WARNING: Work must be performed only by thoroughly
trained and qualified personnel to assure quality repair and to
reduce the possibilities of injury to personnel and/or damage
to equipment. If you do not have personnel who are capable of
safe quality repair of this equipment, we advise you to return
the equipment to DEAN PUMP to be repaired.
Always wear the appropriate protective apparel when working
on or around the pumping equipment. Safety glasses with side
shields, heavy work gloves (use insulated work gloves when
handling hot items), steel-toed shoes, hard hat, and any other
protective gear as needed for protection. One example of other
gear would be breathing apparatus when working near toxic
materials.
CAUTION - EXTREME HAZARD
HEART.
Magnets in/from this pump can upset the timing of
heart pacemakers and make them malfunction. This caution
cannot be overstated due to the health risk involved.
EYES, HANDS, FINGERS, EXPOSED FLESH.
Brittle materials
(such as silicon carbide and carbon used for wearing parts)
can fracture and propel hard, sharp particles causing serious
personal injury. Protective equipment must be utilized when
servicing these parts.
The magnets are also very brittle and, if cracked or fractured,
can propel hard, sharp particles causing serious personal
injury. Protective equipment must be utilized when servicing
these parts.
The magnets used in this pump are very strong and can cause
parts and tools to slam together injuring hands and fingers.
This could also crack the magnets and propel particles as
cautioned above.
CAUTION:
In addition to safety related cautions due to the
mechanics of a magnetically coupled pump, safety precautions
must be taken due to the nature of the liquid being pumped.
When it is necessary to open the pump and/or the pumping
system the fluid will be exposed to the atmosphere and personnel
in the area. For the safety of all involved, the risk of exposure of
personnel to the hazards of the pumpage can be reduced by
flushing the entire system with a compatible, non-toxic, non-
hazardous, stable liquid before opening the pump or the system.
In all cases, where the system is flushed or not, use the utmost
care around the pumpage and the pumping system.
Sealless pumps often handle flammable, toxic or hazardous
liquids. The user shall take caution that all the fluid is drained
from the containment shell before disassembly and repair work
is begun.
If the pump was not purchased with casing and shell drains, a
considerable amount of liquid will remain in the pump.
When the pump is handling flammable, toxic or hazardous fluids,
the internals of the pump must be properly decontaminated by
qualified personnel before disassembly. This may include flushing
the pump and system before disassembly. Prior to flushing,
decontamination and disassembly the Material Safety Data Sheet
(MSDS) for the pumped liquid shall be reviewed to ensure proce-
dures and precautions as specified are adhered to. Proper attire
shall be worn during disassembly and decontamination.
Pumps requiring factory repair must not be returned or trans-
ported until a certified and documented decontamination has
taken place.
Decontamination certificate and MSDS must be part of the
shipment package returned for factory repair.
CAUTION:
In spite of thorough cleaning and flushing prior to
maintenance of sealless pumps, some contamination of pump
internals may exist. Repair shop personnel should be advised
of the nature of the hazardous liquid handled, and of the
requirement for protective clothing and equipment needed
during maintenance work. Care must be taken in disposing
of residue and contaminated parts being replaced.
Use only top quality tools.
REMOVING THE PUMP’S ”FRAME ASSEMBLY“
The Dean magnetic coupled pump, with “back pull out” cen-
trifugal design, allows the complete disassembly of the pump
without disturbing the suction or discharge piping.
a) Stop the pump. Turn off the power supply (electricity,
steam, etc.) to the pump driver (motor, turbine, engine,
etc.) and lock the switching device so that it can not be
restarted. Tag the switching device so that no one will
attempt to restart the unit.
b) Close the suction and discharge valves completely to iso-
late the pump from the system. Lock the valves in the
closed position and tag them so that no one will attempt
to open them.
c) Turn off, lock out, and tag all sub-systems and auxiliary
equipment and auxiliary supply lines to isolate the pump-
ing unit from any and all power, energy, and/or fluids.
WARNING: Do not attempt to perform any work on the unit until
you are confident that the pump and its contents have been
stabilized at ambient temperature, and atmospheric pressure.
Put on protective wear to protect human tissue from attack by
fluids contained in the pump and any sub-systems, and from any
vapors or fumes that could possibly be released from these fluids.
This could mean breathing apparatus face shields, heavy long
sleeve rubber gloves, rubber apron, hood, and possibly more,
dependent, of course, on the properties of the fluids involved and
the installed drain and vent piping arrangement. Personal injury
and/or death can occur if adequate precautions are not taken
with regard to the fluid, the installation and the possibilities of
the release of fluid, vapors, and/or fumes.
d) Remove the coupling guard. Remove the coupling spacer.
e) Drain all the fluids from all the auxiliary sub-systems
(lubrication, cooling, heating, etc.) that are connected to
the pump. Drain each fluid into a separate container.
Use caution required for each fluid after reading the
MSDS (Material Safety Data Sheet) for each.
DISASSEMBLY AND ASSEMBLY PROCEDURES
If the pump has optional drain connections, there will be a
drain connection in the bottom of the casing (5) and a contain-
ment shell drain in the bottom of the casing cover (22). Do not
connect these two drains together, as it would cause a “short
circuit” in the internal lubrication and cooling flow. This would
cause severe failure.
BASEPLATE MOUNTING AND ALIGNMENT
The sequence of mounting which must be observed for proper
baseplate and pump mounting is:
1)
Place baseplate, with pump and driver mounted there-
on, on the pump foundation.
2)
Use wedges under the baseplate edges, adjacent to each
foundation bolt, to properly level the unit. Check this with
a spirit level. Tightly pull down the baseplate mounting
bolt nuts and recheck for levelness. Correct if necessary.
3)
Check driver rotation by removing the coupling spacer
and bumping the motor starting button.
Operating the
pump in reverse rotation may cause extensive damage.
If driver rotation is correct, proceed with alignment. If
not, reconnect the motor wiring properly and again
check for rotation. When the driver rotation is correct,
proceed with the alignment.
4)
Align the driver to the pump. (See PUMP AND DRIVER
ALIGNMENT.)
5)
Grout the baseplate.
Do not grout the baseplate to the
foundation until the pump and driver are correctly
aligned.
6)
Determine that piping to the pump is in exact alignment
with the pump flanges and imposes no piping strain on
the pumping unit. When the alignment is exact, the
piping may be bolted in place.
7)
Recheck pump and driver alignment to ensure that no
distortion of the pump unit has been caused by piping
strain. Correct piping if misalignment has occurred and
again align pump and driver.
8)
When alignment is correct, install the coupling spacer.
9)
The pump and driver alignment must again be checked
at the operating temperature and alignment corrected
under the hot condition.
10)
After about two weeks of normal pump operation, the
pump and driver alignment should again be checked
under the hot condition. If alignment is still correct, the
driver feet may be doweled to the baseplate. If the
alignment has changed, realign the unit and recheck
after two weeks.
PUMP AND DRIVER ALIGNMENT
Proper running life of a pump and driver unit depends on the
accuracy with which the axis of the driver shaft coincides with
the axis of the rotor shaft when the unit is running. Although
pumps and drivers are check aligned at the factory, handling
during shipment and installation will cause the alignment to
change.
The pump and driver alignment must always be
checked and corrected before the baseplate is grouted to the
foundation and again before the pump is first started.
If the
baseplate mounting instructions have been carefully followed,
no difficulties in making the alignment should be experienced.
Failure to properly align the unit will result in vibration and
short bearing life, and unit failure.
Pumps are not constructed to be used as pipe anchors. Both
suction and discharge piping must be supported independently
of the pumping unit and thermal expansion joints provided to
guard against expansion loads on the pump. Pipes should be
anchored between the expansion joint and the pump and as
closely to the pump as possible. Failure to provide proper
piping support and expansion joints may impose strains on
the pumping unit which will result in serious misalignment.
Maximum allowable piping loads are shown on page 11 of
this manual.
No allowance for thermal expansion is made for motor driven
units in mounting the driver. Allowance for turbine mounting
should be in accordance with the turbine manufacturer‘s
recommendations.
Final alignment must always be checked
and corrected at the operating temperatures of the pump
and driver.
Misalignment of the two shafts is of two kinds. The first of these
is angular misalignment where the axis of one shaft is at an
angle from the other. The other is offset alignment where the
center of one shaft is offset from the center of the other shaft.
These effects usually occur together so that both angular and
offset misalignment are present.
Coincident alignment of the driver and rotor shaft is measured
at the faces of the coupling hubs. Because of the variety of
coupling types furnished at customer’s request, the procedure
given here is general in nature but may be applied by simple
adaption to most coupling types.
The first step is to remove the spacer from the coupling. To one
of the remaining coupling hubs, firmly seated on the shaft,
attach a dial indicator. Let the indicator button ride on the face
of the other coupling hub and near the outside diameter. Rotate
the shaft on which the dial indicator is mounted, allowing the
indicator button to move on the stationary coupling hub. The
indicator dial movement will show the difference in distance
between the two hubs. This indicates the amount of angular
misalignment between the hubs and, therefore, the shaft axes.
Good practice suggests alignment to within 0.002" T.I.R.
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