er els CHAPTER 4 MAINTENANCE In onder to eliminate pump troubles, to minimize parts consumption and repair and to ‘maintain best efficiency over long periods the operator must aim at perfect maintenance of the pump. 1, CAUTION DURING OPERATION (1) Nevers throttie=the-suction- valve. in-any--case® duuringoperation otherwise troubles may occur due to dry operation (2) Never--operate- che pump. for over 3--minutes with dischange=saivescompletslysclosedm When 4 centtifugal pump is operated without is charge, most of the power changes into heat and as a result temperature ofthe liquid in the pump casing rises to the boiling point causing Seizure of the interior of the pump and accident may occur, expecially when dangerous liquids are pumped. (3) Never-operate-the-pump- with dry--condition. (4) Except that the driver is with the constant speed like electric motor, keep the discharge valve open in full and itis desirable to adjust discharge flow by changing speeds. The adjust iment of discharge flow by the degree of dis- charge valve opening is not recommendable because of loss of driving eneray. (5) When opesatingsmoresthsne2spumpssin-parale! bbe sure to keep the dischargerpressure"oPereh pumpealwayssequal, If the speed of some pump decreases during operation and its shutoff pressure drops below the discharge pressure Of the remaining pumps, it is operated with zero flow even though its discharge valve is opened and thus the result willbe the same as mentioned in (2) before in this chapter. In such a case try to make the speed of the pump in question same as those ofthe remaining Pumps, snd if this is impossible stop that pump immediatly (6) When operating the pump at the rated speed with the discharge valve open in full available NPSH decredses as the liquid level in the tank lowers and finally discharge becomes zero die to cavitation. In such a case pumping ability can be restored if discharge 1 decreased, 20 for the reason mentioned above lowerthen-speed=without throting-the.diseharge-valve-as-the fiquid TE¥El o @) With lowering of the liquid level in the tank suetion pressure approaches the vapor pressure ‘of liquid and vapor develops in the suction line and pump suction and, moreover, air is sucked through the suction bellmouth until pumping ability decreases to such extent that discharge stops. In order to prevent this, vapor and gas coming into the pump inside must be drawn through that vent on the casing by means of stripping ‘pump or some other extracting devices. When. cavitation occurs, eventhough. the pamp spoed-becomesminimum, discRarge™=murbe decreased. by..thiotlling..the—discharge-salve, Tf othis,remedynis»ineffective”StOp"the=pump. 2. BALL BEARING @ @ @ In consideration of lubricating ability of the grease and running clearance of the bearing due to thermal expansion and liquid tempe- rature pumped, the bearing temperature is so designed as to stand up to 90°C. However from viewpoint of service life it is desirable to keep it below 75°C. For the lubrication of ball bearing grease is use. ‘The recommendable grease and the interval of re- placement grease are shown in Table 4.1 and 4.2. For supplying grease for the bottom ball bearing, take the grease drain plug away. 3, MECHANICAL SEAL @ o) 9) @ | SHINKOIND.LTD, Cautions before starting and during standstill Care must be taken so that no dust enters part (@) in Fig. 4.1 Pouring lubricating oil in (a), when the pump is at a standstil, will prevent dust from sticking If dust accumulates here and sticks hard seal ring (54-4) may stick and sliding face (S) can not be tightened. When the pump is delivered, a strip of cloth tape is put over the gap around the impeller shaft to prevent foreign matter from invading. Check of flushing ‘The mechanical seal may be considered to be working perfectly if there is no heating near the sliding parts and no abnormal noise81 8 C Fig, 41 @— 4s} Flushing from discharge side (@) Leakage from mechanical seal Under normal operational conditions there is no leakage, but in case there is a leakage of over 30 cefh there must be some trouble inside, so a remedy must be taken as early as possible (4) Heating of sliding parts and abnormal noise Insufficient fusing to the sliding face causes ab- normal weardown of the carbon due to heating and dry contact. If fushing temperature ses to mote than 10°C above the liquid temperature being pumped it is necessary t0 trace the eause and remove it. When operated under the condition of dry contract abnormal sliding noise may occur. 4, GEAR COUPLING (Standard) (1) Misalignment between pump and driver Since the gear coupling has selfalignment action to some extent small misalignment within the permissible values shown in Table 2.1 and 2.2 can be absorbed. However the excessive misalignment causes too much slip between the teeth and as a result wear becomes excessive, vibration oceurs and the coupling may be damaged. (2) Lubrication Lubrication oil has a very important function in reducing friction and wear and in hydrau- lically distributing contact pressure on the gear flanks by forming oil film in the gap between them, ‘The recommendable oils and the interval of 1e- placement oil are shown in Tables 4.1 and 4.2. a } (3) Filling lubricating oil (@) Fill off through an oil plug hole on the coupling by using a grease pump till the oil begins to flow out from the other oil plug hole on the ‘opposite side. (b) After filling the oil replace the oil plugs se- ccurely and give several turns to the shaft so that the oil may reach the interior of the coupling. If too much oil i filled, excessive oil may leak from the key way but this is acceptable because necessary oil is kept in the'coupling. $. BULKHEAD STUFFING BOX (Standard) (1) When operating for the frst time after repacking the stuffing box tighten once the gland firmly before starting, then loosen the gland nuts to such extent that the coupling can be tumed lightly by turning bar, Supply grease to the gland packing for lub- ricating and to Keep gas-tightness between the pump room and engine room, ‘The recommendable greases and the interval of replacement grease are shown in Tables 4.1 and 42. ‘Start the pump and adjust the gland nuts gradu- ally and evenly. If the gland is tightened su- ddenly or too much or unevenly there may be a danger of seizure of overheating. If the packing becomes det @ @) @ ‘ness can not be kept no matter how much the sland is tightened. In such case renew the packinga1 9 6, MAINTENANCE CHECK LIST Maintenance and check for the followings can extend a life of the pump. Item Inspection procedure Remedy in case of trouble ‘Check everyday if there isno abnormal | Stop pump immediately and check Saotion presente: pressre op. suction line. In the cae of above ambient tempersture plus 40°C or above 85°C, stop pump and Bearing temperature ‘Chock and record everyday, liminate cause. ‘Check olin gear coupling everysay through ol hole on it ‘Supply oi if any. Lubricating of! abnormal note or overeating occurs, al orig (eck abmonal noise everyday. Sop pump and clninate eau, sd renew tall bert any Mechanisalseal (hac eke eating noe everyday. | Stop pomp and remove cause Vibration (heck vibration everyday. Check ligament Tie 7. LUBRICANTS Replacement (1) Replacement of lubricants: Location “After Talat aaa The replacement of the lubricants is based on ri co deteoratono¢ contamination ofthe brat Sauce wuss wee eng use However, Table 4.1 shows recommendable Gear coupling 7 Every 6 months replacement, ‘Bulkhead [Every operation | Every operation stuffing box Q) Lubricants NLGI No, 2 (Nationel Lubricating Grease Institute) for grease forthe ball bearing on the pump and inter- mediate shaft and for its stuffing box, and ISO VG 320 (International Standard Organization) ~ VG 560 for gear ol for the gear coupling are recommendable The brand names ofthe lubricants equivalent to the recommendable ones are shown in Table 4.2. @) Filling quantity of grease Filling quantity of grease is as follows. Pump model Kv200_| Kvas0 | _KVAW | KVASDa | KVAGOa | KV S002 ‘reas for pump uppor beating «@ | __70 70 110 150 a0 20 Grease for pump lower bearing ig) [_50 30 0 no 150 210 Gieas for ner alTuppeT —@ | 70 7 | no 10 | 270 330 Gisaseforiner deflower ww | 70 70 110 130 | _20 380 See cem 5 | aie 20 280 300 360 00 8, STANDSTILL ‘When there isa fear of freezing, drain the pump completely after stopping, In the case of a long standstill clean each sliding part thoroughly and apply rust preventive where necessary. TRESS ca G | SHINKO IND.LTD.si | 10 Tabie 4.2 ‘Name of Geeme ea i compen a be TP ENERGREASE men? TEP ENERGOL GR a eRe io feastnon—_|spsieerot ara ‘CASTROL ALPHA Sta80 fpanxvoon |ovnamicmr2 TROGEAR ee Exxon justana SPARTAN E60 Jautron — [cvurcnowncreaseNo2 | ctr ErLusmicaNT D480 pgs [oarune coRONEXGREASENO] DamiNE CECONROUND sees fxvopo on |usontx crease No.2 OSERTESGEAR G0 arsonist on ptawoND MULTIFURFOSNO2 | DIAMOND.GEAR LUBE sso Marv2en ou |ustax2 SWACOL SP460| leenNon, _ |Atubrieak eee RERORA LupRicawr 60 [siowson. [ros sunticurwo2 HOSEL EC ASOSP frexacoon. |wviriraxno2 ‘TEKACO MEROPA #60 CHAPTER § STANDARD CLEARANCE AND LIMIT OF USE ‘The bigger the clearance between impeller and mouth ring becomes, the more the counter- flow from discharge side to suction side becomes, and consequently pump capacity de- creases. Tobie 8.1 as Tan Tailofaw Name of pct oss | induct [Lent r sn | Gpprsea [towers] * [Uppal [Lover KY 300 03 15.9 15.9 1 | 2 By ‘= | @ sso} ass | ss | se | a | os | anne wo fox {iss fuss | 1 | wo | ita | [ieee ee Meee ies ‘mechanical 4 2 soo) angel Poa tes [mo | set) a Se § SHINKOIND.LTD. {7