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TABLE OF CONTENTS

GUARANTEE........................................................................................................... 3
HOW TO USE THIS MANUAL..................................................................................4
1. SAFETY PRECAUTIONS....................................................................................6
2. GENERAL DESCRIPTION OF VBN PUMPS.......................................................8
2.1 Casings and impellers................................................................................................................... 8
2.2 Rotating Assembly and Bearings...................................................................................................8
2.3 Technical Data............................................................................................................................... 9
2.3.1 High/low temperature applications.........................................................................................9
2.3.2 Pump serial number...............................................................................................................9

3. TRANSPORT AND INTERMEDIATE STORAGE...............................................10


3.1
3.2
3.3
3.4
3.5
3.6

Shipping Preparation / Crating....................................................................................................10


Lifting........................................................................................................................................... 10
Jobsite receiving and Inspection.................................................................................................10
Short Term storage......................................................................................................................11
Long Term Storage...................................................................................................................... 11
Re-rating and Upgrades...............................................................................................................11

4. INSTALLATION..................................................................................................12
4.1 General........................................................................................................................................ 12
4.2 Pump installation and foundation................................................................................................12
4.3 Pump - motor alignment..............................................................................................................14

5. START- UP AND OPERATION...........................................................................15


5.1 Warnings...................................................................................................................................... 15
5.2 General........................................................................................................................................ 15
5.3 Start-up procedure....................................................................................................................... 17
5.3.1 Lubrication requirements......................................................................................................17
5.3.2 Flushing and filling of bearing housings...............................................................................17
5.3.3 Initial start-up procedure.......................................................................................................18
5.4 Pump operation........................................................................................................................... 19
5.4.1 Standby operation................................................................................................................20
5.5 Pump shutdown........................................................................................................................... 21

6. MAINTENANCE AND SERVICING....................................................................22


6.1
6.2
6.3
6.4

Introduction.................................................................................................................................. 22
Maintenance and Inspection schedule........................................................................................23
Major Inspection checklist............................................................................................................24
Factory replacement parts...........................................................................................................24

7. FAULTS : CAUSES AND REMEDIES................................................................26


8. DISASSEMBLING AND PARTS REPLACEMENT : Bearings & Seals............28
8.1 Warnings / cautions..................................................................................................................... 28
8.2 General........................................................................................................................................ 30

Man0.doc - rev. 0 - nov-02

8.3 Bearing housing - removal.........................................................................................................30


8.3.1 Antifriction Bearing - removal.............................................................................................31
8.3.2 Antifriction bearings - replacement......................................................................................33
8.4 Bearing housing replacement...................................................................................................33
8.5
Mechanical seal - removal and replacement......................................................................35

9. VBN PUMPS : INNER PARTS REPLACEMENT...............................................37


9.1 Pump disassembly....................................................................................................................... 37
9.2 Wear rings - removal and replacement........................................................................................38
9.3 Balancing..................................................................................................................................... 39
9.4 Rotor replacement....................................................................................................................... 39
Table 1 : Recommended Bolt Torque.................................................................................................40
Table 2 : Minimum Running Clearances.............................................................................................41
Attachment 1:VBN Cross Section.....................................................................................................42
Attachment 2:VBN-DS Cross Section...............................................................................................43

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GUARANTEE
Seller guarantees to Buyer that the equipment at the time of shipment is free from
defects in material and workmanship and conforms in all respects to the agreed
technical specifications. This guarantee shall be ineffective and shall not extend to :

equipment subjected to misuse, neglect, accident;


equipment which has been improperly installed or maintained;
equipment which has been altered or repaired by anyone other than the
Seller or its authorized representative;
equipment which has been repaired using non-original repair parts;
equipment which has been installed and used under climatic and
environmental conditions that differ from those stated in the Purchase
Order.

This guarantee shall not cover normal wear parts (as per API 610 - VIII ed. - 1.4.32),
such as wearing rings, bushings, shaft seals and bearings, nor gaskets / O rings,
after pump disassembling.
This guarantee shall be ineffective if the guarantee period indicated in the Purchase
Order, with reference to the time of shipment, has elapsed.
Sellers sole obligation under the foregoing guarantee is limited, at Sellers option, to
replacing or repairing defective equipment.
The guarantee contained herein is made only to and for the exclusive benefit of
Buyer and does not extend to any subsequent purchaser or user of the equipment,
unless specifically mentioned in the Purchase Order.

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How to use this Manual

HOW TO USE THIS MANUAL


This instruction manual contains installation, operation and maintenance instructions
for the pump identified in the Pump Data Sheet included in this manual. It should be
reviewed carefully by the user before attempting to install and operate the pump,
and should be kept in a location convenient to the user for ready reference during
operation and maintenance.
warning
A complete reading of this manual by personnel
in contact with the pump is essential to safety.
INCORRECT INSTALLATION, OPERATION AND MAINTENANCE
OR PARTS REPLACEMENT CAN RESULT IN INJURY TO THE PERSONNEL AND
DAMAGE TO THE PUMP, DRIVING MACHINERY AND PLANT.
This Instruction Manual consists of several sections, as listed in the table of
contents. Since this is a general instruction manual, describing the general pump,
the description and illustrations contained herein may differ in minor details from the
unit actually supplied. However all general installation, operation and maintenance
procedures are applicable. For those pumps supplied with optional lubrication
systems, control systems accessories/instrumentation and/or driver, refer to the
combined description, operation and maintenance procedures in the Documentation
Section supplied with this manual.
The instructions contained in this manual do not attempt to cover all details, nor
provide for every possible contingency to be met in connection with installation,
operation and maintenance.
The supplying of instructions does not imply in any manner that Pompe Gabbioneta
accepts liability for work carried out by a customer or contractor personnel. Liability
is limited to and as stated in our Terms and Conditions of Sale.
Should further information be desired, or should particular problems arise which are
not covered sufficiently for the purchasers purposes, the matter should be referred
to Pompe Gabbioneta.
All inquiries regarding installation, operation and maintenance, spare parts or
service should be directed to :
Pompe Gabbioneta SpA
Viale Casiraghi, 68
20099 SESTO SAN GIOVANNI (MI) - Italy
Tel: +39 02 24 1001 ; Fax: +39 02 22 47 3881
E-mail: after.sales@pompegabbioneta.com

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How to use this Manual

A typical pump nameplate is given below.


The actual nameplate data can be found in the Documentation Section.

STATEMENT
Pompe Gabbioneta pumps comply with the following European Directives :
Machinery Directive
PED
Electro Magnetic Compatibility Directive

98/37/CE
97/23/CE
89/336

and amendments.
Refer to the Documentation Section for the Declaration of Conformity and/or the
Declaration of Incorporation, as applicable to the specific Purchase Order.

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01 - Safety Precautions

1. SAFETY PRECAUTIONS
This pump has been designed to provide safe and reliable service within the
designated specifications. It is a pressure containing, rotating machine; therefore,
good judgment and proper safety practices must be exercised by responsible and
qualified personnel to avoid damage to the equipment and surroundings or possible
serious injuries.
It is assumed that the operators safety department has an established safety
program based on a thorough analysis of industrial hazards. Before installing and
operating or performing maintenance on this pump, it is suggested to the operator to
review the safety program and ascertain that it covers the hazards arising from
rotating machinery and pressure vessels.
Proper installation and continued maintenance of protective guards and shutdown
devices and other safety devices are necessary for safe pump operation.
It is important that due consideration is given to all hazards resulting from the
presence of :
electrical power
hot liquids
toxic gases
flammable liquids and gases.
Noise levels of the pump unit are given in the Data Sheet supplied in the
Documentation Section of the manual.
This manual contains four types of hazard seriousness messages. They are as
follows :
danger
immediate hazards which will result in severe personal injury or death

caution
hazards which could result in serious injury to the pump operator and others, or
extensive damage to the pump unit or surroundings.

warning
hazards which could result in damage or malfunction to the pump or its parts,
leading to subsequent downtime and expense.

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01 - Safety Precautions

note
a message to clarify or simplify an operation or technique or to avoid a common
mistake.

major warnings
DO NOT START OR OPERATE this pump unless the installation has been verified
to be correct and all pre-startup safety and control functions have been checked.
DO NOT START OR OPERATE this pump unless you have a complete
understanding of the location and function of all upstream and downstream
equipment that may affect the flow of liquid to or from the pump.
NEVER WEAR NECKTIES or other loose clothing while in the proximity
of the pump or auxiliary equipment.
NEVER DISCONNECT THE SUCTION OR THE DISCHARGE FLANGES
of the pump, without first isolating the pump from the inlet and outlet
systems by closing and tagging block valves. Open connections
not protected with block valves should be covered with blind
flanges, rated for the pressure conditions that may prevail.
ALL DRAINS must be opened to depressurize the pump.
DO NOT REMOVE any covers, guards, gland housings,
drain covers, plugs etc, while the unit is operating.
DO NOT MAKE ANY MODIFICATIONS OR REPAIRS
that are not described in this manual.

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02 - General description
of VBN pumps

2. GENERAL DESCRIPTION OF VBN PUMPS


Pompe Gabbioneta VBN pumps are vertical multistage pumps, normally supplied
with a suction barrel when pumping volatile or hazardous liquids.
Pump column and line shaft may consist of multiple sections, depending upon the
pump setting, specified on the Data Sheet.
As a standard, VBN pumps are provided with a thrust bearing, inside the discharge
head, and:
one flexible coupling with spacer, between driver and pump;
or
one flexible coupling with spacer between driver and bearing housing and
one rigid coupling with spacer, between bearing housing and pump.
When specified by the Purchase Order, VBN pumps can be supplied without thrust
bearing. In this case, axial thrust and rotor weight are taken by a thrust bearing in
the special motor.
2.1 Casings and impellers
Pump casings are of the diffuser type to minimize radial loads.
Interstage bushings are shrink fitted into the casings.
Impellers are of the single suction, closed type, with front and rear wear rings, to
minimize axial thrust.
Renewable casing and impeller wear rings are mounted with threaded dowels in
accordance to API 610 standards, latest edition.
2.2 Rotating Assembly and Bearings
As a standard, the rotating assembly is supported by an oil-lubricated, double-row
ball bearing.
Product lubricated, intermediate bushings are located in each casing and in each
column section.
The span between the bushings is a function of the rotational speed, to avoid
resonance, as specified by applicable standards.
Bearing housings are air cooled, with or without fan, depending upon the conditions
of service specified on Data Sheet and Purchase Order.
As a standard, bearing housings are equipped with replaceable labyrinth end seals
and deflectors.
If specified by the Purchase Order, the end seals (or bearing isolators) can be of the
Inproseal type (non contacting oil seals of the labyrinth type) or magnetic type.

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02 - General description
of VBN pumps

2.3 Technical Data


This VBN pump has been specifically built for the application mentioned in the data
sheet. Information about the main characteristics of this pump is recorded :

on the pump nameplate


on the pump data sheet ( refer to the Documentation Section of the manual).
on the test certificates.

2.3.1 High/low temperature applications


Pompe Gabbioneta recommends the installation of a circulation system on VBN
pumps when the operating temperature is substantially higher or lower than the
ambient temperature, unless otherwise specified by the Purchase Order.
Refer to Section 5.4.1 for details on the circulation system.
2.3.2 Pump serial number
Pump nameplate and certified drawing specify the pump serial number. This
number is a unique identifier of the pump; it must be specified when ordering
replacement parts and in all correspondence with the factory.
The serial number is also stamped on the discharge flange O.D. of the casing, for
identification and reference purposes. It is an alphanumeric code of 5 digits and 1
letter (item).

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03 - Vertical pumps:
Transport &
intermediate
storage

3. TRANSPORT AND INTERMEDIATE STORAGE


3.1 Shipping Preparation / Crating
After testing, the pump is drained and dried. Oil is drained from bearing housings of
oil lubricated pumps, whilst grease lubricated bearings are filled with grease.
A rust inhibitor is sprayed inside the pump.
The pump is then masked and painted. All unpainted surfaces not inherently
corrosion-resistant, such as exposed portions of the shaft, are coated with a rustpreventive and / or wrapped.
Flange covers are installed on all open-flanged connections.
Prior to crating, the pump unit is given a final inspection from a quality inspector,
who checks for completeness and appearance.
3.2 Lifting (1)
caution
Lifting and handling operations must be carried out by specialized personnel.
POMPE GABBIONETA SpA refuses all responsibility for any damage to
persons or property caused by failure to comply with the safety provisions
governing lifting and handling operations inside or outside the factory
For correct rigging, refer to the unit weights specified on the Certified Drawing in the
Documentation Section of the manual.
Lift slowly and carefully to ensure stability and safety.
caution
NEVER attempt to lift the unit USING pump or driver eyebolts. These
eyebolts are intended for lifting the individual components only. Using any
of the eyebolts to lift the entire unit presents a SERIOUS SAFETY HAZARD.
3.3 Jobsite receiving and Inspection
Visually inspect components for physical damage by opening packages and crates.
Verify that plugs and caps are in place, desiccants are unsaturated and equipment is
lubricated as required.
Verify that loose components and separate packages match with packing lists and
ensure that loose parts are not discarded with the packing material.
Handle all parts with care.
Report any damage to the shipping company and file a claim immediately.
1

Refer to API Practice 686 - 1996, Chapter 2

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10

03 - Vertical pumps:
Transport &
intermediate
storage

Contact Pompe Gabbioneta SpA, for missing parts.


3.4 Short Term Storage (2)
Pompe Gabbioneta pumps are normally prepared for short term storage up to 6
months. The unit should be stored in a clean non-corrosive atmosphere and
protected against damage, loss, weather and foreign material, such as dust or sand.
The equipment should remain in its container, if any (refer to P.O.), with all covering
left intact. Indoor storage is preferred, where temperature and humidity are
maintained at levels preventing condensation.
3.5 Long Term Storage
Long term storage is defined as storage exceeding 6 months.
Long term storage must be carried out in a warehouse maintained at temperature
preventing condensation. As with short term storage, the unit should be protected
against damage, weather and foreign material such as sand or dust.
If Long Term Storage was specified in the Purchase Order, the units have been so
prepared at the factory and can be stored for a maximum of 18 months.
If Long Term Storage was not specified at the time of the Purchase Order, or the
first 18 months have elapsed, the Long Term Storage Procedure, supplied on
request by Pompe Gabbioneta, should be applied.
This Procedure should be repeated at 6 months intervals.
3.6 Re-rating and Upgrades
Pompe Gabbioneta pumps can eventually be re-rated to different conditions of
service. Contact Pompe Gabbioneta factory to determine if a re-rating or upgrading
can meet your needs.
caution
Materials used in pump construction vary with the characteristics of the pumped
liquid. These materials were selected according to the original rating of the pump.
NEVER attempt to RE-RATE a pump without the assistance of the
manufacturers representative. Misapplication of materials COULD
result in serious equipment damage and/or personal injury.

Refer to API Practice 686 - 1996, Chapter 3, as a "minimum acceptable guide" for storage and
protective care.

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11

04 - Vertical pumps:
installation

4. INSTALLATION (1)
4.1 General
Proper installation of pump and driver is vital for successful operation of the system.
It is for this reason that competent and experienced personnel should be employed
during installation.
Refer to the Certified Drawing in the Document Section of this manual, prior to
installation.
The following recommendations and instructions are provided to assist the
purchaser and/or his contractor. Fully qualified labour, including qualified supervision
is required for proper installation, start-up and subsequent operation.
The services of a Pompe Gabbioneta serviceman or authorized personnel are
recommended for supervision of installation and start-up of the pump.
To achieve satisfactory operation, the following steps must be carried out in
sequence :

Refer to the certified outline drawing and carefully read all installation notes,
piping connection details, dimensions and any other special data.
Remove all protective coatings and foreign matter from the unit.
Provide a proper and adequate foundation for the pump sole plate or suction
barrel (if any).
Insert shims around each anchor bolt and level suction barrel flange.
Grout the suction barrel to the foundation as required.

4.2 Pump installation and foundation


A foundation or frame must maintain alignment under all normal and abnormal
conditions. This includes the way a foundation or frame is supported on the soil
and/or superstructure, soil settling, soil resonance, thermal distortion and piping
forces.
Sufficient space should be provided around and above the foundation to allow for
proper installation and maintenance.
Frame mounted pumps
If required by the Purchase Order,vertical pumps can be mounted on a frame across
a sump. This frame shall be installed in accordance with the construction drawing
and levelled within 0.2 mm per meter, for correct operation of the vertical pump.
Can mounted pumps
On vertically suspended can pumps, the foundation shall be designed so that the
pump can is directly attached to the mounting plate and is removable without
damaging the grout. The foundation must be water tight.
1

Refer to API Practice 686-1996

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12

04 - Vertical pumps:
installation

A minimum clearance of 50 mm (2") should be maintained between the outside of


the can and the inner liner surface.
An axial clearance of 300 mm (1 foot) should be maintained between the bottom
surface of the cavity and the bottom of the pump can, to prevent distortions due to
thermal growth.
The foundation (or the support structure) must minimize vibration by being nonresonant within the operating range of the pump unit.
Normal excitation frequencies( i.e. : 1- and 2-times running frequencies or bladepassing frequencies) can cause abnormal vibrations.
Upon request, an elastically tuned ring (item 64 on the cross sectional drawing)
can be inserted between motor and supporting bracket (26/1) to eliminate risks of
resonance induced by the motor.
A certified outline drawing is furnished with each pump unit and is included in the
Documentation Section of the manual. This drawing includes dimensions for locating
anchor bolts, unit overall weight and single component weights, as well as general
information required to determine foundation dimensions and design.
A generous safety factor should be used when determining foundation thickness.
Anchor bolts must be positioned accurately, while the foundation is cast. Skilled
craftsmen should be able to set anchor bolts to a tolerance of 3 mm by locating and
drilling holes in the template after they have been secured to the brace forms.
note
Templates must be rigid enough to prevent bolts from shifting while concrete is
being poured. After concrete has been poured and before it has hardened,
recheck positions of anchor bolts.
Mounting plates, if required by the Purchase Order, are designed in accordance to
the guidelines given in Chapter 4 - Section 2.6 of API Practice 686, i.e.:
-

mounting plate diameter is at least 50 mm (2") bigger than the pump/can


flange diameter;
anchor bolt holes have a minimum 3 mm annular clearance with the anchor
bolt, for field alignment;
mounting plates are provided with vertical leveling screws.

The mounting plate shall be installed in accordance with the construction drawing
and leveled with a master level or a precision machinist's level.
The mounting surface is to be leveled within 40 m per meter (0.0005 in/ft) by
adjusting the jacking screws and inserting shims.

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13

04 - Vertical pumps:
installation

4.3 Pump - motor alignment


After the installation of the motor, motor to pump alignment must be checked, prior
to inserting the bolts on the coupling halves.
Generally no operation is required, because alignment between motor and pump
shaft is ensured by the rabbet joint provided on motor to pump mounting surface.
It is however advisable to check concentricity of the motor fit and perpendicularity of
its mounting surface, by turning the motor shaft by hand, after installing on this one
a bracket carrying a dial gauge. Both readings shall not exceed 0.025 mm.

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14

05 VBN pumps:
Start-up and
Operation

5. START- UP AND OPERATION


5.1 Warnings
The operator should read Section 2 and the Documentation Section to become
familiar with the pump, before attempting to start and operate it.
warning
DO NOT START OR OPERATE this pump unless the INSTALLATION has been
verified to be CORRECT and all SAFETY FUNCTIONS have been checked.
warning
DO NOT START OR OPERATE this pump unless you have a COMPLETE
UNDERSTANDING of the location and function of all components on suction and
discharge piping and ancillaries, including valves, bypasses, vents and drains
and any equipment that may affect pump and seal operation
warning
DO NOT START OR OPERATE this pump unless you have a COMPLETE
UNDERSTANDING of the lubrication system and all auxiliary mechanical, electrical,
hydraulic and pneumatic system, as well as the meaning of all monitoring gauges,
meters, digital readouts and warning devices.
warning
For pumps operating IN PARALLEL be sure that relative
performance curves are strictly similar
5.2 General
The following recommended start-up and operation procedures apply to the basic
pump configuration. For information on any optional equipment refer to the
Documentation Section of the manual.
warning
None of the recommended start-up and operating procedures contained in this
manual shall be interpreted in any way as relieving the user of his responsibility
for compliance with the requirements of any regulatory body, or for the exercise
of normal good judgement in the start-up, operation and care of the pump unit.

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15

05 VBN pumps:
Start-up and
Operation

To ensure trouble-free operation, the pump must be:

cleaned accurately prior to start-up, and kept clean at all times;


properly lubricated at regular intervals, as recommended in Section 6;
regularly inspected and maintained according to a scheduled preventive
maintenance program;
operated according to the procedures specified in the present instruction
manual.

The following is a recommended list of items that should be checked before start-up:

examine suction and discharge piping for manually operated check valves
and re-circulation line. All check valves must be fully open, before start-up;
identify the pipe section fitted with the temporary suction strainer (if any). The
installation of this strainer (refer to fig. 1) is a recommended practice to
prevent dirt or welding slags from entering the pump, which may damage the
impeller and other internal components. The strainer must be made in
stainless steel, with an open area from 3 to 5 times the cross section of the
suction piping. ( 14 mesh is a recommended practice )
identify the differential pressure gauge, installed on the strainer. This gauge
must be monitored to detect clogging and need for cleaning or replacement.
visually inspect the unit, the grouting and the anchor bolts for any missing or
improperly fitted component;
check the correct installation of the re-circulation valve, if included in the
scope of supply;
check oil levels;
check water cooling lines, if installed;
check flushing lines to seal(s) against pump and seal manufacturers
instructions;
on motor driven units, check electrical connections and motor auxiliaries
against motor manufacturers instructions;
on turbine driven units, check steam piping and turbine auxiliaries against
turbine manufacturers instructions

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16

05 VBN pumps:
Start-up and
Operation

5.3 Start-up procedure


5.3.1 Lubrication requirements
Several lubrication options are available; the selected option, installed on this pump,
has been specified in the Purchase Order.
Unless otherwise specified, bearing housings are arranged for oil lubrication. The
oil slinger, running on the pump shaft picks up oil from the reservoir in the bearing
housing and conveys it to the bearing.
The oil level within the bearing housing must be sufficiently high to allow the slinger
to run in the oil. However, an oil level that is too high may result in oil leakage past
the shaft seals or in excessive friction.
Check oil level in the glass level gauge installed on the bearing housing.
For details on the recommended type of oil refer to the Lubricant List, in the
Documentation Section of this manual.
In many applications the bearing housing may be air cooled. (Refer to the certified
drawing).
5.3.2 Flushing and filling of bearing housings
Before starting the pump for the first time, open all bearing housing drains and allow
any residual oil to drain. Then close the drains and fill the bearing housings with a
light, warm oil. Rotate the shaft and then drain this oil.
The oil recommended for permanent operation (see below) should now be added to
the bearing housing through the vent plug hole, after removing the vent plug and the
constant level oiler, until oil comes out from the oiler hole.
Re-install the oiler and add oil as necessary through the constant level oiler, until the
oil level in the level gauge is correct.

Fig. 1

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17

05 VBN pumps:
Start-up and
Operation

The constant level oiler maintains a constant level of oil in the bearing housing as
long as there is oil in the bottle and the oiler operates properly.
warning
The presence of oil in the constant level oiler does not necessarily
mean that oil in the bearing housing is at the proper level.

warning
CLEANLINESS is essential for long and trouble-free service of the bearings.
Care must be taken to ensure that NO FOREIGN MATERIAL enters bearing
housings or constant level oilers when performing maintenance operations.

The Lubricant List, given in the Final Documentation, indicates :

type of oil suggested;


the quantity of oil required;
the estimated consumption under normal operating conditions;
the recommended frequency of oil changes.
for oil mist or pressurized lube oil systems refer to the documents supplied in
the Documentation Sections of this manual namely: P&I, Instrumentation List,
Instrumentation Data Sheet and Logic Diagram.

5.3.3 Initial start-up procedure


Before starting the pump the following precautions should be taken :

review the warnings in Section 5.1;


check that suction and discharge pipes are properly connected and that all
bolts are tight;
remove coupling guard and remove mechanical seal locking tabs, if installed;
check that pump and driver rotate freely;
check the direction of rotation of the driver, as per installation drawing (see
the rotation arrow attached to the pump casing);
re-install coupling guard;
check oil levels in bearing housings;
admit cooling water to bearings, if required, and check circulation;
check circulation of the auxiliary seal liquid to the seal, if an auxiliary system
is installed;
check the forced feed lube oil system, if installed;
check that either the electrical tracing or the pump heating jacket are
activated, obviously if they are provided;

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18

05 VBN pumps:
Start-up and
Operation

close the gate valve on the discharge pipe and open the valve on the suction
pipe
open very slowly the hand valves on the vent line(s), if installed, or
temporarily remove vent plug(s), so as to fill completely the pump; this
operation will bring the system pressure up to the suction pressure;
when the pressure gage indicates that the suction pressure has been
reached, fully open the suction valve;
close the valve(s) on the vent line(s) or re-install the vent plug(s);
start-up the driver according to manufacturers instructions. Check
mechanical running. When the driver has reached its normal operating speed,
check pump discharge pressure against the shutoff pressure indicated on the
data sheet.
slowly open the discharge gate valve until the required flow and pressure are
reached.

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19

05 VBN pumps:
Start-up and
Operation

caution
Pump operation at SHUT-OFF (discharge valve closed) is allowed
for a max of 20 seconds, after which the valve must be opened.
Failure to comply with this practice may result in dangerous
OVERHEATING of the pump and SEIZURE OF THE ROTOR.
5.4 Pump operation
During pump operation, regularly check oil levels, bearing temperatures and
vibration levels.
Bearing temperatures may vary depending on type and size. Continuously rising
bearing temperatures or abrupt temperature rises are indicative of premature wear
of bearings and short term failure.
Recommended TEMPERATURE SETTINGS are listed in the following table :
TYPE
of
BEARINGS

TEMPERATURE
GAUGE
LOCATION

ALARM

TRIP

antifriction
bearings

bearing
outer race

87

95

thrust bearing
shoe

87

95

line bearing
shoe

87

95

hydrodynamic
bearings

Oil must be regularly changed according to a schedule that is influenced by the


pump duty. On normal duties, it is recommended to change the oil every 4000
working hours or at least every 6 months.

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20

05 VBN pumps:
Start-up and
Operation

VIBRATION LEVELS should be checked and recorded regularly. Continuously rising


vibration levels are indicative of internal wear, incipient damage or other
irregularities.. The following table should be adopted, unless otherwise specified in
the Purchase Order.
TYPE OF
VIBRATION SENSOR

ALARM SETTING

TRIP

proximity probe
(m peak to peak)

65

100

velocimeter
(mm/s RMS)

5.4

8.5

These limits apply to the broad band r.m.s. values of vibration velocity and
displacement, in the frequency range from 10 Hz to 1000 Hz, and are valid for
operation at the rated flow rate of the pump.
The vibration levels indicated on the table are applicable only for the vibration
produced by the machine itself and not for the vibration which is transmitted to the
machine from external sources.
When an excessive background vibration is suspected, measurements should be
made with the machine shut down, to determine the degree of external influence.
If the vibration with the machine stationary exceeds 25 % of the value measured
when the machine is running, corrective action is recommended, to reduce the effect
of background vibration.
5.4.1 Standby operation
Pumps that are not running continuously are in standby operation, where they
must be ready to operate at any time with little or no advance notice.
Pumps on high or low temperature duties are very sensitive to temperature
gradients that may affect intern cwedefxdxxdal clearances, due to differential
thermal expansion of rotating and stationary components, resulting in rubbing or
seizure at the wear rings or bushings.
Therefore, a circulation system (heating jacket) must be foreseen by the plant
operator to keep high temperature pumps at a specified and uniform temperature
during standby operation.
warning
No attempts should be made to rotate the shaft of a HOT STANDBY PUMP,
unless the pump has been accurately and uniformly warmed-up.

Man05.doc - rev. 0 - nov-02

21

05 VBN pumps:
Start-up and
Operation

5.5 Pump shutdown


Shutting down the pump may be accomplished as follows :

close the discharge gate valve and shut down the driver, following the specific
instructions;
close the suction gate valve and the valves of the auxiliary systems.
note

In some applications, both the seal flushing and the heating pump system must be
maintained open during pump shutdown, to prevent the formation of crystals.

Man05.doc - rev. 0 - nov-02

22

06 - Maintenance
& Servicing

6. MAINTENANCE AND SERVICING


6.1 Introduction
This pump is a high quality machine that has been carefully assembled and
thoroughly tested at the factory. It requires periodic maintenance and service. This
section describes periodic maintenance requirements.
Refer to Section 8 for major service and overhaul instructions.
warnings
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR MODIFY
ANY PART of this pump unit WHILE IT IS IN OPERATION, unless
such action is expressly described in this instruction manual
NEVER DISCONNECT SUCTION OR DISCHARGE FLANGES
of the pump without first isolating the pump from the system
by CLOSING AND TAGGING BLOCK VALVES.
Open connections not protected by block valves
must be covered with blind flanges.
Both ALL PUMP DRAINS and ALL HEATING JACKED DRAINS must be opened to
depressurize the pump.
MAINTENANCE PERSONNEL should be thoroughly FAMILIAR with
the pump and accessories, before attempting any maintenance
or service. A complete reading of this manual is recommended.
When RESTARTING a pump after repair or maintenance,
always treat the pump as if it were A NEW PUMP being
started for the first time. Refer to Section 5.

Man06.doc - rev. 0 - nov-02

23

06 - Maintenance
& Servicing

6.2 Maintenance and Inspection schedule


Maintenance requirements may vary with the application and the service conditions.
The following guidelines are recommended for pumps operated under normal
conditions. It is also recommended to establish a Maintenance Program.
Suggested Maintenance and Inspection Schedule

Frequency

Maintenance or Inspection Procedure


Check for smoothness of operation, unusual noises or other
changes in operating conditions.

daily

Check oil level in bearing housing(s).


Add oil, if required.
Check oil temperature
Carefully inspect baseplate to detect signs of leakage
from mechanical seal.

monthly

Sample the lubricating oil and replace it, if necessary.


Check and record vibration levels.
Replace the lubricating oil

every 6 months
Check cooling jacket on bearing housings for sludge or
sediments.

Man06.doc - rev. 0 - nov-02

24

06 - Maintenance
& Servicing

6.3 Major Inspection checklist


Pompe Gabbioneta recommends that the pump be periodically shutdown and
subjected to a major inspection. The frequency of this inspection will depend on the
service conditions, the convenience of scheduling the shutdown and the users
experience with similar machines.

Parts to be inspected

Inspect for

Action required

Wear Rings

Wear, signs of foreign matters Treat with fine emery cloth

Sleeve

Wear, signs of foreign matters Treat with fine emery cloth

Antifriction bearings

Excessive radial play

Replace bearings

Hydrodynamic
bearings

Wear, scratches

Use a scraper. Do not use emery


cloth.

Mechanical seal

Scratches on mating surfaces

Relap the surfaces.

Gaskets

----------------------------------

Replace all gaskets.

6.4 Factory replacement parts


Pompe Gabbioneta recommends that only original parts be used in their pumps.The
use of Pompe Gabbioneta parts ensures that the replacement components are
manufactured from the highest quality materials, exacting tolerances and
specifications, thereby ensuring efficient and long-lasting operation, under service
conditions that the pump was built for.
warning
The use of non- original repair parts shall be considered
IMPROPER MAINTENANCE and shall VOID ALL guarantee clauses.
When required, Pompe Gabbioneta can supply the most frequently requested spare
parts on an emergency basis, for shipment worldwide.

Man06.doc - rev. 0 - nov-02

25

06 - Maintenance
& Servicing

The following is a list of recommended spare parts that should be kept in inventory
at the users plant to handle all repairs, excepted the most extensive ones :

one set of casing wear rings


one set of impeller wear rings
one shaft sleeve
one complete mechanical seal
one set of bearings
one set of gaskets
one set of O rings

The serial number, identifying the pump, should be used in all inquiries and parts
orders. The serial number is an alphanumeric code, consisting of 5 digits and 1
letter (item).
This number appears on the nameplate and is stamped on the discharge flange
O.D. of the pump casing.

Man06.doc - rev. 0 - nov-02

26

07 - Faults : causes
and remedies

7. FAULTS : CAUSES AND REMEDIES


This Section should be consulted when the pump is not operating satisfactorily.
The following table lists the most common symptoms, probable causes and
corrective actions that should be taken.
If the problem cannot be completely remedied using the table, refer your questions
to :
Pompe Gabbioneta SpA
Viale Casiraghi, 68
20099 SESTO SAN GIOVANNI (MI) - Italy
Tel: +39 02 24 1001 ; Fax: +39 02 22 47 3881
E-mail: after.sales@pompegabbioneta.com
When contacting the factory, it is of the greatest importance to provide suction and
discharge pressures, power input, rotational speed as well as electric motor data or
steam pressures, in the case of turbine driven equipment.
Symptom

Probable Cause

Corrective Action

Pump does not


deliver liquid

Pump and suction pipe have


Thoroughly vent suction pipe and pump
not been filled completely with casing.
liquid

Pump does not


deliver enough
liquid

1. Air leaks into suction pipe


2. Suction lift too high
3. Speed too low
4. Wrong
rotation

direction

5. Impeller(s) damaged
6. Worn wear rings

Check and tighten bolts on suction flange.


Replace gasket on suction flange.
Check installation against drawings
Check driver electrical or steam
connections
of Change power input cables to motor.
Check rotation arrows on turbine and
pump. If incompatible, review terms of
Purchase order.
Replace impeller(s)
Replace wear rings

Pump loses
prime after startup

7. Air or gas in liquid - see Tighten bolts on suction piping or replace


n 2 & 3
gaskets on suction line.

Insufficient
discharge
pressure

8. Viscosity too high or see Check actual liquid against pump data
n 4 & 7
sheet

Man07.doc - rev. 0 - nov-02

27

07 - Faults : causes
and remedies

Pump overloads
driver

9. Specific
gravity
or
viscosity of the pumped
liquid different from the
rated ones
10. Head
and
capacity
different from the rated
ones
11. Wrong alignment
12. Mechanical defects : bent
shaft ; internal rubbing

Check pump and motor data sheet.

Adjust discharge valve

Re-align the unit - see Section 4


Disconnect coupling and check shaft
runout. Replace shaft if runout exceeds
0.025 mm at shaft end - Refer to Section 8.
13. Packing or mech. seal Loosen packing gland bolts.
spring too tight, causing Check setting of mechanical seal.
excessive friction

Pump vibrations

14. Pump operates at too low Open valve on discharge piping


capacity
15. Misalignment
Disconnect coupling and check alignment
as per Section 4.
16. Worn bearings
Replace bearings Refer to Section 8.
17. Unbalanced coupling
Remove coupling halves and check for
unbalance.
18. Piping strain
Check piping supports. Refer to Section 4.

Bearing failure

19. Improper lubrication


20.
21.
22.
23.
24.

Seal failure

Verify that the proper lubricant is being


used.Check oil for sediments and
condensate.
Improper water cooling
Adjust water cooling to maintain oil
temperature as recommended by Section
5.
Wear or scratches in Replace sleeve bearings, drain the oil,
sleeve bearings
clean bearing housings and add new oil.
Misalignment
See Vibrations n 16
Excessive thrust
See Mechanical defects n 13
Rust
Rust may develop during improper storage
of the unit. Refer to Section 3.

25. Improper flushing of seal Check flushing line(s) for circulation of the
cavity
flushing liquid
26. Wear of the shaft sleeve
See Mechanical Defects n 13

Man07.doc - rev. 0 - nov-02

28

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

8. DISASSEMBLING AND PARTS REPLACEMENT : Bearings & Seals


8.1 Warnings / cautions
caution
DO NOT attempt to ADJUST, REPAIR, DISASSEMBLE OR MODIFY
this pump unit WHILE IT IS IN OPERATION, unless such action
is expressly described in this instruction manual

caution
NEVER DISCONNECT SUCTION OR DISCHARGE FLANGES of the
pump without first isolating the pump from the system by CLOSING
AND TAGGING BLOCK VALVES. Open connections not protected
by block valves must be covered with blind flanges.
ALL DRAINS must be opened to depressurize the pump.

caution
DO NOT remove any COVERS, GUARDS, GLAND HOUSINGS etc.
while the UNIT IS IN OPERATION.

caution
NEVER SUBSTITUTE A BOLT of unknown or lesser grade
for an original bolt supplied with the pump. DO NOT MIX BOLTS
during disassembly. Failure to use the proper grade bolt could
result in serious FAILURE of pressure containing components.

warning
MAINTENANCE PERSONNEL should be thoroughly FAMILIAR with the pump
and accessories, before attempting any maintenance or service.
A complete reading of this manual is recommended.

warning
Maintenance personnel must be aware that the USE OF NON-GENUINE
Pompe Gabbioneta parts shall VOID ALL WARRANTY clauses.

Man-08.doc - rev. 0 - nov-02

29

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

warning
When RESTARTING a pump after repair or maintenance, always treat the pump
as if it were A NEW PUMP being started for the first time. Refer to section 5.

warning
CLEANLINESS is ESSENTIAL for long, trouble-free service of
bearings and rotating components in general. Take care to ensure
that no foreign material enters bearing housings or constant level oilers,
when performing maintenance operations.

note
Before proceeding to pump disassembling, disconnect auxiliary piping,
remove instrumentation and, in general, all ancillary equipment.

Man-08.doc - rev. 0 - nov-02

30

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

8.2 General
Any pump part can be replaced in the field using instructions presented in this
section, if qualified personnel and facilities are available. If not, it is recommended to
call on a service representative from Pompe Gabbioneta to supervise the field
repairs.
Before disassembling VBN pumps, it is important to understand that the locknut
(42/16) controls the axial adjustment of the complete rotating assembly, whose total
end float is approximately 8 10 mm.
For correct operation of the pump, the rotor is normally lifted 5 6 mm from its
lowest setting.
Prior to pump disassembly, it is recommended to:
1. ensure that the pump and the barrel have been depressurized and drained
through the proper drain connections;
2. lock the setting tabs into the slot of the mechanical seal sleeve;
3. unscrew the set screws of the mechanical seal cartridge, according to the
instructions given in the Documentation Section of this manual, to loosen the
seal cartridge from the shaft;
8.3 Bearing housing - removal
VBN pumps are fitted with antifriction bearings mounted inside an oil-lubricated
bearing housing . To remove the complete bearing housing from the pump, refer to
cross section and proceed as follows:
Remove constant level oiler (50) and oil level gage (50/1);
Unscrew the screws on the upper flexible coupling;
Mark the setting of the rotating assembly, (e.g.: distance from upper coupling
flange to locknut) to facilitate reassembling.
Remove screws (28/147) and unscrew locknut (42/16) until the rotor reaches
its lowest setting. Remove the spacer from the coupling between motor and
pump.
VBN pumps with two couplings
Unscrew screws (28/27) on the lower coupling (410/5).
Unscrew screws (28/33) between bearing housing (174) and motor bracket
(26/1)
Hoist the complete bearing housing (174) with shaft (5/3) and remove it from
the pump. Lift slowly and carefully.
VBN pumps with one coupling
Using a suitable puller, remove coupling half and key (14/1).
Remove fan (228), if installed.
Remove shaft locknut (42/16) after removing screws (28/147).
Unscrew screws (28/33) between bearing housing (174) and motor bracket
(26/1).

Man-08.doc - rev. 0 - nov-02

31

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

Hoist the complete bearing housing (174) and remove it from the pump. Lift
slowly and carefully.

Alternatively, install the rig, shown in fig. 1. When specified by the Purchase Order,
this rig is supplied to facilitate removal of the complete bearing housing. Proceed as
follows:
Install pulleys (A) on the bearing housing (174) and pulleys (B) on the upper
flange of the bracket (26/1), with eye bolts (C):
Install cables (D) as shown on the figure. Using suitable pullers (not
supplied), gradually lift the housing from position to position .
Using screws (E), install bars (F) on bracket (26/1), under the bearing
housing.
Lower the bearing housing until it rests on the bars (position ').

Remove the cables and manually slide the housing to position , where it
can be hoisted and moved to the maintenance shop for disassembly.

8.3.1 Antifriction Bearing - removal

Remove plug (57/2) and drain the oil from the bearing housing.
Using a suitable puller remove coupling half and key (14/1), if not already
removed.
Remove fan (228), if installed.
Remove shaft locknut (42/16) after removing screws (28/147), if not already
done.
Remove screws (28/4) and bearing cover (38/5) with oil deflector (22/1).
Note that the angular position of the bearing cover is defined by a dowel.
Mark the position of the dowel on the bearing housing, to facilitate reassembly.
Remove distance sleeve (12/2) or anti-rotation ratchet, if installed.
Using a suitable puller remove the bearing adapter sleeve (43) and the key
(14/16) from the shaft (VBN pumps with two couplings).
To remove the bearing (25/8) from the adapter sleeve, lift the tab on
lockwase (64/5) and unscrew oil flinger(100). Remove lockwasher (64/5).
Using a suitable puller remove the bearing from the adapter.
warning
When removing or replacing antifriction bearings mounted on the adapter,
NEVER PRESS or apply force on THE OUTER RACE, as this may
damage the internal components of the bearing.
NEVER HAMMER on either the inner or outer races.

note

Man-08.doc - rev. 0 - nov-02

32

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

If the bearing BINDS during installation or removal, DETERMINE THE CAUSE


AND CORRECT it, rather than apply more force.

Man-08.doc - rev. 0 - nov-02

33

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

Fig.1

Man-08.doc - rev. 0 - nov-02

34

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

To complete the disassembling, unscrew set screws (185/5) and remove


locknut (42/4) on the lower coupling half (410/5), if installed (VBN versions
with two couplings).
Using a puller, remove coupling half (410/5) from the shaft.
Unscrew set screws (185/2) and remove oil deflector (22/2).

Bearing housing seals and oil deflectors - Options


Optionally, oil deflectors can be of the fan-type - refer to Cross Section. Removal
and installation procedures do not differ from standard types.
Lip-seals may be provided on request. In this case the oil deflector is press-fitted
onto a shaft sleeve that runs under the lip seal. Unscrew set screws and remove oil
deflector and shaft sleeve.
Inproseals are optional, non-contacting oil seals that replace standard labyrinth type
bearing housing seals. Refer to the Documentation Section at the end of this manual
for removal and installation of Inproseals.
Magnetic type bearing isolators may be installed on the bearing housings, instead of
the standard oil labyrinths. Refer to the Documentation Section of this manual for
removal and installation of these seals.
8.3.2 Antifriction bearings - replacement

Install the new bearing (25/8) on the adapter sleeve (43).


warning
HEAT THE BEARINGS prior to assembly. Bearings must be heated slowly
and evenly to a temperature NOT EXCEEDING 120 C (250 F),
using electrical heaters or an oil bath.

Replace lockwasher (64/5) and tighten oil flinger (100) according to torque
values given on Table 1. Bend the lock tab to lock the flinger into position.

8.4 Bearing housing replacement


For VBN pumps with two couplings, the bearing housing can be completely preassembled prior to the installation on the pump. Proceed as follows:
On shaft (5/3) install the bearing assembly, i.e. adapter sleeve (43) with
bearing (25/8) and oil flinger (100) with key (14/16).
Insert shaft (5/3) and bearing assembly into the bearing housing (174).
Insert the distance sleeve (12/2) or the anti-rotation ratchet, if supplied, into
the bearing housing.
Install cover (38/5) and tighten screws (28/4).

Man-08.doc - rev. 0 - nov-02

35

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

Install locknut (42/16) on the shaft, without tightening it.


Insert oil deflector (22/3) loose on the shaft.
Reinstall upper and lower coupling halves on shaft (5/3).
Mount bearing housing (174) on bracket (26/1) and tighten screws (28/33) to
the torque values given in Table 1.
Rotate locknut (42/16) to lift the upper shaft (5/3), until spacer (410/3) can be
installed between the coupling halves of the lower coupling.
Unscrew locknut (42/16) until the faces of coupling halves (410/5) and
(410/4) are in metal to metal contact with spacer (410/3).
Insert screws (28/27) and tighten them to the torque values given in Table 1.
Check the axial position of the rotating assembly and compare with previous
readings (see Section 8.2).
Insert upper coupling spacer. Rotate locknut (42/16) and lift the complete
rotating assembly until the upper coupling halves are at the specified distance
(see Documentation Section at the end of this manual). Insert screws on the
coupling and tighten them to the torque values given in Table 1.
Check that the rotating assembly has been lifted by at least 7 mm, reaching
the original setting.
Position deflector (22/2) so as to leave 1 mm axial clearance with respect to
the stationary labyrinths and tighten set screws (185/2).
Check that the rotor rotates freely.
Install screws (28/147) on locknut (42/16) and tighten them.
Tighten set screws on the mechanical seal cartridge, as specified by the seal
instruction manual and remove the settings tabs.

For VBN pumps with one coupling proceed as follows:


Install the bearing assembly, i.e. adapter sleeve (43) with bearing (25/8) and
oil flinger (100) into the bearing housing (174).
Insert the distance sleeve (12/2) or the anti-rotation ratchet, if supplied, into
the bearing housing.
Install cover (38/5) and tighten screws (28/4).
Insert oil deflector (22/3) loose on the shaft (5/2).
Insert bearing housing on shaft (5/2), seat it on bracket (26/1) and tighten
screws (28/33) to the torque values given in Table 1.
Install locknut (42/16) on the shaft, without tightening it.
Reinstall upper coupling half on the shaft with key (14/1).
Insert the coupling spacer. Rotate locknut (42/16) and lift the complete
rotating assembly until the coupling halves are at the specified distance (see
Documentation Section at the end of this manual). Insert screws and tighten
them to the torque values given in Table 1.
Check that the rotating assembly has been lifted by at least 7 mm, reaching
the original setting.
Position deflector (22/2) so as to leave 1 mm axial clearance with respect to
the stationary labyrinths and tighten set screws (185/2).
Check that the rotor rotates freely.
Install screws (28/147) on locknut (42/16) and tighten them.
Man-08.doc - rev. 0 - nov-02

36

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

Tighten set screws on the mechanical seal cartridge, as specified by the seal
instruction manual and remove the settings tabs.

8.5 Mechanical seal - removal and replacement


Perform the operations 1) and 2) and 3) outlined in Section 8.2
following:

and note the

on VBN pumps with two couplings, the mechanical seal cartridge can be
removed without removing the bearing housing. Proceed as follows:
Unscrew screws (28/27) on upper coupling half (410/5) and gradually bring
the pump rotor to its lowest setting (the total end play must be 7 to 8 mm).
Unscrew screws (28/27) on lower coupling half (410/4) and remove the
coupling spacer (410/3).
Remove screws (185/5) and unscrew locknut (42/4) on the lower coupling
half (410/4).
Using a suitable puller, remove the half coupling and the key (14/6) from the
pump shaft
The mechanical seal cartridge can now be removed according to the
instructions contained in the Mechanical seal Instruction manual - Refer to
the Documentation Section.

on VBN pumps with one coupling, the mechanical seal package can be
removed according to the instructions contained in the Mechanical seal
Instruction manual (refer to the Documentation Section), after removing the
bearing housing according to Section 8.3.

notes
All SHARP edges must be REMOVED before mounting the mechanical seal.
Care should be taken during mounting of the O rings to
prevent damages with spanners, pins etc.
The shaft or the shaft sleeve should be lightly lubricated
before installing the mechanical seal.
NO LUBRICATION is required on the FACES of the seal.
NEVER OPERATE a mechanical seal DRY, unless so required
by the mechanical seal instruction manual.
To replace the mechanical seal, follow the instructions given in the Documentation
Section of this manual and reassemble the pump in reverse sequence, i.e.:

Man-08.doc - rev. 0 - nov-02

37

08 - Disassembling &
Parts replacement
VBN pumps
Bearings & seals

Check the concentricity and perpendicularity of seal chamber with pump


shaft axis (see points 2.7.3.11 2.7.3.13 of API 610 8th Ed.).
tighten the screws on the seal gland;
Install coupling halves and spacer. By tightening screws (28/27) on upper
coupling half the complete rotor is lifted to reach its original setting.
tighten the set screws on the seal sleeve;
remove setting tabs.

Man-08.doc - rev. 0 - nov-02

38

09 - Inner Parts
replacement
VBN Pumps

9. VBN PUMPS : INNER PARTS REPLACEMENT


Pompe Gabbioneta VBN pumps are vertical multistage pumps, normally supplied
with a suction barrel for volatile or hazardous liquids.
Pump column and line shaft may be split in multiple sections, depending upon the
pump setting, specified on the Data Sheet.
Pump casings are of the diffuser type to minimize radial loads. Impellers are of the
closed type, with front and rear wear rings, to minimize axial thrust. If specified by
the Purchase Order, the first stage impeller may be of the double suction type for
minimum suction barrel length.
9.1 Pump disassembly
To remove the pump, remove motor and supporting bracket, then perform the
operations outlined in Section 8.2. Disconnect suction and discharge flanges and:
Remove nuts from stud bolts (36/9).
Hoist pump discharge head (26) and lift the complete pump out of the suction
barrel (or sump). Proceed slowly and carefully.
Lay the pump horizontally and start disassembly from the suction end.
Remove the suction strainer (11), if any.
VBN pumps with single suction 1st stage
Unscrew nuts on stud bolts (36/68) and remove suction casing (3) with
bearing bushing (147/2). This bushing is shrink fitted into the casing. It can
be removed by pressing it out with a washer of suitable diameter.
VBN-DS pumps with double suction 1st stage
Unscrew screws (28) and remove lower suction casing (3) with bearing
bushing (147/2). This bushing is shrink fitted into the casing. It can be
removed by pressing it out with a washer of suitable diameter.
Proceed as follows:
Remove circlip (20/8) and pull sleeve (87/1) off the shaft. Remove key (14/4).
Unscrew locknut (42/9).
note
Identify FIRST STAGE impeller, before removing it from the pump.
This will facilitate reassembling.

Remove split ring (102/1), impeller (6/1) and key (14).

Man09.doc - rev. 0 - nov-02

39

09 - Inner Parts
replacement
VBN Pumps

warning
The impellers are secured to the shaft with a sliding fit and a key.
Separation of the impellers from the shaft may require a puller,
due to the presence of crusts or scales.
DO NOT apply HEAT to ease removal of impellers or sleeves.

Unscrew nuts on stud bolts (36/6) and remove casing (1).


Bearing bushing (147) can be removed from casing by pressing it out.
Proceed until all impellers and casings have been removed. During pump
disassembly, the shaft must be accurately supported to prevent bending.
Remove sleeve (87) from the shaft.
Inspect impeller wear rings for wear or scoring.
Inspect the casing wear rings for wear or scoring.
Replace wear rings when the clearance between stationary and rotating parts
has doubled with respect to the value indicated on the data sheet.
Inspect the pump shaft for scoring or corrosion. Shaft and shaft sleeves
should not be corroded nor oxidized. In case of corrosion, replace the part.

To complete column and shaft disassembly, proceed from the opposite end, i.e. from
the discharge end of the pump.

Unscrew nuts on stud bolts (36/6) and separate the discharge head from the
column.
Unscrew nuts on bolts (54/34) and remove columns (151/1), (151/2) etc.
Unscrew set screw (185/6) on shaft coupling (410/6) and slide the coupling
along the shaft until split rings (20/4) can be removed.
Remove keys (14/21).

Bushing (147/1) can be removed from the carrier inside the column, by pressing it
out.
Shaft sleeve (87/3) can be removed after removing circlips (20).
9.2 Wear rings - removal and replacement
Impeller and casing wear rings can be removed using a suitable puller, after removal
of the set screws.
Replacement of wear rings requires drilling and tapping of new holes for the set
screws.
note
After replacement of the wear rings,
impeller re-balancing is required. Refer to section 9.3

Man09.doc - rev. 0 - nov-02

40

09 - Inner Parts
replacement
VBN Pumps

9.3 Balancing
Impellers of VBN pumps shall be dynamically balanced to the unbalance limit
specified by the applicable standard , i.e. ISO 1940 Grade 1.0.
Before proceeding to the balancing, calculate the residual admissible weight with the
formula:

where:
p =residual admissible weight
Pe
P =impeller weight
p
r r =impeller radius where material is removed
e =residual admissible eccentricity of the
center of gravity (C.G.)

grams
kg
mm
m

The value of e is given by a diagram and can be found in the following table for the
most commonly used rotational speeds.
rotational speed

(rpm)

1450

1750

2950

3550

6.3

5.6

3.15

2.8

e = residual admissible eccentricity of C.G. (m)

Balance each impeller by removing some material from the discs, at radius r, by
milling or grinding.
9.4 Rotor replacement
From the discharge end of the pump, reinstall column and shaft sections as
previously described, in reverse sequence.
From the suction end of the pump proceed as follows:

Install circlip (20/11), coat the shaft with light oil and install shaft sleeve
(87/20).
Coat sleeve (87/20) with light oil and install bearing bushing carrier (254).
Tighten nuts on stud bolts (36/6). torque as per Table 1.
Install split ring (102), impeller key (14) and impeller (6).
Complete pump reassembling in reverse sequence, lift the pump and install
it into the suction barrel (or sump).
Tighten nuts on stud bolts (36/9) - torque as per Table 1.

Man09.doc - rev. 0 - nov-02

41

09 - Inner Parts
replacement
VBN Pumps

note
Correct tightening brings COVER (26) IN CONTACT with suction barrel flange.
Using a feeler gauge, check metal-to-metal contact
between cover and flange of the suction barrel at various angular positions on the
cover outer diameter.
Install mechanical seal gland and seal cartridge as per instructions given in the
Documentation Section of this manual.
Complete pump reassembling as per Section 8, in reverse sequence.

Table 1 :

Recommended Bolt Torque


(Nm)

Bolt Size
(mm)
M6x1
M8x1.25
M10x1.5
M12x1.75
M16x2
M20x2.5
M24x3
M30x3
M36x3
M42x3
M48x3
M48x2

Man09.doc - rev. 0 - nov-02

Bolt Material
(inch)

1/4 x 20 UNC
5/16 x 18 UNC
3/8 x 16 UNC
1/2 x 13 UNC
5/8 x 11 UNC
3/4 x 10 UNC
1 x 8 UNC
1 x 8 UN
1 x 8 UN
1 x 8 UN
2 x 8 UN
2 x 12 UN

A 307 A
A 193 B8
A 193 B8M
5
10
20
30
100
140
350
700
1100
2000
3000

A 193 B7
7
15
30
45
150
210
520
1050
1650
3000
4500
6000

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Table 2 :

Minimum Running Clearances

Diameter of Rotating Member at Clearances


(mm)
< 50
50 to 64.99
65 to 79.99
80 to 89.99
90 to 99.99
100 to 114.99
115 to 124.99
125 to 149.99
150 to 174.99
175 to 199.99
200 to 224.99
225 to 249.99
250 to 274.99
275 to 299.99
300 to 324.99
325 to 349.99
350 to 374.99
375 to 399.99
400 to 424.99
425 to 449.99

Man09.doc - rev. 0 - nov-02

Minimum Diametral Clearance


(mm)
0.25
0.28
0.30
0.33
0.35
0.38
0.40
0.43
0.45
0.48
0.50
0.53
0.55
0.58
0.60
0.63
0.65
0.68
0.70
0.73

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Attachment 1:

Man09.doc - rev. 0 - nov-02

VBN Cross Section

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VBN Pumps

Attachment 2:

Man09.doc - rev. 0 - nov-02

VBN-DS Cross Section

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