Series Z22

Split casing pumps

EN Installation and Maintenance Instructions

www.sulzer.com

1.1116en 07.12
1 Installation 3 Shaft Seals

1.1 Storage 3.1 Mechanical Seals

1.2 Handling 3.1.1 Single, Unbalanced Mechanical Seal
3.1.2 Single, Balanced Mechanical Seal
1.3 Location
3.1.3 Single Mechanical Seal with Quench
1.4 Fixing 3.1.4 Sealing liquid
1.4.1 Horizontal Pumps
3.2 Gland Packing
1.4.1.1 Pump and Motor separately
3.2.1 Gland Packing with internal sealing liquid
1.4.1.2 Common Baseplate
3.2.2 Gland Packing with external sealing liquid
1.4.2 Vertical Installation
3.2.3 Running Maintenance
1.4.2.1 Installation Version ”a”
3.2.4 Re-packing
1.4.2.2 Installation Version ”b”
3.2.5 Running-in
1.5 Fitting a Coupling
1.6 Alignment
1.6.1 Alignment with Feeler Gauge 4 Dismantling and assembly
1.6.2 Alignment with Clock Gauge
1.6.3 Alignment with Laser Equipment
1.7 Piping 4.1 General
1.7.1 Tanks 4.2 Dismantling standard version
1.7.2 Valves 4.2.1 Dismantling upper pump casing part
1.7.3 Suction Piping 4.2.2 Removing complete rotor unit including
1.7.4 Discharge Piping bearing housings
1.7.5 Minimum Flow 4.2.3 Dismantling rotor unit (bearings, seals,
1.7.6 Piping for Sealing Liquid sleeves, impeller)
1.8 Pressure Testing of Pipework 4.3 Assembly of standard version
1.9 Pressure Transients and Fluctuations
1.10 Reverse Rotation

2 Start-up and Running Maintenance

2.1 Before Start-up

2.2 Starting
2.3 After Start-Up
2.4 Matching the Pump to the System
2.4.1 Suction
2.4.2 Discharge
2.5 Stopping
2.6 Maintenance
2.6.1 Bearings
2.6.1.1 Grease lubrication Series Z22 - Intervals - quantity
2.6.1.2 Oil-Lubricated Bearings
2.6.1.3 Checking the Bearings
2.6.2 Shaft Seals
2.6.2.1 Mechanical Seals
2.6.2.2 Gland Packing
2.6.2.3 Miscellaneous
2.7 Replacement of Motor
2.8 Shut-downs

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

 Operating Instruction
1
Series Z22
Installation

1.1 Storage
If the pump unit is to be stored for a lengthy period,
Max. 60°
the following points should be noted:
…… Vibrations which could damage the bearings
must be avoided.
…… The covers fitted to the suction and discharge
ports should be retained in place undamaged.
ATTENTION
…… If there is a risk of freezing tempera­tures, the
pump should be completely drained.
…… When stored for a lengthy period in corrosive
environment, a pump of cast iron or nodular Fig. 1 Fig. 2
iron should be rust pre­vented inside. The shaft Lifting of a Z22-pump When lifting a vertical Z22-pump four
end(s) should also be protected. eye bolts should be used.
If the pump is to be stored for a very long time, any
gland packings should be removed.

1.2 Handling

ATTENTION
m
Care in handling is required, particularly to pre-
vent damage to the shaft end(s) and sealing liquid Fig. 3
pipes. Smooth lifting of the pump as in Figs. 1 and Dismantling the casing top half.
2 is suggested. Note that the two eye bolt sock-
ets in the casing top half must not be used for
lifting the complete pump. Never lift by means of
the pump or motor shafts.
See also Para ”Transport” in our Safety Instruc-
tion 1.1071.

1.3 Location
The pump should preferably be installed to make
inspection and servicing easy. Ensure adequate
space exists for dis­mantling. Suitable lifting equip-
ment should be fitted for the dismantling of the top
half and rotor. See Fig. 3.
If the pump is fitted with gland pack­ings, a suit- Fig. 4a
able drainage should be arranged. Version CK, clockwise rotation.
Z22 pumps can be installed horizon­tally and be
driven from both sides and will then rotate clock-
wise and anti-clockwise respectively (as viewed
from the shaft end), as shown in the Figs. 4a and
4b. Note that the location of the motor must be
stated in the order, as the pump must be adapted
to clockwise or anti-clockwise drive.
The pump can also be driven from both sides Fig. 4b
when double shaft end is specified. Version JK, anti-clockwise rotation.

1.1117en 07.12
 1.4 Fixing
The construction of the foundation and the secur-
ing of pump-motor should be made with care, so
that vibrations are prevented, pipe stresses ab-
sorbed and pump/motor alignment maintained.
Before installation, pockets in the foundation or
concrete floor must be made for foundation anchors
or foundation bolts. The dimensions are stated in
the dimension print.

1.4.1 Horizontal Pumps

Z22-pumps should preferably be installed on a
Fig. 5
Pump and motor are preferably placed on a concrete
concrete foundation, as in Fig. 5. This installation
foundation. type is very rigid and is espe­cially suitable at large
pumps.
The pump and motor can also be placed on a
fabricated baseplate, as shown in Fig. 6.

1.4.1.1 Pump and Motor separately (Fig. 5)

1. Fit the foundation anchors to the pump and mo-
tor. Use tape to centre the screws in their holes.
See Fig. 7. By using spacers between the foun-
dation anchors and motor, a pump and motor of
slightly differing shaft heights can be mounted
without changing the foundation anchors.
2. Lift pump and motor on to the founda­tion with
the foundation anchors hanging in the pockets.
3. Adjust the pump, so that the flanges and shaft
are vertical/horizontal. There are threaded
holes in the pump feet for adjustment screws.
4. Align pump/motor with great care. See para
1.6 Alignment.
Fig. 6 5. Grout the foundation anchors with fine con­
A common baseplate is an alternative. crete. After hardening, check that the bolts are
well tightened.

1.4.1.2 Common Baseplate (Fig. 6)

1. Lift baseplate with pump and motor. Place the
unit on its foundation.
2. Raise the baseplate about 10mm by applying
wedges or washers near the foundation bolts.
Centre the 3. Align the baseplate carefully. Ensure that the
screw flanges and shaft are verti­cal/horizontal.
4. Grout under and inside the baseplate. The
space be-tween foundation and base­ plate
should be completely filled. Tighten the founda-
~5 mm tion bolts, when the concrete has hardened.
Foundation
anchors ATTENTION
A concrete foundation must have an ade-
quate reinforcement in two directions to pre-
vent cracking. Pockets for foundation anchors
should be reinforced as well.

1.4.2 Vertical Installation

Fig. 7
Locating the foundation anchors before grouting. The
screws are to be well centred in the holes of pump
and motor to facilitate final alignment.
Z22-pumps can be installed vertically in two ver-
sions:
a) The motor is placed on a higher floor and drive
is via a long cardan shaft, Fig. 8.
b) The motor is mounted on a tripod as in Fig. 9
and drive via a short cardan shaft.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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1.4.2.1 Installation Version ”a” (Fig. 8)
1. Attach the foundation anchors to the pump
stool.
2. Lift the pump and place it with the anchors
hanging in the pockets.
3. Adjust the pump carefully, so that the flanges
and shaft are vertical.
4. 4. Grout the foundation anchors with con-
crete and - when hardened - check that they
are tightened. Also check that the pump is still
vertical.
5. Mount the coupling half and any foundation
anchors on the motor and place it on its floor.
The motor can be mounted in various ways: on
a concrete foundation, on a steel plate or on a
fabricated baseplate.
6. Adjust the motor carefully, so that its shaft is
vertical and check that the distance between
the shaft ends cor­responds to the cardan shaft
length. Fig. 8
7. Align the motor to the pump, so that the cardan The pump is mounted on a stool. The drive is via a
shaft angle lies within 0-3o. cardan shaft from the motor, which is placed on a
higher floor.
8. Tighten the motor screws and ensure that the
motor is still vertical and that the cardan shaft
angle does not exceed 3o.
9. Lift up the cardan shaft and mount it to pump
and motor. Normally this will require a lifting
device fitted near to the hole in the motor floor.
10. Normally the pump can take weight of the
cardan shaft. However, check always that this
is the case.

1.4.2.2 Installation Version ”b” (Fig. 9)

1. Fit the foundation anchors to the pump stool.
2. Lift the pump and place it with the foundation
anchors hanging in the pockets.
3. Adjust the pump carefully, so that the flanges
and shaft are vertical.
4. Grout the foundation anchors with concrete
and - when hardened - check that they are
tightened. Also check that the pump is vertical.
5. Adjust the tripod, so that its plane is horizon-
tal and that the hole is con­centric to the motor
shaft. The top casing half must be positioned
between two legs to make dismantling possi-
ble. Fig. 9
The pump is mounted on a stool and the motor on a
6. Drill holes and mount the stool with expansion- tripod. Drive via a short cardan shaft.
shell bolts.
7. Fit the coupling parts on pump and motor. Nor-
mally a short cardan shaft is used. Mount the
motor on the tripod.

1.5 Fitting a Coupling

Various types of couplings can be used. Mount the
coupling according to the manu­facturer’s recom-
mendation.
As a rule the coupling halves are heated to facili-
tate fitting. Tighten grub screws thoroughly.
Normally the coupling half is pushed home to be
flush with the shaft end plane.
ATTENTION
A Sulzer coupling guard must be fitted to ensure
complete personal safety. The guard must not be
subjected to abnormal loads.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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Fig. 10
Begin coupling alignment by elimina-
ting angular displacement.
Fig. 11
Use a feeler gauge for measuring be-
tween the coupling halves.
1.6 Alignment
The alignment pump/motor may be affected, when
the piping is connected. Final alignment must be
carried out after the following site activities are
completed:
…… Pump and motor (baseplate) have been grout-
ed and the fixing screws thoroughly tightened.
…… Piping has been connected.
…… Piping and tanks have been filled.
…… The pump has attained operation tem­perature
(applies to temperatures above 60oC).
Proper alignment will prevent vibrations, exces-
sive wear on coupling parts and shaft seals and
overheating of bearings. Alignment can be made
with feeler gauge, clock gauge or laser.
Note that the manufacturer’s statements of max.
radial and angular displacements must be fol-
lowed to ensure complete safety.

1.6.1 Alignment with Feeler Gauge

Fig. 12 Fig. 13
Radial alignment is required. Measure the misalignment with a steel
rule and feeler gauge.
Start by ensuring the shafts are aligned correctly,
i.e. eliminating angular misalignment, see Fig.
10. Mark reference points on the coupling flang-
es. Measure the distance between the coupling
halves with a feeler gauge, see Fig. 11. Measure
at one quarter, one half and three-quarter turns
from the original position. Adjust with shims - pref-
erably under the motor - so that the difference will
be max. 1/1000th of coupling dia e.g. 0.1mm for
each 100mm of dia.
To obtain concentric alignment, see Fig. 12, place
a steel rule on the coupling and measure the dif-
ference at four positions around the periphery, see
Fig. 13. By adjusting uniformly under the motor
feet the difference should be brought down to an
accept- able value, of 1/2000th of the coupling dia-
metre e.g., 0.05mm for each 100mm of dia.

1.6.2 Alignment with Clock Gauge

An accurate method is to attach a clock gauge to
one of the coupling halves, letting the point of the
gauge rest on the other half. Turning the shafts
and reading the gauge will reveal necessary ad-
Fig. 14 Fig. 15 justments.
Measuring the angular displacement Measuring the radial displacement with Place the clock gauge on the side of the opposite
with a clock gauge. a clock gauge. half to measure the angular displacement, see Fig
14. The clock gauge should be placed on top of
the opposite half to measure the radial displace-
ment, see Fig. 15.

1.6.3 Alignment with Laser Equipment

To align by laser contact the laser manufacturer.

Fig. 16
The pump must not carry piping loads.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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1.7 Piping
Correct functioning of the pump can be affected
by external factors. The piping, tanks and valves
must be properly engineered into the system. This
is particularly important on the suction side. Errors
here can cause cavitation, bad inflow angles of
liquid into the pump impeller or the formation of
”voids” in the liquid.
Loads on the pump flanges arising from pipe Fig. 17
stresses must be minimised and within allowed The outlet of a tank should be funnel-shaped. A paral-
values. Piping and valves must be carefully sup- lel sharp-edged entry will throttle the flow.
ported, see Fig. 16. Excessive pipe stresses can
deform the casing resulting in impeller ”binding”
and changed alignment.
Ensure that pipes and pump are properly cleaned
internally before connection. Debris in the pipe
can lead to seizures and unnecessary wear.

1.7.1 Tanks
If a pump takes its suction from an open tank, the
tank volume should not be to small. A good rule is
that the volume turnover should not exceed twice
per minute to achieve a relatively steady liquid
level and conditions for self deaeration. The inlet
to the suction tank should be designed to avoid air
Fig. 18
entrainment.
Valves before the pump suction should be of full flow
To minimise flow losses and reduce the risk of type. The flow path should not be throttled in any
air in the suction pipe, the inlet to the suction pipe way.
should be properly designed. A funnel shaped en-
try as in Fig. 17, is suggested.

1.7.2 Valves
Valves in the suction pipe should be used for iso-
lating only. During pump operation they should be
fully open. Valves near the pump (up to 10 x d)
must be of full flow type, so that the flow path is not
disturbed. Seal or butterfly valves (Fig. 18) should
not be installed near the pump.

Fig. 19
A taper in front of the pump should have a horizontal
top edge.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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Fig. 20
Suction piping should be continuously rising towards
the pump, when the tank is below the pump.
1.7.3 Suction piping
The feed pipe from the suction tank should be as
short as possible. Pipes causing air pockets must
be avoided. Flow velocity should be less than 3m
per second and the pipe diameter should be cal-
culated accordingly. As a general rule this will re-
sult in a pipe diameter one size larger than that of
the pump inlet.
Inlet tapers should have a flat top as shown in
Fig. 19 on the previous page to avoid problems
with air pockets.
With a suction lift the pipe should rise continu-
ously to the pump, see Fig. 20, and conversely,
with a positive suction head, it should fall continu-
ously towards the pump, see Fig. 21.
In a common manifold for two or more pumps
avoid straight tee´s. Use swept tee´s or a Y-piece
to minimise losses, see Fig. 22. The pumps should
not be connected directly to a 90° bend acc. to Fig.
23.
If a 90° bend is unavoidable in the suction, en-
sure there is at least a straight length of min. 5
pipe diameters before the pump, see Fig. 24 on
page 7.
Z22-pumps (double-suction) can have a 90°
bend on the suction branch provided it is in the
same plane as the impeller, see Fig. 25 on page 7.

Fig. 21
Suction piping should be continuously falling when
the tank is above the pump.

Fig. 22
Connection of pumps to common suction header.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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1.7.4 Discharge Piping >5 x D
A stop valve should be installed in the discharge
piping close to the pump, but down-stream of any
non-return valve. See also Para 1.9. Acute branch-
es and sudden increases in diameter give unneces-
sary losses and may cause noise. See Fig. 26.

1.7.5 Minimum Flow

ATTENTION
D
If its likely that the pump will operate close to or
below its minimum flow, then a bypass must be Fig. 23 Fig. 24
installed to avoid excessive temperature increase Avoid bends directly to the pump. Ensure there is at least a straight length of
and vibration. Consult Sulzer for actual minimum min. 5 pipe diameters before the pump.
flow.

m
Both suction and discharge valves must never be
closed when the pump is running. Closed valves
can cause overheating and an explosion of the
pump.

1.7.6 Piping for Sealing Liquid

Design of the pipework for cooling, quench (low
pressure) and sealing liquids depends on the
seal arrangement, see seal assembly drawing.
See also ”Shaft Seal” Para 3.1 for mechanical
seals and Para 3.2 for soft packed glands. Gener-
ally speaking, the final connections to the pump
Fig. 25
should be flexible and easily detached. Inlet bend in impeller plane.

1.8 Pressure Testing of Pipework

ATTENTION
If the pipe system is pressure tested at a pres-
sure above max. working pressure for the pump,
the pump have to be isolated from the system. At
pressure testing the pipe system have to be care-
fully vented.

1.9 Pressure Transients and L > 5 x (D2 - D1)

Fluctuations
ATTENTION
Each pump is designed for its stated pressure rat- D1 D2
ing. If this pressure is exceeded, including instanc-
es of overpressurising due to pressure transients Fig. 26
(pressure fluctuations), continued satisfactory op- ”Right” and ”Wrong” ways of connecting to a
eration of the pump cannot be guaranteed. common discharge header. The discharge dia-
meter should not be increased suddenly.
Pressure transients occur, if the flow velocity
in a pipe is changed. The more rapid the rate of
change, the larger the pressure fluctuation. In a
long pipe even a slow rate of change may cause a
strong pressure surge.
Starting and stopping pumps or opening and
closing valves are obvious causes of fluctuations.
Centrifugal pumps should be started against a
closed or partially closed valve installed near the
pump. The valve should then be slowly opened.
The pump is normally stopped in the reverse or-
der.
Quick acting valves and long pipelines, particu-
larly those which are inadequately vented or gas-
or airfilled, call for special attention with regards to
pressure fluctuations.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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If the electricity supply should suddenly fail, the
pump speed will drop and the flow in the system
will change in an uncontrolled way. With very long
pipelines the possible consequences of such an
interruption should be considered when the sys-
tem is being designed.

1.10 Reverse Rotation

ATTENTION
If there is no non-return valve in the system, the
pump may rotate backwards, when the motor is
stopped. This can cause damage to seals and mo-
tor.
If reverse rotation cannot be prevented, contact
Sulzer.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB


Series Z22
Start-up and Running Maintenance
2.1 Before Start-up
ATTENTION
m
…… Re-lubricate the bearings with small quantities of grease,
if the pump has been stored for a long time since the deliv-
ery. See Para 2.6.1 for quantity and quality.
…… Open the valves for sealing liquid, quench and cooling
liquid, if any. A me­chanical seal should normally not leak,
but a soft-packed gland should drip significantly during the
start-up period.
…… Check that the waste liquid outlet is not blocked.
…… Prime the pump by filling it with liquid or by venting or
priming. Note that there must be no air left in the pump
suction chambers when starting.
…… Ensure that the shaft can be turned freely.
…… Check the direction of rotation by running the motor for
a few seconds. The direc­tion of rotation is shown by an ar-
row on the bearing bracket.
2.2 Starting
…… When starting the pump, the discharge valve should be
closed or almost closed and the suction valve fully open.
…… Check the shaft seals.
ATTENTION
Mechanical seals: Mechanical seals must never be run
dry. Adjust the sealing, quench and cooling liquids flows,
where applicable.
Soft-packed glands: Ensure that the glands are dripping
adequately. Should overheating occur, slacken of the gland
nuts to increase cooling. During running in, the glands are
adjusted to normal leakage: 25 to 50 drops per minute.
…… Gradually open the discharge valve, until the required
flow is attained. If the rated capacity is significantly ex-
ceeded, the electric motor may be overloaded.
…… Check that the sound and vibration levels are normal.
Operating Instruction
2
2.3 After Start-up
…… Check the shaft seals. A packed gland must always drip.
Otherwise it will overheat, and rapidly wear down the shaft
sleeve. A mechanical seal should be visuably leak-proof.
…… Check the temperature and for any noise of the bearings.
The temperature will normally stabilise in a day after start-
up, and should be within 50o to 80oC de­pending on speed
and liquid temperature.
…… Check that the sound and vibration levels are normal.
2.4 Matching the Pump to the System
2.4.1 Suction
The suction valve must always be fully open during operation.
The flow must never be regulated with this valve, as there is a
risk of cavitation.
2.4.2 Discharge
During normal operation the discharge valve should be fully
open. If the discharge valve is heavily throttled, this indicates
that the pump is operating inefficiently. The pump should then
be matched to the system, either by reducing impeller diam-
eter or the speed. Thus large energy savings will be made and
the life of bearings and shaft seals in­creased.
Decide on the required flow and head and then get in contact
with the nearest Sulzer sales company, which will assist when
cal­culating the new impeller diameter.
ATTENTION
To eliminate the risk of overheating, there must always be a
liquid flow through the pump when in operation.
2.5 Stopping
…… Close the discharge valve.
…… Stop the motor.
…… Close any valves for cooling and sealing liquids.
1.1118en 07.12
2.6 Maintenance

2.6.1 Bearings
2.6.1.1 Grease lubrication Series Z22 - Intervals - quantity

Table 1
Pump size Radial bearing Thrust bearings Relubrication after operating hours at dif- Grease quantities in
ferent speeds in rpm grams
Type No. of Type No. of 1800 1500 1000 750 A*) B**)

Z22 250/200-40 6310 1 7310 BECB 2 10.000 12.000 15.000 - 30 15

Z22 350//300-35 6310 1 7310 BECB 2 10.000 12.000 15.000 - 30 15

Z22 400/300-55 6317 1 7317 BECB 2 8.000 10.000 13.000 - 80 40
Z22 400/300-60 6317 1 7317 BECB 2 8.000 10.000 13.000 - 80 40
Z22 350/300-61 6317 1 7317 BECB 2 8.000 10.000 13.000 - 80 40
Z22 500/300-75 6222 1 7321 BECB 2 7.000 8.000 12.000 - 110 60

Z22 350/350-45 6313 1 7313 BECB 2 9.000 11.000 14.000 - 50 25

Z22 400/350-70 6321 1 7321 BECB 2 7.000 9.000 12.000 - 110 55

Z22 450/400-40 6313 1 7313 BECB 2 9.000 11.000 14.000 16.000 25 25

Z22 500/400-50 6317 1 7317 BECB 2 8.000 10.000 13.000 15.000 80 40
Z22 500/400-55 6317 1 7317 BECB 2 8.000 10.000 13.000 15.000 80 40
Z22 500/400-60 6319 1 7319 BECB 2 8.000 9.000 12.000 - 90 45
Z22 500/400-70 6321 1 7321 BECB 2 7.000 9.000 12.000 - 110 55
Z22 500/400-80 6224 1 7321 BECB 2 7.000 9.000 12.000 15.000 110 45
Z22 600/400-90 6328 1 7322 BECB 2 3.500 6.000 10.000 - 120 100

Z22 500/500-70 6319 1 7319 BECB 2 9.000 12.000 15.000 - 90 45

Z22 800/500-105 6232 1 7328 BCB 2 - - 8.000 11.000 200 70

Z22 600/600-65 6224 1 7224 BECB 2 - 8.000 11.000 14.000 90 45

Z22 600/600-75 6321 1 7321 BECB 2 - - 12.000 14.000 110 55
Z22 800/600-120 6336 1 7236 BCB 2 - - 8.000 11.000 240 140

Z22 700/700-65 6321 1 7321 BECB 2 - 9.000 12.000 14.000 110 55

Z22 800/700-80 6226 1 7226 BCB 2 - - 10.500 13.000 95 50

Z22 900/800-90 6230 1 7230 BCB 2 - - 9.000 12.000 120 60

Z22 1000/100-90 6230 1 7230 BCB 2 - - 9.000 12.000 120 60

A*) Thrust bearing B**) Radial bearing (motor side)

The bearings are normally grease lubri­cated. Suitable grease Table 3

qualities are stated in the table below.
Manufacturer Grease quality
Table 2
BP Energol HLP D68
Manufacturer Grease quality
MOBIL DTE Oil Heavy Medium
BP Energrease LS 2, Energrease LS 3
Q8 Haydn 68
Q8 Rembrant EP 2
Shell Tellus Oil 68
Shell Alvania RL 2, Alvania RL 3
Statoil Hydraway HMA 68
SKF LGMT 2, LGMT 3
TEXACO Rando Oil HD 68
Statoil Uniway L1 42, Uniway L1X 43
Mobil Mobilux EP 2, Mobilgrease HP 103 2.6.1.3 Checking the Bearings
The state of the bearings should be checked regularly by
2.6.1.2 Oil-Lubricated Bearings measuring the temperature and/or vibration level.
Oil lubricated bearing assemblies are fitted with a vent-plug oil
level indicator. The oil should be changed twice a year, see Ta-
ble 3. Fill through the hole in the top of the bearing assembly,
until the oil is visible in the level indicator.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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2.6.2 Shaft Seals
In double suction pumps (Z22), the seals are positioned in the
inlet part of the pump. The pressure at the seals is conse-
quently equal to the pump inlet pressure. At installa­tions with
suction lift, the pressure is below atmospheric pressure. Thus
there is a risk of air leaking through the seals, which is elimi­
nated by connecting sealing liquid.
For clean media the sealing liquid is fed through pipes from
the pressure side. If the pumped liquid is contaminated or cor-
rosive, external sealing liquid is used. See also ”Shaft Seal”
No. 3.

2.6.2.1 Mechanical Seals

A mechanical seal is normally leak-proof, and shouldn´t drip. If
it starts leaking heavily, it must be replaced immediately.
If external sealing liquid is provided, check that it is working
and that flow and pressure are adequate.

2.6.2.2 Gland Packing

Check the gland packing once or twice a week. The gland
should leak about 25 to 50 drops a minute - more for hot li­
quids. Otherwise the packing braids will get hot, their lubrica-
tion disappears, causing rapid wear on the shaft sleeve. In
the case of external sealing liquid, check its function and that
pressure and flow are adequate. (Min. 1 bar above the pump
inlet pressure.)
Should the gland leak excessively, tighten the gland nuts
lightly, and check the leakage after about 10 minutes. If the
leakage still is excessive, re-tighten and allow the packing to
resettle.

2.6.2.3 Miscellaneous
Check the sealing liquid regularly and also the waste liquid out-
let. On pumps with gland packings, the temperatures should
be checked. An increasing temperature indi­cates that the flow
through the seal is not sufficient.

2.7 Replacement of Motor

ATTENTION
After any replacement or repair of the motor, the unit must be
re-aligned and the direction of rota­tion checked. After a tem-
porary disconnec­tion, the direction of rotation must likewise
be checked.

2.8 Shut-downs
During prolonged shut-downs, the system should normally
be completely drained to eliminate the risk of damage from
corrosion or freezing. If the pumped liquid is likely to solidify
and thereby block the me­chanical seals, the sealing chambers
should be flushed clean e.g. by the sealing liquid.
If there are vibrations in the pump founda­tion which exceeds
0,8 mm/s, the pump shaft should be turned every week to
eliminate bearing damage.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

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 Operating Instruction
3
Series Z22
Shaft Seals

m
The pumps can be supplied with a number of
various shaft seal arrangements. The standard ar-
rangements and seal types are described in this Fig. 1
general instruction. We refer to the actual seal Mechanical seal of standard type
assembly drawing and to the seal manufac­turer’s for clean or slightly contaminated
instructions. liquids at me­dium inlet pressures.
Please note that the seal pressure of Z22-pumps
is equal to the pump inlet pressure.
ATTENTION
A shaft seal must never run dry! If the fric­tion heat
is not dissipated, the tempera­ture will rise rapidly.
In packed glands, the shaft sleeve will be subject
to heavy wear, when the lubricant disappears from
the packing braids.
In mechanical seals, dry running will cause severe
damage on seal faces and elastic components.
When servicing the pump, the actual seal assem-
bly drawing should be at hand.

Fig. 2
3.1 Mechanical Seals Balanced mechanical seal for clean
A mechanical seal consists of two rings of high or slightly contami­nated media at
surface finish, which are optically flat. One is sta- higher inlet pressures and/or high
tionary and the other rotates with the shaft. Spring tem­peratures. On district heating
pumps, return water can be used as
force and pump liquid pressure will press the rings
sealing liquid.
together, both of which are sealed with elastic
components.
The seal should not drip during normal operation,
but is not leak-proof. However, the leakage - only
some ccm a day - evaporates or is carried away by
the sealing liquid.

3.1.1 Single, Unbalanced Mechanical

Seal (Fig. 1)
This seal type is mainly used for clean or slightly
contaminated liquids. The standard design has a
single spring, but on large pumps multispring de-
Fig. 3
sign is an alternative. The range of application of Mechanical seal with quench is
unbalanced seals is stated in the diagram on the suitable for corrosive or highly conta-
next page. minated liquids and fibre slurries, e.g.
paper stock. The pumped liquid will
not be diluted.
3.1.2 Single, Balanced Mechanical Seal
(Fig. 2)
From a design point, this type is similar to the un-
balanced one, with the exception that the rotating
ring is placed closer to the shaft. In this way the
seal will be released from pressure (balanced).
This type is used on pumps at high inlet pressures
and/or high temperatures. For range of operation
see the diagram on the next page.

1.1119en 07.12
Diagram

Temperature limits Unbalanced seals <100°C

Balanced seals 100°C-140°C
Max. temperature depends on pump size and speed.

Pressure Limits for Mechanical Seals

For type Z22: Seal pressure = inlet pressure

Use balanced seals above and to the right of the limit lines
Pressure in bar

Seal size in mm

3.1.3 Single Mechanical Seal with

Internal Quench (Fig. 3)
External
sealing liquid The mechanical seals in Paras 3.1.1. and 3.1.2
sealing liquid
can be equipped with quench by adding a small
gland packing (two rings). The cavity between the
seal and gland packing is flushed by low-pressure
liquid to prevent fibres or crystals from collecting
at the seal rear. This arrangement is used for cor-
rosive liquids and slurries, e.g. paper stock.

3.1.4 Sealing liquid

The mechanical seals in Paras 3.1.1 and 3.1.2 can
be provided with internal or external sealing liquid
depending on the type of pumped liquid. See Fig.
4.

Fig. 4 3.2 Gland Packing

There are two types of sealing liquid.
When servicing the pump, the actual seal assem-
bly drawing should be at hand (Fig. 5).
The gland packing (See Fig. 5) consists of:
1. Packings rings, which are compressed by the
gland.
2. A lantern ring is fed with sealing liquid to pre-
vent air ingress through the gland packing.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

2
3.2.1 Gland Packing Packing braids
With Internal Sealing Liquid
If the pumped media is clean, sealing liquid is fed Gland
to the gland packing from the pump discharge
through a pipe. See Fig. 4.

3.2.2 Gland Packing

With External Sealing Liquid.
When handling slurries and contaminated liquids,
external sealing liquid should be provided. This
sealing liquid can also be used for cooling, if the
pumped liquid temperature exceeds 100oC.
Clean, cold water is normally used as sealing
liquid.

3.2.3 Running Maintenance

See ”Start-up and Running Maintenance” No. 2,
Para 2.6.2.2.
Lantern ring

3.2.4 Re-packing
First lock-off the starter and close suction and Fig. 5
Gland packing with lantern ring, which is fed by
discharge valves. A hot pump must be allowed to
internal or external sealing liquid.
cool. If possible, drain the pump completely.
1. Remove the glands and use a packing extrac-
tor to remove all packing rings and the lantern
ring. Clean the boxes thoroughly.
2. Check the shaft sleeves. Replace them, if they
are scored or badly worn. Table 1
3. Flush the sealing liquid pipes to check for Dimensions of Packing Rings
blockages. Pump Packing Length No. of rings in
4. Select new packings according to Table 1. A size size, mm mm each box
slightly larger packing may be used, but never
a smaller size.
Z22 250/200-40 10 260 2+2
5. Cut the ends at right angles using a sharp
knife. Each ring should be long enough for the Z22 350/300-35 10 260 2+2
ends to be pressed together when inserted. Z22 400/300-55 20 440 2+3
6. Stagger the joints half a turn.
7. Position the lantern ring at the connection for Z22 350/350-45 16 320 2+3
sealing liquid in the box.
Z22 450/400-40 16 320 2+3
8. Tighten the gland nuts evenly, so that the pack- Z22 500/400-55 20 440 2+3
ing rings are somewhat compressed. Then Z22 500/400-60 16 450 2+3
loosen the nuts slightly before starting. Z22 500/400-80 20 610 2+3

Z22 500/500-70 20 430 2+3

3.2.5 Running-in
After re-packing, a careful running-in is important. Z22 600/600-65 20 550 2+3
1. Prime the pump. The gland packing should leak Z22 600/600-75 20 490 2+3
considerably. Z22 800/600-120 20 800 2+3
2. Start the pump and observe the gland packings
for some time. If leakage is excessive, tighten Z22 700/700-65 20 550 2+3
the nuts progressively. If leakage stops com- Z22 800/700-80 20 600 2+3
pletely, loosen the nuts until dripping restarts. If
Z22 900/800-90 20 650 2+3
the packing overheats, stop the pump and allow
the shaft sleeve and gland to cool. When the Z22 1000/1000-90 20 650 2+3
pump is running, it can occasionally be cooled
by water outside the gland packing casing.
ATTENTION
The gland packings must never run dry!
3. Check the pump regularly during the initial 1
to 3 hours of running-in. The gland packings
should then be regularly observed during the
first 24 hours.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB

3
 Operating Instruction
4
Series Z22
Dismantling and assembly

4.1 General 4.2 Dismantling standard version

Series Z22 have 24 pump sizes. 16 pumps have similar de- At inside inspection and repair it’s recommended to remove
sign and can be described in one sectional drawing 188386 upper pump casing part and, if nedded, take the complete ro-
(enclosed). Following pump sizes (standard version pump) are tor unit out from the pump for further dismantling. Following
in this group. maintenance and repair can be done without taking the upper
casing part away.
Z22-400/300-55 Z22-600/600-65
…… Changing stuffing box rings and check shaft sleeves condi-
Z22-350/350-45 Z22-600/600-75 tion.
Z22-400/350-70 Z22-800/600-105 …… Make a visible inspection of mechanical seal condition by
dismantling the seal covers. Be careful in order to avoid
Z22-450/400-40 Z22-800/600-120
damage to stationary seal ring.
Z22-500/400-55 Z22-700/700-65 …… Inspection or change of bearings at the free end of the
Z22-500/400-60 Z22-800/700-80 pump and in some cases also at coupling end (if a spacer
coupling or cardan shaft is used). Be careful in order to
Z22-500/400-80 Z22-900/800-90
avoid damage to mechanical seal (seal covers have to
Z22-500/500-70 Z22-1000/1000-90 be loosened). For bearing dismantling and assembly see
Para 4.2.3 and 4.3.
The instruction is based on dismantling (4.2) and assembly
(4.3) for the standard pump sizes. See sectional drawing 188386 for part items.
Remaining pump sizes have some divergences in design from
the standard version and are described in following drawings 4.2.1 Dismantling upper pump casing part
(enclosed): Remove the threaded dowels in the flange between lower and
upper pump casing and the pipes for external shaft seal flush-
Drawing Pump sizes ing, and priming/venting.
1. Remove the screws in glands (stuffing box) or the seal
188391 Z22-250/200-40, Z22-350/300-35
covers (mec. seal) and move glands or seal covers on the
188387 Z22-400/300-60, Z22-350/300-61, shaft to a position close to the bearing cover.
Z22-500/400-70 2. Remove all bolts in flange between upper and lower pump
188388 Z22-500/300-75, Z22-600/400-90 casing part.
188389 Z22-500/400-50 3. Separate upper and lower casing part by using jack screws.
4. Assemble two eye bolts in the sockets at the top of up-
Dismantling and assembly instruction for these sizes is also per pump casing part and lift the upper part away from
based on the instruction for standard versions. the pump. Put upper part on the floor or on a bench. It’s
not allowed to stay under suspended load. Also note that
it’s not allowed to lift the complete pump in this eye
bolts! (See also “Installation” Para. 1.2 and Saftey Instruc-
tion 1-1071).

4.2.2 Removing complete rotor unit including

bearing housings
1. Remove the coupling guard.
2. Disconnect shaft couplings in accordance to instruction for
actual shaft coupling type.
3. Loosen the bearing housings (306, 307) from pump casing
by removing screws and (in single cases) threaded dow-
els.
4. Lift the complete rotor unit with bearing assemblies out
from the pump. Place the unit in a safe way on a bench
and support the impeller in order to avoid moving.

1.1120en 07.12
4.2.3 Dismantling rotor unit
(bearings, seals, sleeves, impeller)
1. Remove coupling from shaft end. A puller normally has to
be used.
2. Remove the outer bearing covers (308, 311) and the
screws in inner bearing cover (309, 310). Now the bearing
housings (306, 307) can be removed. At this stage also
wear rings and locking wire for wear rings can be removed.
3. Turn up the flaps of lock washers (316, 317) and remove
shaft nuts (314, 315) and lock washers.
4. Pull bearings (312, 313) from the shaft by using a puller on
deflectors (304, 305) or inner bearing covers (309, 310),
which will be dismantled together with the bearings.
5. For stuffing box version the glands (340), gland packing
rings (342), lantern ring (341) and stuffing box bushing
(347) now can be removed. For mechanical seals the first
step is to remove seal cover with stationary seal ring. Be
careful in order to avoid damage on seal ring (carbon)!
Thereafter the rotating seal parts can be removed. For
seals with single spring it’s recommended to make a mark
on the spring in order to get it back to correct end of the
shaft at assembly. Figure 1 shows how the springs should
be mounted related to rotation.
Fig. 1
6. Remove outer shaft sleeves (346) by pressing in a sharp
edge or similar between outer and inner sleeve and press
them apart. Do the same operation for inner sleeves (345)
(against impeller hub). In some cases it can be necessary
to make a minor heating of the sleeves before dismantling.
Remove o-rings (326) for shaft sealing.
7. Remove impeller (201) by hanging the shaft in vertical di-
rection. Place the lower shaft end on a wood piece or simi-
lar and press or knock on impeller. Be careful if impeller
suddenly drops down! In some cases it can be necessary
to heat up impeller for dismantling. Remove key (302) if
necessary.
ATTENTION
This instruction is for a complete dismantle of a Z22 pump
in standard version, but the instruction can also be used for
partly dismantling.
…… dismantling for change of bearing(s). Can also be done
without splitting the pump.
…… dismantling for inspection and/or change of seal(s).
…… dismantling for change or turning of impeller (from one side
of the rotor unit).
For this partly dismantling only actual parts of instruction
above have to be used.
ORIGINAL INSTRUCTION
2
4.3 Assembly of standard version
Before assembly an inspection of eventual wear or damage
on pump parts have to be done. Pay special attention on o-
rings, wear rings, sleeves, shaft seals and bearings. Parts with
severe damage have to be changed. A new gasket between
lower and upper pump casing part will often be needed. Be
sure that a sheet of gasket material is available.
See sectional drawing 188386 for part items.
1. Place key(s) (302) in their grooves in the shaft (301). Clean
and lubricate the shaft with anti-friction grease and push
on the impeller (201). The impeller shall be able to enter
the shaft with only a very light press force. For stainless
material, care have to be taken in order to avoid seizing.
ATTENTION
Assemble impeller correct way for actual rotation direction.
See figure 2.
Fig. 2
2. Push inner shaft sleeves (345), o-rings (326), and outer
shaft sleeves (346) onto the shaft. Sleeves don’t have to
be assembled with great force (use anti-friction grease).
Note! Outer sleeves can have different length at coupling
and free shaft end.
3. Place wear rings outside the impeller.
4. Fit shaft seal parts on inner sleeves.
- For stuffing box version, fit box bushings (347), lantern
rings (341), and glands (340). Note that stuffing box bush-
ings shall be assembled with the narrow side in direction to
impeller and lantern rings with the threaded holes in direc-
tion to bearings. Gland packing rings will be fitted after the
rotor have been placed in the lower pump casing part.
- For mechanical seal version, assemble the o-rings in ro-
tary seal rings and push the springs on the seal rings neck.
Push the complete rotary part into correct position and at
the correct side of the shaft (for guiding see fig.1). The o-
ring can be lubricated by soap water in order to make as-
sembly easier and safer. Assembly stationary seal rings
with the o-rings in the seal covers (363). Also now soap
water can be used. Clean seal faces (both rotating and sta-
tionary rings) carefully and fit o-ring (ev. also gasket) and
seal covers with stationary seals on inner shaft sleeves.
Cover the seal parts with a cloth or similar to protect the
seal faces for dust until complete assembly of the pump.
5. Push deflectors (304, 305) with radial seals (319, 320) and
inner bearing covers (309, 310) onto the shaft.
COPYRIGHT © SULZER PUMPS SWEDEN AB
6. Put a small amount of grease in all bearings before as- 14. Assemble the upper pump casing part carefully into correct
sembly. Press the ball bearing 312 (coupling side) and an- position and fit the fixing screws. Fit all flange screws.
gular contact bearings 313 (free side) onto the shaft. Use
a sleeve and press on inner ring. Note that the angular - For stuffing box version, tighten the gland with the gland
contact bearings must be arranged in accordance to fig. 3. screws in order to slightly compress the stuffing box rings.
Assembly will be easier if bearings are heated up before After that the gland screws have to be loosened again (for
fitting (max. 110 °C). running in the box see part 3.)
- For mechanical seal version, fit the o-ring and seal cover
to the pump casing. Check before assembly that seal fac-
es and o-rings are clean and free from damage.
15. Check that it’s possible to rotate the shaft. The friction in
shaft seals can make it necessary to use some kind of tool,
especially for bigger pump sizes.
16. Assemble pipes or pipe connections for seal water, venting
or priming.
17. Assemble shaft coupling and guard(s) in accordance with
instructions for actual shaft coupling type.

Fig. 3

7. Fit the two lock washers (316, 317) and tighthen shaft nuts
(314, 315). Check that deflectors, sleeves and impeller are
properly stacked on the shaft. Lock nuts by folding one flap
of lock washers.
8. If flange gasket (104) between upper and lower casing
half have to be replaced, the split flanges will be carefully
cleaned. A new gasket is made from a gasket sheet by
placing the sheet on the lower casing part flange and the
contour is knocked out with a hammer.
9. Lift the rotor unit and place it slowly in the lower part of the
pump casing (102). Check that wear rings (203) and stuff-
ing box bushing (347) are in correct position.
10. Push the lock wires (204) into the grooves of the wear
rings. Turn the wear rings in the direction of rotation of the
pump so that all of the lock wires will be in the lower part of
the pump casing. Fit the screw to stop the wear rings from
rotating if not already fitted.
11. Fit bearing housings at both sides with screws and (in sin-
gle cases) the dowels. Tighten the screws.
12. Fit the bearing cover (310) first and tighten screws. Then
fit the bearing cover (311). There shall be a small gap (0.1-
0.5mm) to bearing housing (307). This ensure that there
is no play in bearing assembly (313). The bearing covers
(308) and (309) can be fitted in any order.
13. Fill stuffing box with gland packings and lantern (see also
part 3). This operation can also be done after complete as-
sembly of the pump.

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS SWEDEN AB