on the drive ring at the inscribed location on the shaft sleeve Note The drive ring should be set before the inscribed line such t...

Page 73: ... element assembly onto the shaft Secure the seal gland to the stuffing box using with correctly sized hex head bolts and lockwashers 15 Thread the external flush line fitting into the top of the seal gland 16 Repeat for the inboard side of the pump 17 Install stuffing box pins into each stuffing box 18 Ensure pins are installed into each casing wear ring Align casing wear ring pins to their respec...

Page 74: ...ings into the pump Once lowered into the pump fasten the bearing housing to the pump casing See the next two images for rotating assembly installation with bearing housings 19 Lift the rotating assembly and install it within the lower casing Ensure all pins rest within their respective grooves 20 Continue the assembly process by following the instructions outlined in Bearing and bearing housing as...

Page 75: ...nterbore Ensure shaft sleeve keyway is aligned with its shaft keyway counterpart 5 Place shaft sleeve key into the shaft keyway 6 Slide tab washer onto shaft against the shaft sleeve 7 Thread the locknut onto the shaft Align tab washer prongs with sleeve nut gaps Bend tab washer prongs over the sleeve nut gaps to secure the locknut 8 Repeat steps 6 12 for the inboard side of the pump Stuffing box ...

Page 76: ...from one another when placing rings around the shaft Instead gently twist the ends of each packing ring away from one another as they are placed on the shaft Note Ensure packing rings are installed at a 90 degree rotational offset from one another This technique will mitigate leaks between rings 4 Assemble the two packing gland halves together and lightly fasten them to the stuffing box Do not tig...

Page 77: ...s removed from operating area and disconnected from piping proceed to step 9 If the pump is not disconnected from its piping follow Bearing and bearing housing assembly on page 79 and lower the entire rotating assembly including bearing housings into the pump Once lowered into the pump fasten the bearing housing to the pump casing See the next two images for rotating assembly installation with bea...

Page 78: ...ins rest within their respective grooves 10 Continue the assembly process by following the instructions outlined in Bearing and bearing housing assembly on page 79 MR7 MR8 Cartridge seal on sleeve assembly instructions Shaft sleeve assembly 6 Maintenance 76 e XC INSTRUCTION MANUAL ...

Page 79: ...er prongs over the sleeve nut gaps to secure the locknut 8 Repeat steps 6 8 and 1 4 of Stuffing box and cartridge seal assembly for the inboard side of the pump Stuffing box and cartridge seal assembly 1 Lubricate and roll O rings into the grooves along the outer diameter of the stuffing box 2 Fasten the cartridge seal to the stuffing box ensure the flush line inlet port of the cartridge seal is o...

Page 80: ...tuffing box pins into each stuffing box 8 Ensure pins are installed into each casing wear ring Align casing wear ring pins to their respective grooves within the lower casing NOTE If pump is removed from operating area and disconnected from piping proceed to step 9 If the pump is not disconnected from its piping follow Bearing and bearing housing assembly on page 79 and lower the entire rotating a...

Page 81: ... assembly process by following the instructions outlined in Bearing and bearing housing assembly on page 79 Bearing and bearing housing assembly 1 Prepare the bearing seal ring for installation Lubricate O ring and install into the groove located along the inner diameter of the bearing seal ring 6 Maintenance e XC INSTRUCTION MANUAL 79 ...

Page 82: ...d horizontally to orient the grease and drainage ports of the gland correctly 6 Place the bearing shoulder ring against the outboard end shaft step 7 Heat the ball bearing to expand the bore 8 Using insulated gloves install the bearing onto the shaft against the shoulder ring Allow the bearing to cool Coat the exposed side of the bearing with two to three ounces 60 to 85 gm of grease 9 Slide tab w...

Page 83: ...housing unless vibration and temperature sensors will be installed at the end of the pump assembly 16 Slide bearing gland gasket and bearing seal ring against the bearing housing Tighten the bearing gland bolts Important Do not tighten bearing seal ring set screws until the inboard bearing housing assembly is fixed to the pump Tightening the seal ring set screws requires the shaft to be rotated Ro...

Page 84: ...access each set screw 22 Grease the bearings according to Regrease the bearings Upper casing assembly 1 Insert tapered pins into the upper casing 2 Using proper lifting equipment place the upper casing onto the lower casing using the tapered pins for alignment 3 Once placed fasten the four large casing bolts and washers located near the stuffing boxes in an alternating fashion 6 Maintenance 82 e X...

Page 85: ...corrosion Shaft guard and flush line assembly 6 Place each shaft guard around the exposed shaft between the bearing housing and seal chamber Align the slots on either side of the shaft guard with the holes located near the bearing housing flange 7 Fasten the shaft guards to the bearing housing 8 Fasten the four arm tube into the top of the upper casing 9 Insert the appropriate plug into the top of...

Page 86: ...uring reassembly Any other parts that are reused should be thoroughly cleaned before reassembly The main casing joint gasket should be trimmed according to the parting flange profile of the lower casing Ensure the gasket is flush with the inside edges of the casing Note Assemble the outboard side elements of the pump first for any given assembly category Impeller assembly 1 Place the impeller key ...

Page 87: ...p the shaft in until the impeller is centered along the impeller key length 4 Lightly grease casing wear ring O rings and roll them into their respective grooves Insert two steel pins into each casing wear ring Slide the casing wear rings over the impeller eye 5 Fix the impeller in place by placing the impeller snap ring adjacent to the outboard impeller hub 6 Maintenance e XC INSTRUCTION MANUAL 8...

Page 88: ...g box assembly 1 Plug the stuffing box flush line inlet port 2 Lubricate and roll O rings into the grooves along the outer diameter of the stuffing box 3 Lubricate and roll O rings into the groove along the outer diameter of the seal gland 4 Assemble O ring and pins onto the stationary mechanical seal face 5 Insert the stationary face of the mechanical seal with O rings and pins into the seal glan...

Page 89: ... wear ring pins to their respective grooves within the lower casing NOTE If pump is removed from operating area and disconnected from piping proceed to step 12 If the pump is not disconnected from its piping follow Bearing and bearing housing assembly on page 79 and lower the entire rotating assembly including bearing housings into the pump Once lowered into the pump fasten the bearing housing to ...

Page 90: ... within their respective grooves 13 Continue the assembly process by following the instructions outlined in Bearing and bearing housing assembly on page 79 MR5 MR6 Cartridge seal on shaft assembly instructions Stuffing box and cartridge seal assembly 6 Maintenance 88 e XC INSTRUCTION MANUAL ...

Page 91: ...ue value of 20 N m 14 75 ft lbs Remove the three or four setup screws and their carriage clips from the back of the seal Note Set screws should never be reused Note Retain the setup screws and clip carriage for future seal maintenance 7 Repeat steps 1 6 for the inboard side of the pump 8 Install stuffing box pins into each stuffing box 9 Ensure pins are installed into each casing wear ring Align c...

Page 92: ...it within the lower casing Ensure all pins rest within their respective grooves 12 Continue the assembly process by following the instructions outlined in Bearing and bearing housing assembly on page 79 6 Maintenance 90 e XC INSTRUCTION MANUAL ...

Page 93: ... an integrated stuffing box may be considered identical to the drop in stuffing box design with a few minor differences Please note differences outlined below and then refer to Pump assembly for pumps with drop in stuffing box and sleeve over shaft dry shaft design on page 65 for seal on sleeve dry shaft configurations and Pump assembly for pumps with drop in stuffing box and sleeveless shaft wet ...

Page 94: ...cable into the lower casing before attempting to install the cartridge seal 2 Close the casing before installing the cartridge seal Packing 1 When following the drop in stuffing box assembly instructions for packing installation lower the impeller and shaft assembly with shaft sleeves into the lower casing and close the pump before attempting to install the packing pings lantern ring and packing g...

Page 95: ... 13 Stiffener Clip 2 Assemble the pedestal 8 to the base frame The pedestal feet should align with pre drilled holes in the base frame In some cases the coupling guard kit may not require a pedestal In these cases the lower guard support 7 will be fixed directly to the base frame or to a flat plate already mounted to the base frame 3 Install the lower guard support 7 on top of each pedestal 8 Secu...

Page 96: ...r 1 guard assemblies together by fastening two serrated hex bolts 9 through the bottom face of the outer guard 2 and into the weld nuts located inside the inner guard 1 8 Place the upper half of the inner guard assembly 1 over the coupling with the closed end of the inner guard facing the pump Align the flanges and faces of the upper and lower guard halves 1 9 Secure the sides of the top half of t...

Page 97: ...Figure 35 Coupling guard assembly diagram 6 6 7 Assemble the hex coupling guard for floating guards Figure 36 Fully assembled coupling guard small bracket 6 Maintenance e XC INSTRUCTION MANUAL 95 ...

Page 98: ...rdless of which size mounting bracket is used Figure 38 Coupling guard exploded view Legend Part Name 1 Coupler Guard Assembly Inner 2 Coupler Guard Assembly Outer 3 Clip 4 Square Spacer 5 Mounting Bracket 6 Hex Bolt 7 Self Retaining Washer 8 Bearing Gland Bolt 9 Washer 10 Threadless Spacer 6 Maintenance 96 e XC INSTRUCTION MANUAL ...

Page 99: ...f of the inner guard 1 to the mounting bracket 5 a Align the horizontal slots of the mounting bracket 5 with the holes located on the front of the inner guard 1 b Thread two hex bolts 6 through the mounting bracket 5 and into the weld nuts located behind the holes of the inner guard 1 Be sure to place a self retaining washer 7 between the mounting bracket 5 and inner guard 1 while threading each h...

Page 100: ...rd Personal injury will occur if you run the pump without a coupling guard 1 Remove the pump from the base 2 Follow the Disassembly procedures applicable to the pump You only need to remove one of the bearing glands bearing caps bearing housings and seal bodies stuffing boxes in order to change the rotation 3 Press the press fitted impeller off of the shaft 4 Observe the direction in which the van...

Page 101: ...e in ft lb Nm The M6 set screw has a rating of 10 N m Size Metric Class 8 8 M10 33 2 45 M12 57 5 78 M16 142 193 M20 277 376 M24 480 651 M30 954 1293 M36 1666 2259 6 9 Dealer servicing If trouble occurs that cannot be rectified contact your local sales and service representative and be prepared to provide this information 1 Complete nameplate data of pump and motor 2 Suction and discharge pipe pres...

Page 102: ...for pipe friction losses Static lift may be too great Measure with mercury column or vacuum gauge while pump operates If static lift is too high liquid to be pumped must be raised or pump lowered Discharge head too high Check pipe friction losses Large piping may correct condition Check that valves are wide open The motor speed is too low Check whether motor is directly across the line and receivi...

Page 103: ... plugged Dismantle pump and clean impeller Cavitation insufficient NPSH depending on installation 1 Increase positive suction head on pump by lowering pump 2 Sub cool suction piping at inlet to lower entering liquid temperature 3 Pressurization suction vessel Defective impeller Inspect impeller bearings and shaft Replace is damaged or vane sections badly eroded Foot valve too small or partially ob...

Page 104: ...igh If no obstruction at inlet check for pipe friction losses Static lift may be too great Measure with mercury column or vacuum gauge while pump operates If static lift is too high liquid to be pumped must be raised or pump lowered Air leaks in suction piping If liquid pumped is water or other non explosive and explosive gas or dust is not present test flanges for leakage with flame or match or b...

Page 105: ...tion or overhaul Check deflection of rotor by turning on bearing journals Total indicator run out should not exceed 0 002 on shaft and 0 004 on impeller wearing surface Mechanical failure of critical pump parts Check bearings and impeller for damage Any irregularity in these parts will cause a drag on shaft Misalignment Realign pump and driver Speed may be too high brake hp of pump varies as the c...

Page 106: ... exploded view Figure 42 Seal on Sleeve Drop in Stuffing Box Design Table 7 Legend1 Number Description 1 External flush line 2 Upper casing 3 Gasket parting flange 4 Outboard end cap 8 Parts Listings and Exploded View 104 e XC INSTRUCTION MANUAL ...

Page 107: ...ear ring 25 O ring casing wear ring 26 Impeller wear ring 27 Impeller 28 Impeller key 29 Shaft 30 Heterotype key shaft sleeve 31 Coupling key 32 Lower casing 1The integrated stuffing box design assembly is identical to the drop in assembly with the exception of items related to the stuffing box item 15 Note Seal chamber components for other sealing configurations including seal on shaft wet shaft ...

Page 108: ...arranty and render the Warranty void Any parts repaired or replaced under the Warranty are warranted only for the balance of the Warranty period Seller shall have no warranty obligations to Buyer with respect to any product or parts of a product that have been a repaired by third parties other than Seller or without Seller s written approval b subject to misuse misapplication neglect alteration ac...

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Page 112: ...io of smart metering network technologies and advanced analytics solutions for water electric and gas utilities In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise with a strong focus on developing comprehensive sustainable solutions For more information on how Xylem can h...

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