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UNIGLIDE

INSTALLATION
&
MAINTENANCE
MANUAL

Weir-EnviroTech (Pty) Limited is the owner of the Copyright subsisting


in this Manual. The Manual may not be reproduced or copied in whole
or in part in any form or by any means without the prior consent in
writing of Weir-EnviroTech (Pty) Limited

DE-MAN-0008
Rev. 2

Approval Signature: .

Approval Date:

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CONTACT DETAILS
For any enquiries regarding the Uniglide Pump Range
contact any one of the following Head Office numbers:

Unit Sales Queries: (011) 929-2821


Aftermarket Queries: (011) 929-2732
Technical Queries: (011) 929-2718
e-mail address: weplpump@weir-envirotech.co.za

or write to us at:

Weir-EnviroTech (Pty) Limited, PO Box 70, Isando, 1600


31 Isando Road, Isando, 1601

Please provide the following information when contacting us:

Model and Size of Pump


Serial Number
Approximate date of purchase
Detail of enquiry, apparent faults

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SAFETY WARNING
For the purpose of definition in this manual, a warning gives information which, if ignored, could
lead to the serious injury of personnel. A caution gives information which, if ignored, could
cause serious damage to the pump or associated equipment.

The WEIR-ENVIROTECH PUMP is a ROTATING MACHINE OPERATING UNDER


PRESSURE..All standard safety precautions for such equipment should be followed before and
during installation, operation and maintenance.

For AUXILIARY EQUIPMENT (motors, belt drives, couplings, gear reducers, variable speed
drives etc) standard safety precautions should be followed and appropriate instruction manuals
consulted before and during installation, operation and maintenance.

DRIVER ROTATION MUST BE CHECKED before belts or couplings are connected. Personnel
injury and damage could result from operating the pump in the wrong direction.

DO NOT OPERATE THE PUMP AT LOW OR ZERO FLOW CONDITIONS FOR PROLONGED
PERIODS, OR UNDER ANY CIRCUMSTANCES THAT COULD CAUSE THE PUMPING
LIQUID TO VAPORISE. Personnel injury and equipment damage could result from the
pressure created.

DO NOT APPLY HEAT TO IMPELLER BOSS OR NOSE in an effort to loosen the impeller
thread prior to impeller removal. Personnel injury and equipment damage could result from the
impeller shattering or exploding when the heat is applied.

DO NOT FEED VERY HOT OR VERY COLD LIQUID into a pump which is at ambient
temperature. Thermal shock may cause the pump casing to crack.

FOR THE SAFETY OF OPERATING PERSONNEL, please note that the information supplied
in this Manual only applies to the fitting of genuine Weir-EnviroTech parts and Weir-EnviroTech
recommended bearing to Weir-EnviroTech pumps.

For your own personal safety, read and take note of the following:

Hazardous Areas These are the areas of the impeller and drive motor shafts, direct
drive couplings and drive belts. Under normal operating conditions
these areas are enclosed by safety covers / guards. Pump intake
and discharge ports, when open, are also hazardous areas. Never
insert your hand in either of these port openings without first ensuring
that the pump drive has been isolated.

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Lifting a Pump Make sure that all slings, shackles, etc are of adequate load carrying
strength for the pump being lifted.

Operating a Pump Ensure that all safety covers / guards are in position and securely
fitted.

Do not wear loose clothing when working in close proximity of


rotating parts.

Never allow water / slurry to rise above the top of the mounting plate.

Maintaining a Pump FULLY ISOLATE THE PUMP before any maintenance, inspection or
troubleshooting involving work on sections which are potentially
pressurised (e.g. casing, gland, connected pipework) or involving
work on the mechanical drive system (e.g. shaft, bearing assembly,
coupling):-
Power to the electric motor must be isolated and tagged out.
It must be problem that the intake and discharge openings are totally
isolated from all potentially pressurised connections and that they are
and can only be exposed to atmospheric pressure.

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TABLE OF CONTENTS
CONTACT DETAILS................................................................................................................................................................. 2
SAFETY WARNING .................................................................................................................................................................. 3
SECTION A ................................................................................................................................................................................. 7
PROCEDURES PRIOR TO INSTALLATION........................................................................................................................ 7
1. General......................................................................................................................................................................... 7
2. Inspection of Equipment............................................................................................................................................... 7
3. Storage ......................................................................................................................................................................... 7
4. Cleaning Prior to Installation ...................................................................................................................................... 7
5. Lay-Out of Pump Parts for Installation........................................................................................................................ 8
SECTION B.................................................................................................................................................................................. 9
FOUNDATION AND BEDPLATE ............................................................................................................................................ 9
1. General......................................................................................................................................................................... 9
2. Pumpset Foundation .................................................................................................................................................... 9
3. Grouting ....................................................................................................................................................................... 9
4. Levelling of Bedplate.................................................................................................................................................. 10
SECTION C ............................................................................................................................................................................... 12
LINING UP AND COUPLING ................................................................................................................................................ 12
1. Initial Checks ............................................................................................................................................................. 12
2. Lining up Pump and Driver ....................................................................................................................................... 12
3. Final Coupling ........................................................................................................................................................... 12
SECTION D ............................................................................................................................................................................... 15
PIPEWORK INSTALLATION................................................................................................................................................ 15
1. General....................................................................................................................................................................... 15
2. Suction Pipework ....................................................................................................................................................... 15
3. Delivery Pipework...................................................................................................................................................... 16
SECTION E................................................................................................................................................................................ 17
OPERATION ............................................................................................................................................................................. 17
1. General....................................................................................................................................................................... 17
2. Priming....................................................................................................................................................................... 17
3. Starting....................................................................................................................................................................... 17
4. Stopping ..................................................................................................................................................................... 18
SECTION F................................................................................................................................................................................ 19
ROUTINE MAINTENANCE ................................................................................................................................................... 19
SECTION G ............................................................................................................................................................................... 24
BEARINGS ................................................................................................................................................................................ 24
1. Introduction................................................................................................................................................................ 24
2. Ball and Roller Bearings............................................................................................................................................ 24
3. Plain Bearings............................................................................................................................................................ 27
SECTION H ............................................................................................................................................................................... 30
PACKED GLAND ..................................................................................................................................................................... 30
1. Gland.......................................................................................................................................................................... 30
2. Packing....................................................................................................................................................................... 30
SECTION I................................................................................................................................................................................. 32
DISMANTLING ........................................................................................................................................................................ 32

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1. PREPARATION PRIOR TO DISMANTLING ............................................................................................................ 32
2. DISMANTLING.......................................................................................................................................................... 32
3. DISMANTLING (Pump with Crane 1A Mechanical Seal) ......................................................................................... 33
4. PUMP RUNNING CLEARANCES ............................................................................................................................. 34
SECTION J ................................................................................................................................................................................ 36
ASSEMBLING........................................................................................................................................................................... 36
1. PUMP WITH PACKED GLAND ............................................................................................................................... 36
2. PUMP WITH CRANE 1A MECHANICAL ................................................................................................................. 37
3. FINAL CONNECTION............................................................................................................................................... 38
SECTION K ............................................................................................................................................................................... 39
LUBRICATION SCHEDULE.................................................................................................................................................. 39

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Section A
PROCEDURES PRIOR TO INSTALLATION

1. General

1.1 Although various methods of installing Weir-EnviroTech pumps can be adopted,


the instructions detailed in this manual and in associated Data Sheets are to be
followed. Any departure from the procedures detailed must be based on good
engineering practice.

2. Inspection of Equipment

2.1 Immediately on receipt of the equipment, inspect and check it against the Weir-
EnviroTech advice note. Examine the crate and wrapping before discarding them,
since parts or accessories are sometimes wrapped individually or fastened to the
crate.

2.2 Report any damage or shortages to Weir-EnviroTech and the carrier immediately.
All claims must be made (or confirmed) in writing.

2.3 If the equipment is not being installed immediately, it must be stored under suitable
conditions.

3. Storage

3.1 Short Term - when it is necessary to store a pump for a short


time before it is installed, place it in a dry location
where it cannot be affected by moisture.
Protective blanking plates, fitted before despatch
from the factory, are not to be removed.

3.2 Ensure that the bearings and couplings are properly protected against the ingress of
sand, grit and other foreign matter. To prevent rusting-in or seizing, lubricate the unit
before storing (refer to DS 100 100). Turn the pumpset by hand at least once a week.

3.3 Long Term- more thorough precautions are required if the


pump is to be stored for an extended period of
time. Refer to Weir-EnviroTech for full
information on long term storage.

4. Cleaning Prior to Installation

All parts of the assembly must be thoroughly cleaned before installation begins. All
traces of rust preventative must be removed from the discharge and suction flange faces,
exposed shafting, and all coupling surfaces.

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5. Lay-Out of Pump Parts for Installation

5.1 Avoid damage to components when handling or installing them.

5.2 If suitable lifting tackle is not available, skids must be employed to transfer heavy
weights to ground level. Loaded crates or individual components or sub-
assemblies must never be dropped to the ground from a transport vehicle.

5.3 Lay out individual components on suitable timbers or other clean surfaces in the
order in which they will be fitted. Check the components against the packing list to
ensure that all are available.

5.4 Any packing or other protective material must be removed before starting the
installation procedure.

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Section B
FOUNDATION AND BEDPLATE

1. General

1.1 Hydraulic and/or electrical plant is usually assembled on a single bedplate. The
bedplate may, however, be supplied in two or more sections.

1.2 To facilitate leveling and grouting, all components should preferably be removed
from the bedplates (refer to "NOTE" following paragraph 4 (2)).

1.3 The bedplates are of fabricated steel channel type construction and very robust
but nevertheless must be properly handled during transport and at site to avoid
undue distortion. To ensure satisfactory operation of the plant it is essential that
the bedplate be properly levelled, bolted down and grouted in.

1.4 The following instructions will ensure satisfactory installation and eliminate trouble
due to misalignment.

2. Pumpset Foundation

2.1 An adequate foundation is essential. It should consist of a solid block of concrete


brickwork or masonry sufficiently massive and rigid to provide continuous support
for the bedplate throughout its whole length, and to maintain this support
throughout the operating life of the equipment.

2.2 The foundation should be kept 25 mm low to allow for levelling of the bedplate(s)
and foundation bolt holes prepared to accommodate the bolts. Each hole is to be
either 100 mm dia. if drilled, or 100 mm square if shuttered.

3. Grouting

3.1 The main reasons for grouting are to prevent lateral movement of the bedplate(s),
to support the channel flanges which, in turn, carry the machined pads and to
reduce vibration. Grout should comprise one part Portland Cement and two parts
sand (no aggregate) with sufficient water to produce a free flowing heavy creamy
consistency. The mixture described should flow easily under the bedplate(s) and,
in order to minimise settlement, it is best to mix the grout and let it stand for two
hours, re-mixing it thoroughly before use but adding no more water.

3.2 The exposed surfaces should be covered with hessian to prevent the grout
cracking by too rapid drying. The hessian should be kept damp until the grout is
sufficiently set (about 48 hours)

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4. Levelling of Bedplate

4.1 Set up and level steel packers adjacent to and on each side of the foundation bolt
holes to within 6 mm of the final height of the bottom of the bedplate pad. Follow this
procedure round the plinth with packers each side of each hole embedding them in
concrete, preferably quick setting compound.

4.2 Sling and lift the bedplate and insert the foundation bolts in bedplate before
positioning the bedplate on the plinth. Align and level to correct height using
laminated packers on top of the packers already set, as in paragraph 4.1.

NOTE: In the case of smaller size bedplate, provided it has been checked to
ensure that no distortion has occurred during transit or handling, it is
acceptable practice to grout the bedplate with pump and motor
mounted thereon together with the foundation bolts in one operation.
Certain contracts may require special instructions in this regard in
which case the Contract Documents are to be consulted.

4.3 The foundation bolts are to be grouted at this stage and each pocket filled with grout
to within 25 mm of the top, thus providing a key for the final grouting of the bedplate.
The bedplate is to be left in position until the grout has set hard (normally 72
hours).

5 After foundation bolts are set an accurate spirit level and steel straight edge should be laid
on the various machined pads on the bedplate to check parallel and diagonal levels and the
amount of packing beneath the adjusted bedplate until all corresponding pads are level. A
degree of level of 0.1 mm per 1000 mm length of bedplate is acceptable. To obtain this
level, should the bedplate have been distorted to any appreciable extent in transit, it may be
necessary to adjust packing under bedplate and tighten certain of the foundation bolt nuts to
strain the bedplate down at certain points. It is for this reason that the foundation bolts are
grouted in first. It should be remembered that when an adjustment is made the level in
another direction will change.

6 After levelling and alignment is completed and all foundation bolts pulled down tightly,
preparation for grouting the bedplate can commence. Shuttering should be erected all round
the bedplate to a height of at least 75 mm above the lower flange of the channel to give a
slight head on the grout, thus the boarding should normally be 100 mm - 115 mm high. The
shuttering should be positioned such that when it is removed a rectangular section of grout
75 mm x 50 mm wide should remain around the outside of the bedplate.

7 Saturate the top of the rough foundation with water and pour the grout between the
shuttering and the bedplate until it passes beneath the lower flanges, so that when hardened
it supports these by rising about 50 mm above the lower flanges. The flow should be
assisted by agitating with a bent wire (or similar) from all sides and from the centre of the
bedplate.

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NOTE: It is important that the grout fills the cavity between the lower flanges and the
foundation and must not shrink from the bedplate after curing.

8 When the grout is set, (normally about 48 hours), the shuttering should be removed and a
smooth finish given to grout and foundation surfaces.

9 Direct Coupling

Instructions for coupling alignment are contained in DS 000 030.

10 In the case of the coupling being of a special type the manufacturer's instructions should be
referred to.

11 Dowel pins, fitted after the machine is correctly aligned and bolted down, are intended to
facilitate correct re-allocation of the machine if it is removed and replaced at any time.
Doweling is done at the time of installation.

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Section C
LINING UP AND COUPLING

1. Initial Checks

1.1 All bearings should be examined for any signs of ingress of cement, dust, grit, dirt
or mechanical damage. If necessary, ball and roller or oil filled bearings should be
cleaned and re-greased or refilled with oil in accordance with instructions in DS
100 080.

1.2 Turn the pump half coupling to ensure that the pump rotating assembly is quite
free and that no distortion or damage has occurred in transit.

NOTE: In the case of a multistage pump with a balance disc, ensure that
before rotating the shaft, the balance disc is clear of its mating
renewable plate face to avoid galling.

1.3 Check that the drive rotor is free to turn.

2. Lining up Pump and Driver

2.1 Mount the pump on the bedplate, care being taken to ensure that the feet of the
pump and bedplate pads are perfectly clean and free from burrs. Locate the
pump by means of dowel pins and holding down bolts. Tighten holding down
bolts.

2.2 The faces and periphery of the half couplings should be cleaned thoroughly to
ensure that all rough or ragged edges are removed, as these would give false
alignment readings.

2.3 Place the driver and/or gear box on the bedplate, having checked that the feet are
perfectly clean and free from burrs, and insert the holding down bolts but do not
tighten up. Check height of the pump and driver and/or gear box couplings and
insert shims (which must be clean and free from oil or burrs) under the driver
and/or gear box feet to obtain initial approximate coupling alignment.

3. Final Coupling

3.1 When running, the half couplings should be separated by a gap dependent upon
the type being used and this distance should be confirmed from the general
arrangement drawing.

NOTE: If a motor is fitted with sleeve type bearings the coupling gap must
be set with motor rotor in its magnetic centre. Most motors have the
magnetic centre marked, but for further details consult the motor
instruction manual.

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3.2 Where dial gauges are available to check coupling alignment follow the procedure
given in (b) overleaf. Where these instruments are not available, the procedure in
(a) may be used.

3.2.1 Lay a straight edge across the rims or hub tops of the two half couplings
and check radial alignment at quarter positions. Both couplings should be
rotated and readings checked at quarter positions. Check the radial gap as
shown, again at quarter positions and rotating both couplings.

REFER DS [100 031] Figure 1

Any repositioning of the motor to correct for redial misalignment must be


followed by a further check on gap clearance which should be carried out
again at four points, at 90 to each other using either a taper or a parallel
gauge in conjunction with feelers.

REFER DS [100 031] Figure 2

3.2.2 Parallel Alignment

3.2.2.1 Clamp a dial gauge to the coupling halves as shown in Figure 4


and zero the gauge.

3.2.2.2 Link the coupling halves so that both shafts can be rotated
together. If the shafts cannot be linked together, mark each
coupling half with a coincident line.

3.2.2.3 Rotate both shafts and take readings at each quarter revolution.
If the shafts are not linked together, move first one shaft through
a quarter revolution, then move the other until the lines marked in
paragraph 2 coincide. Take a reading and repeat at each quarter
revolution.

REFER DS [100 031] Figure 3 and 4

3.2.3 Angular Alignment

3.2.3.1 Clamp two dial gauges to the coupling halves as shown in Figure
6 and zero the gauges.

3.2.3.2 Link the coupling halves or mark them as described in paragraph


3.2.2.2 above.

3.2.3.3 Rotate both shafts through 180 and note the gauge readings. If
both gauges are the same (but not necessarily zero), the angular
alignment in the vertical plane is correct.

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3.2.3.4 Rotate both shafts through a further 90 and note the gauge
readings. If the readings are the same (but not necessarily zero),
the angular alignment in the horizontal plane is correct.

3.3 Once final alignment is complete, the driver and/or gear unit feet should be tightened
down and the alignment rechecked.

Check the coupling alignment after the pumpset has been running for a period of
4 - 6 weeks (or until settlement of foundations is completed), then fit dowel pins to
driver feet.

NOTE: i) Where possible, couplings should be aligned within


0.025 mm i.e. 0.050 mm full indicator movement on dial
gauge.

ii) It must be emphasized that, since pin and bush type


couplings are designed to reduce the transmission of shock a
earings, etc, and do not compensate for misalignment, they
require the same accuracy of alignment as rigid couplings.

iii) Some couplings, notable double engagement gear type,


laminated metal element spacer type and rubber tyre type
couplings, can operate satisfactory with a greater degree of
misalignment. The greater flexibility of these couplings is
intended to compensate for misalignment which may develop
during operation, due to pipework loads, settlement of
foundations, etc and does not preclude the need for accurate
initial alignment. For procedure to be followed when aligning
these couplings, see separate instructions supplied by
manufacturer.

iv) Alignment procedures for electric motors depend on motor


construction. Motors with end shield mounted bearings can
be aligned by moving the complete machine. This will not
upset air gaps. Motors with bedplate mounted pedestal
bearings are aligned by moving bearing pedestals. This will
alter motor air gaps, and stator must then be moved to
equalise air gaps. Check air gaps at 12, 3, 6 and 9 o'clock
positions, making measurements at both ends. Turn rotor
through 180 and repeat measurements. No measured air
gap should differ from the mean of the measured air gaps by
more than 5%.

v) When checking the direction of the motor rotation, ensure that


the pump has been disconnected from it source of power, i.e.
disconnect coupling/belt drive as appropriate.

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Section D
PIPEWORK INSTALLATION

1. General

It is essential that no load be imposed on the pump branches as this is liable to disturb
shaft and bearing alignment resulting in excessive wear and possibly seizure. The
pipework should, therefore, be independently supported and anchored against the pipe
thrusts. When erecting the pipework, the pump flanges should be the final closure joints.
Check coupling alignment before and after the pump flanges have been tightened. Any
alteration in alignment is indicative of pipework loading on the pump branches and steps
must be taken to remove the load.

2. Suction Pipework

2.1 Where possible arrange for the pump to operate on a positive suction.

2.2 Eliminate all possibility of air pockets being trapped in the suction pipework e.g.
ensure pipework rises continuously towards the pump and where pipe diameter is
reduced in direction of flow, use flat topped taper pieces.

2.3 The diameter of the suction pipe should be sized according to the flow and a
llowable head loss and may not, therefore, be the same diameter at the pump
suction branch.

2.4 A short straight length of pipe adjacent to the pump suction branch is desirable.
Where a bend is unavoidable, it should be of the largest possible radius.

2.5 The suction pipe should be accessible and not embedded in concrete.

2.6 When choosing foot valves, strainers, bends, etc select those which will provide
minimal restriction to flow.

2.7 Some care must be taken in the design of the suction inlet. Ideally the pipe end
should be at a depth of at least 5 pipe diameters below the surface, and at least
0.5 m from any side wall. If the pipe must be at a depth significantly less than this,
it is recommended that it be positioned within 150 mm of the side wall to reduce
the possibility of vortex formation.

2.8 Consult Weir-EnviroTech or nearest Agent, if in doubt.

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3. Delivery Pipework

3.1 It is essential to ensure that delivery pipework is adequately supported and


anchored to resist hydraulic thrust.

3.2 When selecting valves for delivery pipework the following points should be noted:

3.2.1 the diameter of the valve is not necessarily based on the diameter of the
pipework and is dependent on flow.

3.2.2 non-return valves should be sized to give maximum flow velocity of 3 m/s.

Where a surge vessel is fitted to the pipeline or pumps operate in parallel,


consideration should be given to fitting non-slam type non-return valves.

3.3 Where delivery pipes do not rise continuously and air pockets can form, it is important
to provide some form of air release valve.

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Section E
OPERATION

1. General

The following procedure outlines the most important steps involved in pump operation.
Any departure from this procedure must be based on good engineering practice.

2. Priming

2.1 Priming a centrifugal pump involves the removal of air, gas or vapour from the
suction pipework and pump casing. As centrifugal pumps are not self-priming,
they must be primed prior to start up. If this is not done the pump will not operate,
and in addition serious damage to water lubricated bushes could result.

2.2 The simplest method of priming is to arrange the pump so that it has a positive
suction pressure. The air can then be released by opening the air cock provided.

2.3 Where a positive suction is not possible, it is normal practice to fit a foot valve and
strainer to the suction pipe inlet and use one of the following methods of priming.

2.3.1 back priming from the delivery using a by-pass round the non-return valve.
It is important to ensure that the suction pipework and valves are rated for
the delivery pressure.

2.3.2 using a tundish fitted at the highest point on the pump casing fill the pump
and suction pipework using an external water supply.

2.3.3 Vacuum priming equipment such as an air or water operated ejector (jet
pump) or a rotary exhauster can be used to draw water from the suction
into the pump casing.

2.4 In a new system the pump should stay fully primed from shut down to start-up,
making further action unnecessary. However, foot valves are liable to wear or jam
and may lose the prime after a short period. It is advisable, therefore, to check
state of prime before start-up.

CAUTION: IT IS IMPORTANT that air does not leak into the pump during
operation, as even if the pump operates under such conditions,
serious damage may result.

3. Starting

3.1 Before initial start-up, disconnect the drive coupling and check the rotation of the
driver. An arrow on the pump casing indicates the correct direction of rotation.

3.2 Check the pump shaft for freedom of rotation.

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3.3 Where external sealing water is to be provided, check that the supply is available at
the specified pressure (normally 0.6 / 1.0 bar above pump suction pressure).

3.4 Ensure pump and suction pipe are correctly primed.

3.5 Ensure suction isolating valve (if fitted) is fully open.

3.6 Ensure delivery isolating valve is closed.

NOTE: Where starting conditions have been checked the pump may be
started with an open delivery valve.

3.7 Where a surge vessel is fitted in the pipeline check that the air volume is correct.

3.8 Start the driving unit according to the manufacturer's instructions.

3.9 Open the pump delivery valve slowly until the required pressure or flow is obtained.

CAUTION: i) Prolonged running with a closed delivery valve


can damage pump internal components and must be avoided.

ii) If the delivery pressure does not build up, stop the pump and
repeat the priming operation.

4. Stopping

4.1 Slowly close the delivery valve and shut down driving unit according to
manufacturer's instructions.

4.2 Shut off external sealing water supply (if fitted) to relieve stuffing box pressure and
minimize wastage.

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Section F
ROUTINE MAINTENANCE

Routine maintenance and servicing are essential to maintain the plant in a serviceable
condition.

A high degree of cleanliness of the equipment and surrounding area should be maintained as
this will assist in the detection of minor defects, which, if no action was taken, could lead to
more serious defects.

The main factors in determining if overhaul is required are a falling off in the pump flow or
discharge pressure due to an unsatisfactory level or a significant increase in power
consumption.

Depending on operation and environmental conditions, together with a comparison of previous


inspections, the frequency of inspections can be altered to maintain satisfactory operation of the
plant to suit established operating routines. The checks and inspection carried out during the
running-in period will often establish the frequency of future inspections.

The following schedule includes checks applicable to various pump types and gives the
recommended inspections and periods at which they should be carried out.

Where a contract involves a sub-contractor's associated equipment it is imperative that their


instructions are read so that fully comprehensive routines, maintenance and inspection
schedules can be set up to cover all items of plant installed.

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Daily Weekly Monthly 3 Monthly 6 Monthly Yearly Remarks
Check for leaks Extend to weekly of proved satisfactory during running
* * * * * *
in.
Check bearing temperature Extend to weekly if proved satisfactory during running
* * * * * *
in.
Check cooling and lubricating water flows Checks can be made at flow indicators, drain boxes
* * * * * * and tundishes. Extend to weekly if proved satisfactory
during running in.
Check for vibration Extend to weekly if proved satisfactory during running
* * * * * *
in.
Check balance wear indicator Extend to weekly if proved satisfactory during running
* * * * * *
in.
Check that gland drains are clear * Depending on environmental condition
Adjust glands as necessary to maintain slight Extend to 2 weekly if satisfactorily
*
leakage
Clean filter by turning handle (single filter) * Extend depending on quality of water
Change over filters, clean out dirty filters (duplex Refer to sub-contract instructions
*
filters)
Check oil level, top up as required (ring oiled & To be carried out when stationery, except where
*
thrust bearings) running levels are marked.
Check surge tank water levels (manual only) Extended from running in period. (Refer to
*
maintenance instructions)
Clean and recharge ball/roller bearings with grease To be carried out - 3 months after commissioning, then
* *
yearly: refer to maintenance instructions
Lubricate ball/roller bearings * Add only small account of grease
Examine gland/renew packing if gland follower fully Refer to maintenance instructions. Frequency can be
*
up changed depending on findings.
Check coupling alignment (horizontal pumpsets) * Illustration (DS 100 031)
Check holding down bolts for tightness * Check at end of running in period, then as shown.
Lubricate gear couplings * Refer to maintenance instructions
Renew oil in bearings *
OVERHAUL This to be determined by decrease in pump discharge pressure to an unacceptable level.
Refer to maintenance instructions.

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FAULT FINDING

TROUBLE SYMPTOMS
CENTRIFUGAL PUMP - TROUBLE CHECK LIST 1

Pump requires excessive power


Insufficient pressure developed

Pump loses prime after starting


Use this list when operating and maintaining centrifugal pumps.

Insufficient capacity delivered

Hammering in long pipe lines


The "trouble symptoms" and "possible causes" will provide a

Pump overheats or seizes


guide to necessary action during operation or at periods of routine

Pump vibrates or is noisy

Bearings have short life


maintenance.

Pump does not deliver


NOTE: It is advisable to investigate possible hydraulic electrical,

Delivery unstable
application or installation causes of trouble before dismantling
pump. Refer Check List 2 for possible mechanical faults.

POSSIBLE CAUSES

Pump not primed * * * *


Suction lift too high * * * *
Foot-valve too small * *
Foot-valve partially clogged * *
Suction inlet pipe insufficiently submerged * * * *
Excessive pipe thrust on pump *
Operation at very low flows * *
Parallel operation unsuitable for pumps * * * * * *
Pump or suction pipe not completely filled * * * *
Insufficient margin between suction and vapour pressure * *
Excessive air or gas in liquid * * * *
Air pockets in suction line * * *
Air leakage into suction line * *
Air leakage into pump through stuffing box * *
Speed too low * * *
Speed too high *
Wrong direction of rotation * * *
Head higher than pump design * * * *
Head lower than pump design *
Specific gravity of liquid different to design duty * *
Viscosity of liquid differs from pump design duty * * *
Hump in suction line *
Leakage foot-valve, suction pipe or gland * * *
Pump operating on unstable part of H/Q curve * *
Change in electrical supply to motor *
Sudden change in liquid velocity *
Pressure gauges wrongly situated, or not properly vented *
Rapid pump start-up *
Sudden closure of air release valves in delivery pipe *
Non-return valve slam on shut down *
Pump operating at flow different from design duty *
Pump seal pipe plugged *

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TROUBLE SYMPTOMS
CENTRIFUGAL PUMP - TROUBLE CHECK LIST 2

Pump requires excessive power


Insufficient pressure developed

Pump loses prime after starting


Mechanical seal has short life

Insufficient capacity delivered


Stuffing box leak excessive
Pump overheats or seizes
Pump vibrates or is noisy

Bearings have short life

Pump does not deliver


Packing has short life
Coupling failure
POSSIBLE CAUSES

Excessive misalignment, between pump & drive unit * * * * * * * *


Coupling pins or bushes faulty or all not fitted * *
Coupling (gear-type) not greased *
Coupling (H-S) screws not torqued up properly *
Rotating element out of balance * * * * * *
Shaft running off-centre * * * * * *
Shaft bent * * * * * *
Misalignment of rotating element in casing * * *
Excessive hydraulic or mechanical thrust * * *
Impeller blocked or damaged * * * * * *
Bearings worn * * *
Dirt in bearing * *
Excessive grease or oil in bearing * * *
Lack of bearing lubrication * *
Lack of bearing cooling * * *
Condensation in bearing housing (excessive cooling) * *
Bearing rusting due to water ingress * *
Bearing improperly installed * *
Lantern ring incorrectly positioned * * * *
Shaft or shaft sleeve worn or scored * * *
Incorrect type of packing or mechanical seal * * * *
Improperly fitted packing or mechanical seal * * * *
No cooling liquid to stuffing box * *
Dirt in sealing liquid * *
Incorrect sealing liquid pipework * *
Sealing liquid at too low pressure *
Recirculation pipework blocked * *
Gland pressure too high PRV inoperative * *
Gland too tight * *
Mechanical seal setting size incorrect * *
Mechanical seal components damaged * *
Wrong rotation spring fitted * *

Excellent Engineering Solutions


TROUBLE SYMPTOMS
CENTRIFUGAL PUMP - TROUBLE CHECK LIST 2

Pump requires excessive power


Insufficient pressure developed

Pump loses prime after starting


Mechanical seal has short life

Insufficient capacity delivered


Stuffing box leak excessive
Pump overheats or seizes
Pump vibrates or is noisy

Bearings have short life

Pump does not deliver


Packing has short life
Coupling failure
POSSIBLE CAUSES

Mechanical seal spring locked * *


Seal abutment ring retaining screw loose * *
Seal faces not properly bedded in * *
Rotating part rubbing stationary part * * * * *
Grease or oil on seal faces * *
Internal clearance excessive, neck ring worn * * *
Foundation / baseplate not rigid *
Casing gasket defective * *

Excellent Engineering Solutions


Section G
BEARINGS

1. Introduction

1.1 The instructions contained in this data sheet are intended as a general guide to
obtaining good service life from rolling and plain bearings used in equipment of
Weir-EnviroTech manufacture.

1.2 These instructions do not supercede any information issued by the various
bearing manufacturers, to whom application should be made for more
comprehensive literature by personnel responsible for bearing care who wish to
make a detailed study.

1.3 Normally Weir-EnviroTech equipment is supplied with bearings charged with an


approved lubricant and requires no action before being put into service. With oil
lubricated bearings, of course, it has to be ascertained that an adequate supply of
oil is available immediately on initial start-up and thereafter.

1.4 Terminology used is, as far as possible, as employed by bearing manufacturers.

2. Ball and Roller Bearings

2.1 Care and Routine Maintenance

2.1.1 Care and maintenance of rolling bearings is a matter of ensuring that the
bearing is adequately lubricated during operation, is cleaned and re-
charged (grease lubricated bearings) regularly, and removed and fitted with
care.

2.1.2 Grease lubricated bearings, provided they are properly charged, need
cleaning and re-charging only when the pump/motor is being overhauled.
In the absence of any regularized period for this, generally, every 2 to 3
years would be adequate, but much depends upon operational and
environmental conditions. For example, bearings in a pump which is
operating intermittently require different consideration from a machine
which is running continually, because of the relatively low running
hour/period ratio.

2.1.3 The following recommendations give the essential points when handling
rolling bearings.

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2.2 Removing a Bearing

2.2.1 It is advisable to establish, before the removal of a bearing, the type of fit,
e.g. interference fit on shaft, push fit in housing.

2.2.2 Tools, and work areas, should be clean.

2.2.3 Use correctly suited withdrawal equipment. In this regard it must be


remembered that pushing or pulling is not to be done against the rolling
elements or against the outer ring of a ball bearing.

2.2.4 If other means are not available a hammer and soft metal drift may be used
to tap evenly around the circumference of the inner ring.

2.3 Inspection and Renewal

2.3.1 Roller bearings are normally manufactured in two detachable parts which
can be separated for cleaning and examination, or which separate when
machine is dismantled.

2.3.2 Ball bearings should not be dismantled and, therefore, must be cleaned
carefully to remove old grease from the rolling elements before
examination.

2.3.3 Bearing should be cleaned with petroleum solvent, white spirit being
preferred. To avoid risk of corrosion do not use chlorinated solvents such
as trichleothylene or carbon tetrachloride. Do not use compressed air
unless it is water-free, and do not spin a clean dry bearing either by hand or
with compressed air. Avoid handling with the bare hands, if possible, as
perspiration can promote corrosion.

2.3.4 After cleaning, the bearing should be immersed in a light grade lubricating
oil which is compatible with grease or oil in service (when being examined
off the shaft) or impregnated with the oil (when being examined on the
shaft) before examination.

2.3.5 The condition of a ball bearing should be checked by an oscillating


movement (rather than rotary) with slight end thrust applied, first in one
direction then the other.

2.3.6 Bearings with the following faults should be rejected:

- Wear of the rolling elements or tracks


- Indentation or other marks in rolling elements or tracks
- Rust on rolling elements or track
- Rings or rolling elements blued or very brown
- Rust on inner ring or outer ring likely to impair correct fit in shaft or
on housing

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- Marks on rings or cage indicating damage during mounting, or
dismounting
- Significant cage wear (slight wear acceptable)
- Wear of the bore or outside diameter causing incorrect shaft or
housing fit
- Fractures and cracks

2.3.7 Consideration should be given to renewing a bearing when it is known to


have done a considerable amount of service and where the machine is
unlikely to be dismantled again for some time.

2.3.8 Immediately after cleaning and examination the bearing is to be charged


with the approved lubricant (see paragraph 2.4) and protected from dirt and
moisture until required for fitting.

2.4 Charging a Bearing

2.4.1 Ensure the bearing is clean and serviceable (see paragraph 2.1.1). If the
bearing is new the protective film will have to be removed (see paragraph
2.3.1 to 2.3.3).

2.4.2 Pack the bearing full with grease. The grease should be worked into the
bearing from one side until it appears on the other side of the rolling
elements, then turned over (if the bearing charged when off the shaft) and
worked into the other side. Remove surplus grease flush with the inner and
outer rings.

NOTE: Only a thin film of lubricant in a bearing is used actually to


lubricate the rolling elements and tracks; the remainder acts
as a reservoir and as a protection against dirt, moisture, etc.

2.4.3 Ensure the bearing housing or cap is clean, then replenish with grease to
between half and two-thirds full. This partial filling of the housing/cap will
ensure that there is sufficient space for grease that will be exuded from the
bearing as it rotates. The space in the grease in the housing/cap should be
in the form of a radial gap which should not be opposite the filler plug or
grease nipple, nor at the bottom of the housing/cap. See also paragraph
2.5.

2.4.4 If the bearing is mounted on a vertical shaft, then the procedure for
charging the housing/caps is to take account of the possibility of the grease
slumping from the top housing/cover. To this end the top housing/cover
should be only half-filled and the bottom one about three-quarters filled.

2.5 Fitting a Bearing

2.5.1 A new bearing should be the same type and manufacture as the one it
replaces. If an equivalent is used it must be the correct equivalent and fit.

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2.5.2 Ensure the bearing locations, i.e. shaft and housing(s), are clean and
undamaged.

2.5.3 Ensure that components which are to be fitted before the bearing, are
mounted in place.

2.5.4 Small size bearings can be fitted cold. Use correctly suited equipment to
push the bearing onto the shaft with an evenly distributed load on the inner
ring. Do not use force on the outer ring or the rolling elements.

2.5.5 If other means are not available a hammer and length of tubing (to fit over
the shaft and butt against the inner ring of the bearing) may be used to tap
on the bearing.

2.5.6 It is preferable that medium size or large bearings be heated to facilitate


fitting. A suitable method of heating a bearing uniformly is by suspending it
in a bath of mineral oil at a temperature of 80 - 90C. It is important not to
exceed these temperatures as excess heat is harmful. Ensure the bearing
is properly charged with grease when cool (see paragraph 2.4).

2.5.7 Ensure the bearing housing/cap/cover(s) are properly charged with grease
(see paragraph 2.4).

2.6 Storage of Bearings

2.6.1 Bearings are to be stored in conditions which are damp free with normal
humidity and with adequate ventilation, e.g. temperature 20C
approximately, R.H. 55% max.

2.6.2 Bearings should not be removed from the manufacturers packing until
ready for immediate use.

2.6.3 Medium to large bearings should be stored such that lying in the same
position for a considerable time will not cause damage due to their own
weight or surrounding vibration. It is suggested that the storage position is
changed periodically and, especially on larger bearings, that some means
be found to support equally, in the flat position, all three components (inner
ring, rolling elements, outer ring) of the bearing.

3. Plain Bearings

3.1 Oil Filled Bearings

3.1.1 These are to be inspected regularly to ensure that the rings or the
recirculating system are functioning - a burr or bend in a ring may prevent it
from revolving freely, resulting in lack of lubrication.

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3.1.2 The level of oil in the wells is to be checked regularly and topped up as
necessary to the appropriate mark on the sight glass.

CAUTION: DO NOT OVERFILL

3.1.3 At regular intervals the reservoirs are to be drained and cleaned thoroughly
before filling with fresh oil. In reasonably clean surroundings, this
procedure should be adopted every 6 months.

3.1.4 For details of recommended lubricants, see DS [100 100].

3.2 Forced Lubrication Bearings

3.2.1 Motor bearings incorporating this form of lubrication take their supply from
the system supplying the driven machine or plant and adequate lubricating
oil supply indicators and warnings/alarms should be provided.

3.3 Bearing Clearances and Bedding

3.3.1 At the time of cleaning, a check should be made on bearing wear and a
visual examination made for discolouring and pitting. It is particularly
important that no dirt or grit is present when a bearing is opened up as the
bearing surfaces can be completely ruined by the intrusion of such matter
into the housing or oil system.

3.3.2 When new bearing bushes are being fitted, they must first be bedded to the
bearing housings, each half bush should be bedded over 180 and should
be moved smoothly in its seating without rocking when rotated by hand.

JOURNAL / BEARING BUSH CLEARANCES


Side Top
0.15mm (0.006 in.) 0.20 mm (0.008 in.) up to 95 Bore
0.15mm (0.006 in.) 0.23mm (0.009 in.) up to 115
Bore
0.15mm (0.006 in.)
0.25mm (0.010 in.) up to 125
0.15mm (0.006 in.)
Bore
0.28mm (0.011 in.) up to 175
Bore

3.3.3 When bedding existing bushes or new bushes the angle of bedding
between shaft bottom and bearing bush normally should be at 60.
Test for correct bedding with marking paste. If the machine has been
dismantled for any reason the bearing bedding should be checked with
marking paste and corrected if necessary. If the arc of contact between
shaft journal and bearing bush is greater than 60 the bearing temperature
will tend to increase. Arcs of contact up to 75 are sometimes necessary

Excellent Engineering Solutions


as they improve the mechanical stability and tend to reduce motor vibration.
The arc of contact must never be less than 60 as shown in Figure 1.

3.3.4 Under normal operating conditions the temperature of a given bearing


varies very little, though it will fluctuate slightly as the ambient air
temperature or the cooling water temperature rises and falls. Any tendency
for the bearing temperature to increase permanently should be regarded as
an indication that the bearing requires attention. Although a given bearing
varies very little in temperature, there may be quite a big difference in
temperature of similar bearings on similar machines. Nevertheless the
alarm shut-down temperatures are standardised at 68C alarm and 80C
shut-down.

3.4 Michell Type Journal Bearing

3.4.1 This type of bearing may incorporate an internal circulation system and this
type requires little maintenance attention other than level checks and
periodic changes of oil.

3.4.2 The bearings are designed to operate with oil temperatures of about 71C
(160F). This may vary below this figure where motor speeds are low and
loads light, or above this figure (by a few degrees) at high motor speeds
and loads. A rise in normal running temperature is an indication of fault
conditions and if the increase is rapid the unit should be shut down
immediately to enable the cause to be located. Nevertheless the alarm
shut-down temperatures are standardised at 76C alarm and 82C shut-
down.

3.4.3 The instructions described in paragraphs 3.1.2 to 3.1.4 should be followed


also for Michell Bearings.

3.4.4 Where the bearing is special, specific bearing instructions will be provided.

Excellent Engineering Solutions


Section H
PACKED GLAND

1. Gland

The main points to observe in this connection are:

1.1 A separate clean water seal should be provided for the glands when the pump is
handling liquid of a dirty or gritty nature. On normal suction lifts the gland is self-
sealed by water fed from the pressure volute to the lantern ring. On most
Uniglides this sealing water is carried internally via casing drillings, but on the
larger units external piping is employed for this purpose.

1.2 Do not tighten the gland follower to the point where there is no leak from the gland
- the packing should be adjusted to allow the gland to weep slightly when the
pump is running.

1.3 Renew gland packing (all rings) before it becomes hard. The gland is split to allow
for this.

1.4 All plaited packing must be arranged in such a way that the "V" of the plaiting
which is in contact with the shaft sleeve is pointing against the rotation.

The correct method of packing the gland requires considerable care, it should not be
done in a haphazard fashion. Bad packing can result in substantial damage to the shaft
sleeve in addition to the rapid deterioration of the packing material itself, but the most
severe and obvious penalty lies in the reduced, faulty, costly performance that careless
packing imposes on the user.

2. Packing

2.1 If the packing is supplied in taped, form rings it should be used as it is the tape
should not be removed. If it is supplied in hanks it should be cut accurately and
taped at the ends. Packing is normally supplied in a pre-lubricated form and no
further lubrication is necessary prior to insertion.

2.2 Mount the packing ring-by-ring using finger pressure, each turn should be a
perfect fit. It should be inserted with the butt joints of successive rings spaced by
120 and the last joint should always occupy the position shown at "A" in Diagram
1 on DS 120 011.

NOTE: For pump sets fitted with mechanical seals - see separate data
sheets for operating and maintenance instructions.
Uniglide pumps are normally supplied with conventional packed
glands unless a specific request, or particular circumstance,
indicates the provision of mechanical seals. When pumping clean

Excellent Engineering Solutions


water, sealing water is normally recirculated from the pump volute to
each gland. (See arrangement G11 DS [120 011]).

Pumps supplied for handling dirty water will normally be arranged to accept
separate clean water from an external source. (See arrangement G12). The
pressure for this supply should be 1 bar above suction pressure or 1 bar
whichever is the greater.

Pumps fitted with mechanical seals will normally be arranged so that cooling liquid
is re-circulated to the seals from the pump volute (see arrangement G31) if the
pumped liquid is clean, or arranged to accept separate clean liquid supply from
external source (see arrangement G32) if the pumped liquid contains solids.

Excellent Engineering Solutions


Section I
DISMANTLING

1. PREPARATION PRIOR TO DISMANTLING

1.1 Isolate the driving motor from the electrical supply.

1.2 Close the suction and discharge sluice valves.

1.3 Drain the pump and remove ancillary piping from the pump.

1.4 Disconnect pump/motor coupling. (See coupling instructions DS 100 030).

2. DISMANTLING

NOTE: a) The highest possible standard of cleanliness must be


maintained throughout the following operations.

b) During dismantling, all running clearance should be checked so that


a decision can be taken on whether the components can be refitted
on assembly or renewed.

2.1 Ensure that the preparation prior to dismantling of the pump has been carried out.

2.2 Remove the nuts from the gland bolts of both gland assemblies, and remove the split
gland halves.

2.3 Remove the dowel pins at the casing joint and the nuts from the securing studs.
Ease off the top half casing jacking screws, and lift it clear. Remove and discard the
joint gasket (if fitted).

CAUTION: Where a lifting facility is provided on the pump top half casing it is
important to note that this is intended to accept the weight of this half
casing only. Under no circumstances must the complete pump be
lifted by this means.

2.4 Suitably sling the rotating assembly, then remove the screws securing the drive end
and non-drive end bearing housings to the casing.

2.5 Lift the rotating assembly clear of the pump casing and support it in a horizontal
position on suitable blocks. Care must be taken not to damage the impeller neck
rings during this operation.

2.6 Draw off the half-coupling and remove the key.

2.7 Remove the screws securing the drive end and non-drive end bearing caps to the
bearing housings. Withdraw each housing from the assembly.

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2.8 Note that the outer race of the roller bearing will be withdrawn with the drive end
bearing housing.

2.9 Unscrew the shaft nuts at the non-drive end of the shaft and ease off the ball thrust
bearing.

2.10 Remove the bearing housing cap and water thrower (containing an "O" ring in the
internal groove). Discard the "O" ring.

2.11 Remove the packing, lantern ring, stuffing box distance piece, stuffing box bush
from the assembly.

2.12 Remove the shaft sleeve and neck ring.

2.13 Unscrew the shaft nuts at the drive end of the shaft and ease off the roller journal
bearing.

2.14 Repeat operations 9 and 10 at drive end of the pump.

2.15 Clean the shaft, then draw the impeller off the shaft after noting its position and
direction of rotation.

2.16 Remove the impeller key.

3. DISMANTLING (Pump with Crane 1A Mechanical Seal)

NOTE: a) The highest possible standard of cleanliness must be


maintained throughout the following operations.

b) During dismantling, all running clearance should be checked


so that a decision can be taken on whether the components
can be refitted on assembly or renewed.

3.1 Ensure that the preparation prior to dismantling has been carried out.

3.2 Unscrew the seal plates (refer to DS 120 040) and withdraw them sufficiently
along the shaft to permit removal of the "top" half casing. Each seal plate will
contain the seat and seat ring of the mechanical seal assembly. For maintenance
of the mechanical seal refer to DS 100 090 .

3.3 Remove the dowel pins at the casing joint, and the nuts from the securing studs.
Ease off the "top" half casing, using jacking screws, and lift clear. Remove and
discard the casing joint (if fitted).

CAUTION: Where a lifting facility is provided on the pump top half casing it is
important to note that this is intended to accept the weight of this half

Excellent Engineering Solutions


casing only. Under no circumstances must the complete pump be
lifted by this means.

3.4 Suitably sling the rotating assembly, then remove the screws securing the drive
end and non-drive end bearing housings to the casing.

3.5 Lift the rotating assembly clear of the pump casing and support it in a horizontal
position on suitable blocks. Care must be taken not to damage the impeller neck
rings during this operation.

3.6 Draw off the half-coupling and remove the key.

3.7 Remove the screws securing the drive end and non-drive end bearing caps to the
bearing housings. Withdraw each housing from the assembly. Note that the outer
race of the roller bearing will be withdrawn with the drive end bearing housing.

3.8 Unscrew the shaft nuts at the non-drive end of the shaft and ease off the
roller journal bearing.

3.9 Remove the bearing housing cap and water thrower (containing an "O" ring in the
internal groove). Discard the "O" ring.

3.10 Remove the following in sequence: seal plate (with seat and seat ring) - gasket -
rotating seal assembly - abutment ring - stuffing box bush - shaft sleeve - neck
ring.

CAUTION: Great care must be taken to avoid damage to the rotating seal
assembly during removal.

3.11 Unscrew the shaft nuts at the drive end of the shaft and ease off the ball thrust
bearing.

3.12 Repeat operations 9 and 10 at drive end of the pump.

3.13 Clean the shaft, then draw the impeller off the shaft after noting its position and
direction of rotation.

3.14 Remove the impeller key.

4. PUMP RUNNING CLEARANCES

4.1 During dismantling, all running clearance should be checked so that a decision
can be taken on whether the components can be refitted on assembly or renewed.

4.2 When new, the Uniglide pump running clearances are given in DS [120 060] and
the maximum pump performance is available.

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4.3 In pumping systems where the head is mainly static, an increase to double or
treble the "as new" clearance is considered the maximum permissible.

4.4 In systems where the head is largely frictional an increase to eight or nine times
the "as new" clearances is permissible.

4.5 These increases in clearances limits are permitted in full only when the drive unit
is not being overloaded.

4.6 Within these permissible limits, decisions on whether components should be


replaced depend on balancing replacement costs against increased running costs
as a result of reduced pumping efficiencies.

Excellent Engineering Solutions


Section J
ASSEMBLING

1. PUMP WITH PACKED GLAND

1.1 Locate the impeller key in its keyway on the shaft, then assemble the impeller
correctly for direction of rotation and to its original position on the shaft.

1.2 Assemble the shaft sleeves on the shaft securely against the impeller hub. Check
that impeller is still correctly positioned on the shaft.

1.3 Locate the neck rings on the impeller.

1.4 Assemble the non-drive end and drive end stuffing box bushes on the shaft followed
by the distances pieces, lantern rings, and water throwers. Fit new "O" ring in water
throwers before fitting.

1.5 At the drive end, locate the bearing housing cap on the water thrower. Ensure that
the ball thrust bearing is correctly charged with grease (see DS [100 080] - Ball and
Roller Bearings), then gently tap the bearing on to the end of the shaft until it abuts
the water thrower.

1.6 At the non-drive end, locate the bearing housing cap on the water thrower. Ensure
that the ball thrust bearing is correctly charged with grease (see DS [100 080] - Ball
and Roller Bearings), then gently tap the bearing on to the end of the shaft until it
abuts the water thrower.

1.7 Screw the inner shaft nuts on both ends of the shaft. Tighten the nuts against the
bearings, checking that the impeller is still correctly positioned on the shaft. Screw on
and tighten the outer nuts against the inner nuts to lock the complete rotating
assembly in position.

1.8 Assemble the bearing housing in position. Secure the bearing housing caps to the
housings.

1.9 Locate the coupling key in its keyway, then fit the pump half coupling to the shaft.
(See coupling instructions - DS 100 030).

1.10 If Hermatite (or similar) has been used on the casing joint, clean the joint face.
Position the rotating assembly in the bottom half casing. Protect the neck rings from
possible damage during this operation. Locate the neck ring and stuffing box bush
anti-rotation screws in the casing joint face.

1.11 Secure the bearing housings to the casing. Check that the impeller is centralized
between the neck rings.

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NOTE: Where the pump nameplate indicates that a casing joint gasket is
fitted, a new gasket of similar characteristics and thickness to
Permanite, CAF, 0.20mm thick must be fitted. A joint sealing
compound is necessary only where no gasket is employed, in which
case Hermatite (or similar) compound is recommended.

1.12 Ensure swing bolts (if provided) are fitted over swing bolt studs, and fit the top half
casing, run the nuts lightly on to the studs, and check the rotating assembly for
freedom of rotation. Tap in the dowel pins and tighten the nuts down fully. Check
again that the rotating assembly can rotate freely.

1.13 Insert the gland packing, followed by the two halves of the split gland, into the
stuffing boxes. (Refer to DS 120 010 - Glands and Gland Arrangements). Pivot the
swing bolts into the gland slots. Fit the nuts to the bolts but do not tighten at this
stage.

2. PUMP WITH CRANE 1A MECHANICAL

2.1 Locate the impeller key in its keyway on the shaft, then assemble the impeller
correctly for direction of rotation and in its original position on the shaft.

2.2 Assemble the shaft sleeves on the shaft to locate over the protruding ends of the
impeller key and abut the impeller.

2.3 Locate the neck rings on the impeller.

2.4 At the non-drive end, assemble into position: stuffing box bush - abutment ring -
rotating seal assembly - replacement gasket - seal plate (with seat and seat ring) -
water thrower (with new "O" ring) - bearing cap.

IMPORTANT:

2.5 Ensure that the roller journal bearing is correctly charged with grease. (Refer to DS
100 080 - Ball and Roller Bearings). Gently tap the bearing on to the end of the shaft
until it abuts the water thrower.

2.6 At the drive end, assemble into position: stuffing box bush - abutment ring - rotating
seal assembly - replacement gasket - seal plate (with seat and set ring) - water
thrower (with new "O" ring) - bearing cap.

IMPORTANT: Refer to DS 100 090 and 120 070 before fitting mechanical
seal components.

2.7 Ensure that the ball thrust bearing is correctly charged with grease (see DS 100 080 -
Ball and Roller Bearing), then gently tap the bearing onto the end of the shaft until it
abuts the water thrower.

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2.8 Screw the inner nuts on both ends of the shaft. Tighten the nuts against the bearings
checking that the impeller is still correctly positioned on the shaft. Screw on and
tighten the outer shaft nuts against the inner nuts to lock the complete rotating
assembly in position.

2.9 Locate the bearing housings and secure them with screws to the bearing caps.
Ensure that the non-drive end housings contains the roller bearing outer race.

2.10 Locate the coupling key in the keyway, then fit the half coupling to the shafts.

2.11 If the Hermatite (or similar) has been used on the casing joint, clean the joint face.
Position the rotating assembly in the bottom half-casing. Protect the neck rings from
possible damage during this operation. Locate the neck ring and stuffing box bush
anti-rotation screws in the recesses in the casing joint face.

2.12 Secure the bearing housings to the casing. Check that the impeller is centralized
between the neck rings.

NOTE: Where the pump nameplate indicates that a casing joint gasket is
fitted, a new gasket of similar characteristics and thickness to
Permanite, CAF, 0.20mm thick must be fitted. A joint sealing
compound is necessary only where no gasket is employed, in which
case Hermatite (or similar) compound is recommended.

2.13 Ensure swing bolts (if provided) are fitted over swing bolt studs, and fit the top half
casing, run the nuts lightly on to the studs, and check the rotating assembly for
freedom of rotation. Tap in the dowel pins and tighten the nuts down fully. Check
again the rotating assembly can rotate freely.
2.14 Complete the installation of the mechanical seals. (Refer to DS 100 090 and DS
120 040).

3. FINAL CONNECTION

3.1 Reconnect the pump/motor coupling after checking that the pump/motor alignment is
correct. (See arrangement drawing and pump set lining up and final coupling
instructions - DS 100 030).

3.2 Replace any ancillary piping.

3.3 Prime the pump.

3.4 Remake electrical connections.

Excellent Engineering Solutions


Section K
LUBRICATION SCHEDULE

Section 1 - Oil Lubrication

UNLINED SLEEVE TYPE JOURNAL BEARINGS

Splash lubrication (oil rings)

Ambient temperature 0 - 30C Ambient temperature 31 - 60C

BP Energol THB 68 BP Energol THB 77

Caltex Rando Oil 68 Caltex Rando Oil 100


Or Rando Oil HD 68 Or Rando Oil HD 100

Castrol, Perfecto T68 Castrol Perfecto T100

Chevron OC Turbine Oil 68 Chevron OC Turbine Oil 100

Duckhams Zodiac 6 Duckhams Zodiac 7


Or Deenol 20 Or Deenol 30

Esso Tro-Mar T68 - Marine Esso Tro-Mar T77 (Marine use)


Or Nuto H68 - use Teresso T77 (Industrial use)
Teresso 68 - Industrial
Or Nuto H68 - use

Gulf Harmony 68 Gulf Hydrasil 100

Mobil DTE Oil Heavy Medium Mobil DTE Oil Heavy or DTE 18
Or DTE 16

Shell Turbo Oil T68 Shell Turbo Oil T100

Texaco Rando Oil HD 68 Texaco Rando Oil HD 100

Excellent Engineering Solutions


Section 1 - Oil Lubrication

WHITEMETAL LINED SLEEVE TYPE JOURNAL BEARINGS

Splash lubrication (oil rings)

Ambient temperature 0 - 30C Ambient temperature 31 - 60C

BP Energol THB 46 BP Energol THB 68

Caltex Rando Oil 46 Caltex Rando Oil 68


Or Rando Oil HD 46 Or Rando Oil HD 68

Castrol, Perfecto T46 Castrol Perfecto T68

Chevron OC Turbine Oil 68 Chevron OC Turbine Oil 100

Duckhams Zodiac 5 Duckhams Zodiac 6


Or Deenol 10 Or Deenol 20

Esso Tro-Mar T68 - Marine Esso Tro-Mar T68 - Marine


Or Nuto H68 - use Or Nuto H68 - use
Teresso 46 - Industrial Teresso 68 - Industrial
Or Nuto H46 - use Or Nuto H68 - use

Gulf Harmony 46 Gulf Hydrasil 68

Mobil DTE Oil Heavy Medium Mobil DTE Oil Heavy


Or DTE 15 or DTE 16

Shell Turbo Oil T46 Shell Turbo Oil T68

Texaco Rando Oil HD 46 Texaco Rando Oil HD 68

Excellent Engineering Solutions


Section 2 - Grease Lubrication

BALL & LOWER BEARINGS

Ambient temperature 0 - 80C CHARGING: The bearing should be


packed with grease and the housing filled,
BP Energrease LS3 then a quantity removed from the housing
OR Energrease LS2 slightly less than volume in the bearing. In
most cases this will amount to of the
Caltex Regal Starfak Premuim 3 volume of grease in the housing. This
OR Caltex Regal Starfak Premuim 2 should be removed in a segment from the
cover but not from opposite a filling plug,
Castrol Spheerol AP3 nor from the bottom of the cover. On
vertical pumps approximately the grease
Chevron Industrial Grease Medium should be removed from the top cover and
from the bottom cover.
Esso Beacon 3
REPLENISH: Apart from specified cases
Gulf Gulfcrown Grease No. 3 where the housing has to be kept full of
Or Gulfcrown Grease No. 2 grease, replenishment should be carried out
at approximately every 1000 hours of
Mobil Mobilux 2 running, or if there is an obvious grease
Or Mobilplex 47 loss. The bearing should be cleaned out
and the grease renewed at annual overhaul.
Shell Alvania Grease R3
Or Alvania Grease RA CLEANING: Bearings should be cleaned
out using white spirit.
Texaco Regal Starkfak Premium 3
Or Regal AFB 2

Excellent Engineering Solutions