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P2002458

DO NOT RUN PUMP DRY, SEAL

DAMAGE MAY OCCUR.
INSPECT PUMP SEAL

REGULARLY FOR LEAKS,

REPLACE AS REQUIRED.
LUBRICATION REQUIREMENTS

CONSULT MANUALS.

PUMP: POLYUREA-BASED GREASE
FAILURE TO FOLLOW

INSTRUCTIONS COULD

RESULT IN INJURY OR

PROPERTY DAMAGE.

Make sure that all safety instruction decals are always clearly visible and readable.

1.3 User safety

General safety rules

These safety rules apply:

• Always keep the work area clean.
• Pay 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, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices

NOTICE:

Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.

Electrical connections

Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.

Precautions before work

Observe these safety precautions before you work with the product or are in connection
with the product:

• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.

1 Introduction and Safety

G&L Pumps Series A-C 8100 Base Mounted Centrifugal Pump INSTRUCTION MANUAL

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Содержание G&L A-C 8100 Series

Страница 1: ...INSTRUCTION MANUAL AC5659D G L Pumps Series A C 8100 Base Mounted Centrifugal Pump...

Страница 2: ......

Страница 3: ...undation requirements 14 4 1 4 Level the base on a concrete foundation 15 4 1 5 Grout the baseplate 16 4 2 Coupling alignment 16 4 2 1 Prepare for alignment 16 4 2 2 Align the pump using a straight ed...

Страница 4: ...nical seal on the shaft 33 6 6 5 Disassemble the pump with mechanical seals on shaft sleeve 34 6 6 6 Disassemble the pump with packing 36 6 7 Pre assembly inspections 37 6 7 1 Replacement guidelines 3...

Страница 5: ...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...

Страница 6: ...als WARNING Do NOT exceed the maximum working pressure of the pump This information is listed on the nameplate of the pump Alert symbol This safety alert symbol is used in manuals and on the safety in...

Страница 7: ...hin the work area Hard hat Safety goggles preferably with side shields Protective shoes Protective gloves Gas mask Hearing protection First aid kit Safety devices NOTICE Never operate a unit unless sa...

Страница 8: ...with your fingers 2 Rinse the eyes with eyewash or running water for at least 15 minutes 3 Seek medical attention Chemicals or hazardous fluids on skin 1 Remove contaminated clothing 2 Wash the skin...

Страница 9: ...ey will be packaged in a separate container and shipped with the pump or attached to the base plate Shaft alignment Shafts are in alignment when the unit is shipped however misalignment can occur due...

Страница 10: ...ution to ensure the weight is balanced equally distributed across both forks When the baseplate of the assembly is structural channel construction the pump and base plate should be set in place first...

Страница 11: ...ard shackle and end loops Be sure the lifting equipment is of sufficient length to keep the lift angle less than 30 from the vertical See Figure 3 Storage location The product must be stored in a cove...

Страница 12: ...or short term storage apply Store in a covered and dry location Store the unit free from excessive cold or heat below 32 F and above 110 F dirt and vibration Rotate the shaft by hand several times 10...

Страница 13: ...seals normally utilize the pumped liquid to lubricate the seal faces This method is preferred when the pumped liquid is neither abrasive nor corrosive Intended applications WARNING This product can ex...

Страница 14: ...eplate information The pump nameplate gives identification and rating information about the pump Permanent records for this pump are kept by the serial number and it must be used will all corresponden...

Страница 15: ...ed lifting points Lifting devices such as eyebolts slings and spreaders must be rated selected and used for the entire load being lifted Guideline Explanation comment Keep the pump as close to the liq...

Страница 16: ...upply 9 Reducing valve 4 1 3 Foundation requirements Requirements A substantial foundation and footing should be built to suit local conditions and form a rigid support to maintain alignment The found...

Страница 17: ...late does not have to be level 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...

Страница 18: ...ollow these guidelines when you align the coupling Only perform alignment by moving or shimming the motor Make allowances for thermal expansion during cold alignment so that the coupling is aligned at...

Страница 19: ...adius is permissible Feeler gauges 1 Insert feeler gauges between the coupling faces at various points around the circumference Do not rotate the shafts 2 Reposition the equipment until the difference...

Страница 20: ...ipped However this dimension should be checked Refer to the coupling manufacturer s specifications supplied with the unit 1 Check the angular misalignment a Mount the dial indicator base to one coupli...

Страница 21: ...erature then secure the pump and re check the alignment Make sure that you compensate for temperature accordingly NOTICE Elastomeric couplings are specifically designed to accommodate angular shaft mi...

Страница 22: ...2 0 020 2 563 8 0 015 0 025 2 938 9 0 017 0 028 3 500 10 0 020 0 032 4 063 11 0 022 0 037 4 875 12 0 025 0 042 5 688 13 0 030 0 050 6 625 14 0 035 0 060 7 750 4 3 Piping checklists 4 3 1 Piping checkl...

Страница 23: ...selected and installed so that pressure losses are minimized and sufficient liquid flows into the pump when it is started and operated Many NPSH problems can be directly attributed to improper suctio...

Страница 24: ...ws the unbalanced loading of a double suction impeller due to the uneven flow around an elbow that is adjacent to the pump 1 2 3 4 5 1 Pump casing 2 Impeller 3 Pump suction flange 4 Suction elbow 5 Wa...

Страница 25: ...2 1 1 No air pockets 2 Eccentric reducer 3 Gradual rise Figure 14 Gradual rise to the pump correct 1 1 Distance plus eccentric reducer straightens the flow Figure 15 Suction pipe above the pump correc...

Страница 26: ...e pipe system in order to prevent premature failure at initial startup If temperatures of the pumped fluid will exceed 200 F 93 C then warm up the pump prior to operation Circulate a small amount of f...

Страница 27: ...ing to assure that there are no leaks 2 Check and record pressure gauge readings for future reference 3 Check and record voltage amperage per phase and kw if an indicating wattmeter is available 4 Che...

Страница 28: ...r can only come off from the outboard end 2 With the rotating element out of the casing remove the casing from the bedplate and turn 180 3 Set the rotating element back in the casing and reassemble th...

Страница 29: ...Figure 18 Main joint bolts 5 Commissioning Startup Operation and Shutdown G L Pumps Series A C 8100 Base Mounted Centrifugal Pump INSTRUCTION MANUAL 27...

Страница 30: ...sary Use the grade recommended Make sure the seal cages are centered in the stuffing box at the entrance of the stuffing box piping connection Take vibration readings on the bearing housings Compare t...

Страница 31: ...of the lubricants recommended by the coupling manufacturer 6 3 Bearing maintenance Bearing lubrication schedule Type of bearing First lubrication assembled pumps and replacement bearing frames First l...

Страница 32: ...built with Lithium based greases NLGI 2 and do not have lubrication label on pump or bearing frame indicating pump grease type ExxonMobil PolyrexTM EM Shell Gadus S2 V100 2 was Alvania RL 2 Chevron SR...

Страница 33: ...ly before you install new packing Check the condition of the shaft or sleeve for possible scoring or eccentricity and make replacements as necessary When placing new non asbestos packing into the stuf...

Страница 34: ...drain plug located on the bottom of the pump housing Do not reinstall the plug or close the drain valve until the reassembly is complete 4 Drain the liquid from the piping and flush the pump if it is...

Страница 35: ...river or pry bar into the slots between the upper and lower casing halves separate joint 4 Remove all casing main joint capscrews and dowels 2 916 1 Lift off the upper casing half 5 Tap the stuffing b...

Страница 36: ...emove coupling guard and disconnect coupling Refer to instructions on how to remove the hex coupling guard a Remove external tubing 1 939 9 if supplied 3 Loosen but do not remove main joint capscrews...

Страница 37: ...ead 3 402 0 from the pump shaft If set collar 3 421 9 must be removed scribe a line on shaft sleeve 3 009 9 flush with end of seal 13 Loosen set screw 3 902 3 in shaft nut 3 015 9 and remove the nut O...

Страница 38: ...mer to break the seal between the stuffing box and lower casing half and lift the rotating element out of the lower casing A spare rotating element can be installed at this point 6 Remove the four cap...

Страница 39: ...11 1 6 7 Pre assembly inspections Guidelines Before you assemble the pump parts make sure you follow these guidelines Inspect the pump parts according to the information in these pre assembly topics b...

Страница 40: ...spect the surface for damage such as pitting corrosion nicks and scratches Replace these parts if they are damaged 6 8 Dimensions Pump with mechanical seal on the shaft Figure 20 Cross section Figure...

Страница 41: ...55 6x4x14 6 62 6 75 6 00 6 12 7 00 7 12 9 755 8x6x12 6 63 6 75 6 00 6 12 7 00 7 12 9 755 8x6x13 7 31 7 50 6 69 6 88 7 81 8 00 10 625 8x6x17 7 31 7 50 6 69 6 88 7 81 8 00 10 625 8x8x12 7 31 7 50 6 69 6...

Страница 42: ...ng line Figure 28 Cross section Pump size Dimension A Packing size 3x2x11 8 755 3 8 6x4x9 9 312 6x4x10A 9 312 6x4x10 10 625 1 2 6x4x11 10 75 3 8 6x4x12A 10 625 1 2 6x4x12 9 755 3 8 6x4x14 6x6x9 9 312...

Страница 43: ...ould be made using the upper half as a template Lay the gasket material on the casing joint and mark it by pressing it against the edges of the casing Trim the gasket so that it is flush with the insi...

Страница 44: ...within 10 12 minutes to assure proper placements of the mechanical seal 9 Lightly coat the outboard end of the shaft with soapy water or vegetable oil and slide the mechanical seal head 3 402 0 onto t...

Страница 45: ...urface Correct and excessive O ring buckling NOTE Do not cut or damage O rings when lowering the rotating element into position When all four pins are correctly located there will be some casing ring...

Страница 46: ...key slot 2 Apply 1 2 wide bead of Loctite or Permatex sealant to outboard end of shaft 3 from the impeller hub 3 Slide sleeve 3 009 9 onto shaft rotating the sleeve to evenly distribute the sealant ap...

Страница 47: ...Using gloves press the heated bearing onto the shaft against the shaft shoulder 15 Install the locknut and lockwasher or snap ring 3 915 4 on the outboard end of the shaft 16 Cool the bearing to room...

Страница 48: ...bolt torque pattern is shown in the following figure 24 Rotate the shaft by hand to assure that it turns smoothly and is free from rubbing or binding 25 Install the coupling and align Replace the coup...

Страница 49: ...dimension C is maintained Drill a shallow recess in the shaft through the set screw hold in the nut Lock the nut in position with the set screw 3 902 3 6 Repeat steps 3 through 5 for the inboard shaft...

Страница 50: ...uckling NOTE Do not cut or damage O rings when lowering the rotating element into position When all four pins are correctly located there will be some casing ring looseness 19 Install a new 1 64 in th...

Страница 51: ...he inner and outer guards more than necessary for guard installation as it can alter their fit and appearance 4 Straddle the support bracket with the guards and install a capscrew through the hole in...

Страница 52: ...he following information 1 Serial number of the pump 2 Catalog number of the part 3 Quantity of each part 4 Name of the part 5 Material desired Parts will be furnished in original materials unless spe...

Страница 53: ...tatic 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...

Страница 54: ...d 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 temperatur...

Страница 55: ...nlet 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 l...

Страница 56: ...lection 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...

Страница 57: ...arranted only for the balance of the warranty period on the parts that were repaired or replaced Seller shall have no warranty obligations to Buyer with respect to any product or parts of a product th...

Страница 58: ...repaired by third parties other than Seller or without Seller s written approval b subject to misuse misapplication neglect alteration accident or physical damage c used in a manner contrary to Selle...

Страница 59: ...he dealer from whom you purchased the product or visit www xyleminc com for the name and location of the nearest dealer providing warranty service 8 Product warranty G L Pumps Series A C 8100 Base Mou...

Страница 60: ...ork 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...

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