Py Ingersoll-Dresser Pumps ELGIN WTP ONTARIO CLEAN WATER AUTHORITY HLI-4 Vertical Turbine Pumps Serial Number: 94-42-300375, Sales Order Number: 726-00010 ELGIN WTP OCWA PROJECT NO. 5-00-02 ™M.M. DILLON ENGINEERS HLP-1&4 Ingersoll-Dresser Pump Company 5310 Taneytown Pike Taneytown, MD 21787TABLE OF CONTENTS SECTION ONE - PUMP (42-300375) GENERAL ARRANGEMENT DRAWING . GA300375 REV. 02 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS PUMP CROSS SECTION ASSEMBLY - BOWL ASSEMBLY 901.14 PUMP CROSS SECTION ASSEMBLY - FLANGED COLUMN .... 902.01.05 PUMP CROSS SECTION ASSEMBLY - DISCHARGE HEAD 1903.04.02 PUMP CROSS SECTION ASSEMBLY - STUFFING BOX . ceeee ee, 904.02 PUMP CROSS SECTION ASSEMBLY - SPACER COUPLING . 905.01 TYPICAL PERFORMANCE CURVE . cesses 300375CV BILL OF MATERIALS ........020000000000000eeeseeteeeeenees sss. 3 PAGES LIST OF MATERIALS SPARE PARTS LIST COATING/PAINTING PAGES ....... - 76.15.0508 PERFORMANCE TEST PROCEDURE .. 6 PAGES AIR RELEASE VALVES PUMP NAMEPLATE DETAIL ..... cette ceceeeeeceseees 86200599 GAUGE CASE DIMENSIONS SECTION TWO - MOTOR (42-300375) A. PERFORMANCE DATA 1.1 ENGINEERED PERFORMANCE DATA SHEET 1.1.1 (HIGH SPEED) 1.1.2 (LOW SPEED) 1.2 TORQUE VS. SPEED/CURRENT CURVE 1.2.1 (HIGH SPEED) 1.2.2 (LOW SPEED) 1.3 THERMAL LIMIT CURVE 1.3.1 (HIGH SPEED) 13.2 (LOW SPEED) B. DIMENSIONS 2.1 OUTLINE DIMENSION PRINT 2.2 AUXILIARY T-BOX LOCATIONS 2.3 CONDUIT BOX (MAIN) PRINT #3A049Z779r1 2.4 CONDUIT BOX (AUX - WINDING RTD'S) PRINT #3A040D128r1 2.5 CONDUIT BOX (AUX - BEARING RTD'S) PRINT #3A040D129r1 2.6 CONDUIT BOX (AUX - SPACE HEATERS) PRINT #3A040D134 2.7 NON REVERSE RATCHET PRINT #3A040D002 200375100INTENTS SECTION TWO - MOTOR (42-300375 CONT.. (C, CONNECTION DIAGRAMS, 3.1 MAIN LEADS. 3.2 RESISTANCE TEMPERATURE DEVICES 3.2.1 WINDING 3.2.2 BEARING 3.3 SPACE HEATERS 3.4 VIBRATION SWITCH D, DESCRIPTIVE LITERATURE 4.1 RTD TEMPERATURE VS. RESISTANCE 4.1.1 CHART SHOWING SETPOINTS 4.12 CURVE SECTION THREE (42-300375) THREE PHASE SQUIRREL CAGE INDUCTION MOTOR ACCEPTING, INSPECTION, STORAGE, TRANSPORATION ...-...00.05+ 3A057D116E REV. 02 INSTALLATION ceceeevseeeees 3A057D808E REV. 00 OPERATION ....... 3A057D098E REV. 02 MAINTENANCE RECORDS OF DAILY & REGULAR INSPECTION 3A057D097E REV. 02 MAINTENANCE OF ROLLING BEARING . ceteeeessseeeee+, 3A057DI23E REV. 02 STRUCTURE OF BEARING (UPPER) . 3A040D106 REV. 00 STRUCTURE OF BEARING (LOWER) ...... --- 3A040D107 REV. 00 FAULT FINDING AND RECOGNITION . - 3A0S7D068E REV. 02 OUTLINE DRAWING 3A040C737 REV. 01 SCHEMATIC DRAWING (MAIN TERMINAL BOX) . ceee+ 3A049Z779 REV. 01 SCHEMATIC DRAWING (WDG, RTD TERMINAL BOX) |... 3A040D128 REV. 00 SCHEMATIC DRAWING (BRG. RTD TERMINAL BOX) SCHEMATIC DRAWING (SPC. HTR. TERMINAL BOX) CONNECTION DIAGRAM . : NON REVERSE RATCHET ..... RESISTANCE VS. TEMPERATURE CURVE (RTD'S) ... ROCHESTER VT-1215 (ENCL., MOUNT. O/L, AND CONN.) SPECIFICATION TABLE .... ce PERFORMANCE TEST CERTIFICATE FORM A-2 PERFORMANCE TEST CERTIFICATE FORM A-2 VIBRATION AND NOISE TEST CERTIFICATE FORM Y-2 . 3A040D129 REV. 01 3A040D134 REV. 00 3A045D403-1 REV. 00 3A040D002 REV. 02 - 3A040RTD100 REV. 00 C-1055-796 REV. F 3A057D006-536 REV. 02 ~ A-2D4B111-1 REV. OL ~ A-2D4B111-2 REV. 01 - VN-2D4B111 REV. 01 ot20075 06TABLE OF CONTENTS SECTION ONE - PUMP (42-300375) GENERAL ARRANGEMENT DRAWING cece csseeeeeeesses++ GA300375 REV. 02 INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS PUMP CROSS SECTION ASSEMBLY - BOWL ASSEMBLY. 901.14 PUMP CROSS SECTION ASSEMBLY - FLANGED COLUMN ..........++ ceeeeeess 902.01.05 PUMP CROSS SECTION ASSEMBLY - DISCHARGE HEAD - 903.04.02 PUMP CROSS SECTION ASSEMBLY - STUFFING BOX ........02200000500 = 904.02 PUMP CROSS SECTION ASSEMBLY - SPACER COUPLING «........0.0.2055 cere 905.01 TYPICAL PERFORMANCE CURVE . - -300375CV BILL OF MATERIALS ....... ceveceteees ceseteeeeeees 3 PAGES, LIST OF MATERIALS SPARE PARTS LIST COATING/PAINTING PAGES .... ceeeeeteeeees ceeeeesseeeeeees 76.15.0508 PERFORMANCE TEST PROCEDURE .....- . 6 PAGES AIR RELEASE VALVES PUMP NAMEPLATE DETAIL .. ceveeeteeeee cee eetteees 86200599 GAUGE CASE DIMENSIONS 2500375 oe(x eee) prcumery pes oa we Sung 1 REE cog Os onan) PORTE eo av © [auy mea}I) Ingersoll-Dresser Pumps INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS APW Vertical Turbine Pumps Serial Number: 94-42-300375-1/2 126-00010 Sales Order Number NOTE: IT IS IMPORTANT THAT THE ENTIRE CONTENTS OF THIS BOOKLET BE STUDIED BEFORE INSTALLATION. Ingersoll-Dresser Pump Company 5310 Taneytown Pike Taneytown, MD 21787 Refer All Communications to the Nearest Branch Office Listed on the Back of this Page ELGIN WIP. OCWA PROJ. NO. 5-00-02 M.M. DILLON ENGRS. HUP-1, HLP.&Ingersoll-Dresser Pumps — North American Facilities senenconte, Hes sent 1g ee ECan ue Soe Sune? ass Bene estat haere aeeteetngen Baits, Eras ae ae . (508) 660-3969 Boece, Serie, Tes angets, cx : ae isigonse ingersol-Dresser Pumps — International Facilies sent i sere BE emncten Pres PY oreo Seige oe, pa mart Hess s0 192 9851 Suave Medias Wes BEB. ¥S6830 00 OTE TES pene 08251 ost S838 7012 se Tees Ages worn Vesa ‘E38 a1s20 85076 3353 s6221 5 62 Go16 oe sore. we or Rio de Jeneiro 03 Soa 0617 PRG e121 Rede es fone vate ea 30.420 0116 ‘Seoul Dubal " 7h oes ete ete tneen matare Fon b= Hs ot es or = Meee Ohm ee fos Sirs: Brier Se. tiene B27 sent Bon sean a dean BE BGs soroser ‘ies ae Berranguine 21880 4510, FOSS Too a522 55°38 se5 S041 9950 Desio- Mil Arable: tock calevatt 562812 937 ithe PERS 2 Bes ere Sa es Mosques aap ese nt ammem siete Fae" TS Sear 2609 ‘S'ea3s089 fant Fiyaey Sees eeat ‘e Patan Gar ase $55 ein sep bee Frans Hoficeide ° bores Havers” ‘son megs _ see ne imate ets eae val Ingersoll-Dresser Pumps — Repair Center Locations aur ev va note Ne seo aan ems SHB Blas arate Sts anges cone oes $8 vets i403 se3.0288 (201) 227-4565 (6051 878-7276 aa PS ‘ett pen te ET o irate BAe Ton co Seno ou eo vatena we vn Sanat" Barat iors Manufacturing Locations/Werehouses Ooo {a0 S6a'e021 (ator ee eee ah Se. Ean Parts Distribution Center Far a0 I 2 Ingereol overseeTABLE OF CONTENTS 300... 400 500 .... DESCRIPTION GENERAL INFORMATION STARTUP AND OPERATION GENERAL MAINTENANCE, TROUBLE SHOOTING- REPAIR OF SEALING ARRANGEMENT . REPAIR OF COLUMN REPAIR OF BOWL ASSEMBLY . PARTS ORDERING INFORMATION CROSS SECTIONAL DRAWINGS102F NOTE: IT IS IMPORTANT THAT THE ENTIRE CONTENTS OF THIS BOOKLET BE STUDIED BEFORE INSTALLATION. FOREWORD a This manual contains instructions for in- stallation, operation and maintenance of your Ingersoll-Rand vertical turbine pump. It has been designed to provide safe and reliable service. However, itis both a pressure vessel and a piece of ro- tating machinery. Therefore, the opera- tor(s) must exercise good judgment and proper safety practices to avoid damage to the equipment and surroundings and prevent personal injury. The instructions in this manual are intended for personnel with a general training in operation and maintenance of vertical turbine pumps. Itis assumed that your safety depart- ment has established a safety program based upon a thorough analysis of indus- trial hazards. Before installing and operat- ing or performing maintenance on the pump and associated components de- scribed in this manual, it is suggested that the safety program be reviewed to ensure that it covers the hazards arising from high speed rotating machinery. It is also important that due consider- ation be given to those hazards which arise from the presence of electrical power, hot oil, high pressure and temper- ature liquids, toxic liquids and gases, and flammable liquids and gases. Proper in- stallation and care of protective guards, shutdown devices and over pressure pro- tection equipment should also be consid- ered an essential part of any safety program. Also essential are special precautionary measures to prevent the possibility of ap- plying power to the equipment at any time when maintenance work is in prog- ress. The prevention of rotation due to re- verse flow should not be overlooked. In general,all personnel should be guided by all the basic rules of safety asso- ciated with the equipment and the pro- cess. It should be understood that the infor- mation contained in this manual does not relieve operating and maintenance per- sonnel of the responsibility of exercising normal good judgment in operation and care of the pump and its components. In the following safety procedures you will encounter the words DANGER, WARNING, AND CAUTION. These are intended to emphasize certain areas in the interest of personal safety and satis- factory pump operation and mainte- nance. The definitions of these words are as follows: ZX DANGER Danger is used to indicate the presence of a hazard which will cause severe per- sonal injury, death, or substantial prop- erty damage if the warning is ignored. |Z) WARNING Warning is used to indicate the pres- ence of a hazard which can cause severe personal injury, death, or substantial Property damage if the warning is ignored ingersoil-Dresser Pump Company 18102.CHP1028 ZX CAUTION Caution is used to indicate the presence ofa hazard wich will or can cause minor personal injury or property damage if the ‘warning is ignored. NOTICE, Notice is used to notify people of instal- lation, operation, or maintenance infor- mation which is important but not hazard related. Hazard warning should never be included under the Notice word. These safety procedures are to be used in conjunction with the installation, oper- ation and maintenance instructions con- tained in this pump manual. Do not install this equipment other than in accordance with the instructions con- tained in this manual. ‘The descriptions and instructions in- cluded in this manual cover the standard design of the equipment and any com- mon deviations when possible. This man- ual does not cover all design details and variations nor does it provide for every contingency which may be encountered When information cannot be found in ‘this manual, contact the nearest I-R Rep- resentative. ‘These instructions should be read com- pletely before starting installation. The unit is capable of trouble-free operation when properly applied, installed and maintained. These instructions present the basic information and methods re- quired for proper installation and mainte- nance ‘These instructions should be read com- pletely before starting installation. The unit is capable of trouble-free operation when properly applied, installed and maintained, These instructions preseat the basic information and methods re- quired for proper installation and mainte- nance, 18102.CHP Ingersoli-Dresser Pump Company103.1F GENERAL INFORMATION SUMP AND DEEP WELL PUMPS. GENERAL The length of satisfactory service to be obtained from the equipment will, in part, depend on proper installation and maintenance. This instruction manual presents the basic information for operat- DRIVER ing and maintenance personnel. IDENTIFICATION Should questions arise concerning the pump, the factory will require the com- plete serial number to be of assistance. ‘The serial number is stamped on a metal DISCHARGE nameplate affixed to the discharge head ASSEMBLY assembly. The driver will have a separate nameplate attached to it - when request- ing information of the driver both the driver serial number and pump serial number will be required. DRIVERS cOWWMN A variety of drivers may be used, how- ever, electric motors are most common. For the purposes of this manual all types of drivers can be grouped into two catego- ries: 1, Hollow shaft drivers where the head shaft extends through a tube in the center of the rotor and is connected to the driver by a clutch assembly at a BOM. the top of the driver. ASSEMBLY 2. Solid shaft drivers where the rotor shaft is solid and projects below the driver mounting base. This type driver requires an adjustable cou- pling for connecting to the pump. General Arrangement ingersoll-Dresser Pump Company T8151. CHP103.18 DISCHARGE HEAD ASSEMBLY ‘The discharge head supports the driver and bow! assembly as well as supplying 2 discharge connection (the type "UF" dis- charge connection will be located on one of the column pipe sections below the dis- charge head) A shaft sealing arrangement is located in the discharge head to seal the shaft where it leaves the liquid chamber. The shaft seal will usually be either a mechani- cal seal assembly or stuffing box with open lineshaft or a tube packing box with an enclosed lineshaft. COLUMN ASSEMBLY Column assembly is of two basic types, either of which may be used. 1, Open lineshaft construction utilizes the fluid being pumped to lubricate the lineshaft bearings. 2. Enclosed lineshaft construction has an enclosing tube around the lineshaft and utilizes oil to lubricate the lineshaft bearings. Column assembly will consist of column pipe, which connects the bowl assembly to the discharge bead and carries the pumped dluid to the discharge head; shaft, connecting the pump shaft to the driver; and may contain bearings if re- quired for the particular unit. Standard ‘column pipe is of flanged-type construc- tion. Threaded type column pipe is avail- able. Some units will not require column as- sembly, having the bow! assembly con- nected directly to the discharge head. BOWL ASSEMBLIES The bowl assembly consists of impellers rigidly mounted on the pump shaft which rotate and impart energy to-the fluid, bowls to contain the increased pressure and directs the fluid, suction bell or case which direct the fluid into the first im- peller, and bearings located in the suction bell (or case) and in each bowl. The suction strainer, normally attached to the suction bell or casing, may be con- sidered as part of the bowl assembly. 1B1031.CHP Ingersoil-Dresser Pump Company04.1 STORAGE ee RECEIVING Extreme care should be exercised when unloading. Heavy parts should be skidded to the ground if lifting equipment is not available. do aot drop the unit, or any parts, as damage may cause trouble in as- sembly and operation of the units. Inspect unit for signs of transit damage before beginning to uncrate or put into storage. if damage is evident the local transporting company agent should be no- tified before uncrating and a claim filed with the agent. STORAGE If the unit is to be stored prior to instal- lation carefully select a storage space so the unit will not be subjected to excess moisture, extreme weather conditions, corrosive fumes, or other barmful condi- tions. Carefully inspect the unit and clean any rust spots on machined surfaced wich fine emery cloth and coat with a rust pre- ventive. If the unit is stored for a long pe- riod it should be inspected from time to time and cleaned as required. When a pump is stored for extended pe- riods, rotate the shaft several revolutions once each week. Be certain to rest the shaft in a new position. This will prevent damage to rotating element during long term storage in a horizontal position. Driver storage instructions should be checked for special care as may be re- quired. ingersoll-Dresser Pump Company ig1041.CHP201F INSTALLATION GENERAL INSTALLATION CHECK LIST The following checks should be made before starting actual installation to as- sure proper installation and prevent de- lays: 1. With motor driven units be sure the voltage and frequency on motor nameplate agree with the service available. Also make sure the horse- power and voltage rating of the con- trol box or starter agrees with horsepower and voltage rating of motor. 2. Check the depth of the sump against the pump length to be sure there will be no interference, 3. Check the proposed liquid level in the sump against the pump length - the bottom stage of the pump must be submerged at all times. 4. Clean the sump and piping system before installing the pump. 5. Check the installation equipment to be sure it will safely handle the equipment. 6. Check all pump connections (bolts, nuts, etc.) for tightness. These have been properly tightened before leav- ing the factory, however, some con- nections may have worked loose in transit. This is particularly true of some stainless steels which have a tendency to creep. 7. On the hollow shaft drivers check the clutch size against the shaft size which must go through the clutch. 8. On solid shaft drivers check the motor shaft size against the coupling bore size. 9. Proper installation is necessary to provide maximum service from the pump. To insure proper alignment three items are very important dur- ing installation: A.All machined mating surfaces (such as the mating flanges of pump and motor) must be clean and free of burrs and nicks. These surfaces should be cleaned thor- oughly with a scraper, wire brush and emery cloth if necessary and any nicks or burrs removed with a fine file. B. Exterior strain must not be trans- mitted to the pump. The most common cause of trouble in this respect is forcing the piping to mate with the pump. It is recom- mended that flexible connectors be installed in the piping adjacent to the pump. C. All threads should be checked for damage and repaired if necessary. If filing is necessary, remove the part from the pump if possible, or arrange a rag to catch all filings so they do not fall into other parts of the pump. Clean all threads with a wire brush and cleaning solvent, ends of shafts must be cleaned and any burrs removed since align- ment depends on the shaft ends butting squarely. Lubricate all screwed connections with a suit able thread lubricant (an anti-gall- ing compound such as ingersoll-Dresser Pump Company 18201.CHP-2018 "Anti-Seize" should be used on stainless mating threads). Apply thread lubricant sparingly to male shaft threads only when making up shaft connection - excess lubricant should not be allowed to get between the ends of ‘the shaft, FOUNDATION The foundation may consist of any mate- rial that will afford permanent, rigid sup- port to the discharge head and will absorb expected stresses that may be en- countered in service. Concrete foundations should have an- chor bolts installed in sleeves twice the di- ameter of the bolt to allow alignment with the holes in the mounting plate as illustrated in the figure at right. The mat- ing surface to the baseplate needs to be leveled to within .001" per one foot with machine level. When a suction barrel is supplied as in the case of the type "TF" discharge head, the suction vessel must provide perma nent, rigid support for the pump and motor. It should be mounted on a firm foundation. Recommended Anchor Bolt Arrangement 18201.CHP ingersoll-Dresser Pump Company202.17 INSTALLATION PUMPS SHIPPED UNASSEMBLED EQUIPMENT AND TOOLS No installation should be attempted without equipment adequate for the job. The following list covers the principal items required for an installation. 1. Mobile crane capable of hoisting and lowering the entire weight of the pump and motor. 2, Two (2) steel clamps or elevators with bails or cable. 3, Two (2) sets of chain tongs. 4, Cable sling for attaching to the pump and motor lifting eyes. 5. Steel pipe clamp for lifting bowl as- sembly and column pipe. 6. Approximately 15 feet of 3/4” rope. 7. Ordinary hand tools - pipe wrenches, end wrenches, socket set, screw drivers, Allen wrenches, etc. 8, Wire brush, scraper and fine emery cloth. 9. Thread compound designed for type of connection and light machinery oil. ZX, CAUTION The single most common cause of pump vibration is from a bent shaft. Shafting is straightened to stringent tolerances prior to shipping and great care must be exer- cised in its handling. Always support sbafting in at least three places when lift- ing or installing. NOTICE Parts and accessories may be placed in- side shipping containers or attached to skids in individual packages. Inspect all containers, crates and skids for attached parts before discarding, UNCRATING AND CLEANING Clean parts of all dirt, packing material and other foreign matter. Flush the pump inside and outside with clean water. Clean all machined surfaces. Remove any rust spots found on the machined sur- faces with fine emery cloth. Clean all threaded connections and any accessory equipment. Lineshaft when shipped sepa- rately should be left in the crate to avoid damage or loss of straightness. INSTALLING PUMP 1. Position lifting equipment so it will center over the foundation opening. NOTICE, ‘Sump and piping should be thoroughly cleaned of all loose debris before starting installation. 2. Ia base plate is used, level the plate to 001" per foot and then grout and anchor in place. 3. Bowl Assembly A Check for axial clearance or end play, While bowls are in a horizon- tal position you should be able to push or pull the pumpshaft indicat- ing axial clearance. Check all bolts for tightness. Do not lift or handle ingersoll-Dresser Pump Company 182021.CHP202.18 the bowl assembly by the pump shait, B. Carefully lift the bowl assembly and suction with a bail or clamp. When installing a very long 6" or 8" bowl assembly, leave the bowl securely fastened to the wooden’ skid that is attached for shipping until the bowl assembly is raised to a vertical position. This will help prevent breaking the bowls or bending the shaft. C.Ifa strainer is to be used, attach it to the bowl assembly using clips and fasteners provided. D. Lower the bow! assembly into the well or sump. Set clamp or hold- ing device that is attached to bowls on a flat surface. This is to stabilize bowl assembly and re- duce possibility of cross threading shaft. (55) SUCTION BL NY (am) oP somw (oe) sane (55) SUCTION BEL cay ar (422) cop screw Gis) sR ALTERNATE — "CLIP-ON" STYLE SUCTION STRAINER 182021.CHP Ingersoll-Dresser Pump Company208.1F INSTALLATION - DISCHARGE HEAD PRODUCT LUBRICATED DISCHARGE HEAD Pump heads may be shipped with the sealing housing installed. For ease of as- sembly and to prevent damage we recom- mend removing the housing before putting the head on the pump. For pumps supplied with hollow shaft drivers and a one piece headshaft (head- shaft couples below sealing housing) pro- ceed to step 1. For pumps supplied with a two piece headshaft (headshaft couples above seal- ing housing) or solid shaft drivers pro- ceed to step 2 (skip step 1.) 1. Attach the stainless steel headshaft to the lineshaft with a coupling and tighten (left hand threads). 2. Lift discharge head over shaft and lower carefully into place. See back for lifting arrangements. Be certain not to bend the shaft. Fasten the top column flange and bearing retainer if supplied to bottom of head. (W heads do not have a bearing retainer at the top column flange). 3. Lift entire pump and remove col- umn clamp. Lower pump until dis- charge head touches the foundation aligning the pump with foundation bolts. Use shims or wedges between the pump and foundation to level the pump. The shaft must be cen- tered in the discharge head. HEAD MiTH TAO READSHaFT f TE STWE FagzicaTso EAD wie SEU) NOTE HEAQ STYLES ARE FOR LiUSTRATICN ONLY DIFFERENT SHAFT aReANGU: CAN BE SUPPUED WITH Zach STH 1S ingersoll-Dresser Pump Company 182051.CHP205.18 PIN Do not use the lifting pins at the base of the discharge head to lift the discharge head only (unless the head is secured to the slings to prevent “overturning” of the head). The best method is to assemble the head by lifting from eye bolts placed in the top motor flange of the head. Never lift the completely assembled pump with eyebolts thru this flange! FABRICATED wiTH 2 PONT UFTING 2.00 O1&, HOLE HEL STYLE FABRICATED wT '3 BOT LIFTING (82081.CHP Ingersoll-Dresser Pump Company206.17 INSTALLATION SEALING ARRANGEMENT 6. Stuffing Box A Slide the stuffing box over shaft and fit into place (be sure to in- clude the o-ring on bottom side of stuffing box in the groove pro- vided). Bolt securely in place using the studs and nuts provided. B. Packing a, Insert the lower lantern ring (threaded holes up) in bottom of box. b. Insert three packing rings, fit- ting ends together so they con- tact fact to face on an angle. Turn each cut piece 90° from the previous piece. Be sure each piece is set against the piece below it. IA\ CAUTION Do not tamp packing tight in the stuff- ing box. Excessive tamping will stop the flow of fluid through the packing, this will result in destruction of the packing and shaft. c. Insert the second lantern ring (threaded holes up) on top of the packing. The lantern ring should be aligned with the grease port d, Insert three more packing rings on top of the lantern ring, as before. e. Thread two studs into the holes on top of the stuffing box. £ Insert the packing gland on top of packing, press down snug, The packing gland nuts should be tightened together to keep equal pressure on the packing. (G46) (327A) ‘SUNGER NUT, VS o cared PACKING ano (s28a) ‘STUD, PACKING CAND 3) PACING (29) UANTERN RING (355) G3) m4 PACKING srurrng NE so) (2s) sa) Su, vara STUFFING Box (ata) BYPASS (45) ow fme] <= 47) (83) O-RING Swe Box ingersoll-Dresser Pump Company 182061.CHP206.18 The packing must be allowed to leak for proper operation. ‘The proper amount of leakage can be determined by checking the temperature of the leak- age. This should be cool or just lukewarm, not bot. Insert the grease zerk and grease with a high quality grease. C. Ifhigh pressure bypass is neces- sary, remove bypass plug. Install bypass line back to suction side of pump or drain. D. Attach slinger above packing gland. Packing glands must never be tightened to the point where leakage from the pack- ing is stopped. A small amount of leakage ‘is required for lubrication of the packing. Shutting off leakage from the packing will result in bumed packing and scored shaft. a ___ 182061. CHP Ingersoll-Dresser Pump Companyore INSTALLATION ADJUSTABLE FLANGED SPACER COUPLING (WSA) 1. Clean threads on pump shaft and on adjusting nut. Check for burrs and nicks. All burrs, nicks and rust must be re- moved from all mating parts of flanged coupling and pump before installation. Failure to remove all burrs, nicks and rust may result in misalignment causing pump to fail. 2. The key for the driver shaft keyseat should be a snug or tight fit in the shaft keyseat, and a sliding fit in the keyseat of the driver half coupling. ‘The key with pin should be a sliding fit in pumpshaft keyseat and a snug or tight fit in pump half coupling key- seat, Side clearance of keys in keyseats should be checked with a feeler gauge. This clearance should not ex- ceed .003" for a snug fit to .005" for a sliding fit. These are maximum al- lowable clearances. Closer fits are preferred, if possible. It may be nec- essary to file-dress keys to obtain proper fit. 3, Insert the key with pin into pump half of coupling putting the pin in the hole in keyseat. 4, Lubricate pump coupling half and key assembly with light oil and slide it onto pump shaft with flange up. Slide it past threads. 5. Lubricate adjusting aut with light oil and thread it onto pump shaft (left hand threads) with male register down. Thread it on until top of shaft and top of nut are even. 6. Uncrate and lift motor to allow ac- cess to driveshaft. MOTOR SHAFT (42) DRIVER COUPUNG Ot (46A) DRIVE KEY (12a) spur THRUST RING (G14) SPACER (384) CaP SCREW (363) HEX NUT (44) DRIVEN COUPUNG HALF (384) CAP scREW (48) KEY ASSEMBLY (92a) TOP SHAFT ‘The driver must be set on supports capa- ble of carrying entire weight of driver be- fore proceeding to Step 7. Failure of supports could cause damage to motor or loss of life if driver should fall. Ee 7. Clean and check driver shaft. Re- move any burrs. 8. Check the fit of the straight key and split thrust rings in their respective keyseats, (Refer to paragraph 2 re- garding fit of the straight key). ingersoll-Dresser Pump Company 182071.CHP207.18 9. Install straight key into keyseat. The bottom of the key must be above top of circular keyseat for the split thrust rings. 10, Lubricate driver half coupling lightly and slide it onto driver shaft. Slide bottom of coupling above the top of the keyseat for split thrust rings. 11. Install split thrust rings into circular keyseat and slide the coupling down over them. 12, Bolt spacer to driver half coupling usiag the short set of socket head cap screws. The male register should be pointing down. Tighten all cap screws evenly to the bolt torques listed in table. 13, Proceed with driver installation. 14, Refer to pages 209.21 and 209.22 for impeller adjustment instruccions. raz es, 105 3, 738 100 For stainless steel bolts, multiply listed torques by .80. Torque values shown are for standard fas- teners lubricated with a high stess lubri- cant (graphite and oil, moly-disulphite, white lead, ete.) 182071.CHP ingersoli-Dresser Pump Company208.2 INSTALLATION SOLID SHAFT DRIVER SOLID SHAFT ORIVER 1. Clean driver mounting flange on dis- charge head and check for burrs or nicks on the register and mounting face. Oil lightly. ZX CAUTION When lowering motor and driver half of coupling onto pump do not let pump half of the coupling touch the driver half of the coupling. 2. Center motor over pump and rotate to align mounting holes. Electric motors~rotate junction box into desired position. Gear Drives~rotate input shaft into desired position. 3. Lower driver carefully into place making certain that the female regis- ter on the driver mates over the male register on the pump. 4. Bolt driver to discharge head. 5. Check driver manufacturer's instruc- tions for special instructions includ- ing lubrication instructions and follow all “start-up” instructions. 6. Electric drivers should be checked for rotation at this time. Make elec- trical connections "bump" (momen- tarily start, then stop) job motor to check rotation. DRIVER MUST ROTATE COUNTERCLOCK- WISE when looking down at top ead of motor. To change the direction of rotation on a three phase motor, in- terchange any two line leads. To change direction of rotation on a two phase motor, interchange the leads of either phase. ZX cauTIon, Before bumping motor make sure cou- pling halves are not touching and that the driver can rotate freely, without rotating the pump. Driver half coupling must be in proper position so the circular key will not come out. ZX. CAUTION Reverse rotation with the pump con- nected can cause extensive damage to the pump--always check rotation before con- necting driver to pump. 7. ce impeller adjustment instructions before bolting the pump and driver half of the coupling together. Ingersoli-Dresser Pump Company 182082. CHP209.21F INSTALLATION IMPELLER ADJUSTMENT SOLID SHAFT DRIVER IMPELLER ADJUSTMENT Proper impeller adjustment positions the impeller inside the bowl assembly for maximum performance. The impellers must be raised slightly to prevent them from dragging on the bowls, but not raised to high so as to adversely affect hy- draulic performance, The impellers must be down against the bowl seat when starting impeller adjust- ment. When pumps are subjected to suc- tion pressure the pressure acting against the shaft ends to raise it. Make sure the shaft is fully down when starting to adjust the impellers. If, after making the adjustment the pump does not deliver its rated capacity the impellers can be lowered one step at a time until the lowest possible adjust- ment is achieved without the impellers dragging. On the other hand, if the im- pellers appear to be dragging after the ini- tial adjustment the unit should be stopped and the impellers raised one step. Dragging impellers will increase the load markedly and can usually be heard and felt as increased vibration. A sharp rise in motor amperage will occur when impellers drag. This is especially true for semi-open impellers. SOLID SHAFT DRIVER Impeller adjustment when using solid shaft drivers is accomplished in the adjust- able flanged coupling located below the driver. ADJUSTING ADJUSTABLE FLANGED COUPLING 1. Assemble coupling on pump shaft and driver shaft as outlined earlier if not already in place. 2. Check motor rotation as described earlier. THE IMPELLERS FOR THIS PUMP SHOULD BE RAISED 9.25" __ INCHES FOR BEST OPERATION (Includes running clearance). FINAL COUPLING AND ALIGNING 1. Mount two magnetic indicator bases on the discharge head at 90 degrees to each other. Set the indicator tips on the shaft just above the seal and at 90 degrees to each other. (Usually parallel and perpendicular to the dis- charge nozzle) push the shaft (paral- lel to discharge) back and forth (without bending shaft). Note and re- cord the minimum and maximum in- dicator readings. Do the same procedure at 90 degrees to the dis- charge. Set the shaft in the center of the maximum and minimum indica- tor readings both directions. If the shaft will not stay in this position use small wooden wedges between the shaft and seal bolts to hold the shaft. The indicators can now be removed. ALTERNATE METHODS FOR PUMPS WITH PACKING: Using an in- side micrometer measure the space be- tween the shaft and the packing box bore. Do this both parallel and perpendicular to the discharge nozzle. Using the wedges center the shaft so the measurements Ingersoll-Dresser Pump Company 1820821. CHP209.218 taken at 180 degrees to each other are step for the set of jackserews located ‘within 0,004" of being equal. 90 degrees to the first set. Once all For pumps using jack screws for motor skip to alignment step 3. 2. Mount the magnetic base on the drive half coupling ( a band clamp may be necessary to hold base due to limited space). Position the tip of the indicator on the pump shaft just above the seal. Slowly rotate the driver shaft. Note and record the T.LR. reading. If this reading is more than 0.010" for WA and WSA couplings or 0.006 for PA and PSA couplings, unbolt the drive and repo- sition the driver in the direction re- quired to reduce the T.LR. to within the allowable limits. Note: If a regis- ter fit is used for alignment driver will be able to be moved only afew thousandths of an inch. For field alignment only: If enough move- ment is not obtainable then the male register can be filed to obtain an ac- ceptable TLR. readings. (Go to step 4.) 3. On pumps using jackscrews for motor alignment, mount the dial in- dicator base on the O.D. of the motor half coupling. Set the indica- tor on the shaft, position the dial to zero being careful that the indicator is in direct line with one of the jack- screws. Record this reading then ro- tate the motor shaft and indicator 180 degrees. Record this reading being careful to note plus or minus values, Take the difference of the two readings and using the jackscrews move the motor one half of the difference. Repeat this step until the T.LR. reading is a maximum of 0.002". Then repeat this readings are within 0,002" tighten motor bolts and check for any move- ment in readings, 4, Set the impeller setting gap between the adjusting nut and the driver por- tion of the coupling. For this pump the impeller gap should be as listed in paragraph 2, under Adjusting Ad- justable Flanged Coupling, for best operation. Align the match marks on the pump half coupling with the driver half coupling. On pumps with enclosed impellers the match marks can be lined up by increasing the im- peller gap until the marks are in line, with the driver half coupling marks, Note: On pumps with semi-open im- pellers the match marks probably will not be in line when the gap is set. DO NOT try to align the marks on the nut with the other marks. For pumps with enclosed impellers go tostep 8. Using 2 bolts of the coupling, at 180 degrees to each other, slowly raise pump half coupling until impellers are just lifted off the seat. (This can be gauged by trying to turn shaft by hand. At the point the impellers are lifted the pump will turn.) Be sure to lift both sides evenly! 6. Measure the resultant gap between the motor half coupling and adjust- ing nut. 7. Find the difference between the original gap and the new gap. Add iB20821.CHP Ingersoll-Dresser Pump Company8, Bolt the coupling together and tighten bolts by tightening opposite sides. 9. Remove wooden wedges, if used. Mount magnetic base on pump and set the tip of indicator on the shaft just above the seal. Slowly rotate the shaft and note the T.LR. reading. Unless otherwise specified the allow- able TLR. readings are: 209.22 WA and WSA couplings 0.004" PA and PSA couplings 0.002" If the reading is larger than the al- lowable then unbolt the pump and rotate the driver portion of the cou- pling to different hole and repeat Steps 8 and 9 until acceptable read- ings are obtained. 10. If a mechanical seal is used, adjust the mechanical seal at this time ingersoll-Dresser Pump Company 1820921 CHP3011F STARTUP AND OPERATION PRODUCT LUBRICATED PUMPS. PRE-STARTING CHECKS Before starting the pump the following checks should be made: 1. Rotate the pump shaft by band to make sure the pump rotates freely and the impellers are correctly posi- tioned. 2. Make sure the headshaft adjusting nut is properly locked into position. 3. Has the driver been properly lubri- cated in accordance with the instruc- tions furnished with the driver? 4, Has the driver been checked for proper rotation: If not, the pump must be disconnected from the driver before checking. The driver must rotate COUNTERCLOCK- ‘WISE when looking down at the top of the driver. 5. Check all connections to the driver and control equipment. 6. Check that all piping connections are tight. 7. Check all anchor bolts for tightness. 8. Check all bolting and tubing connec- tions for tightness (driver mounting bolts, flanged coupling bolts, gland plate bolts, seal piping.etc.) 9. On pumps equipped with stuffing box make sure the gland nuts are only finger tight-DO NOT tighten packing gland before starting. 10. On pumps equipped with mechani- cal seals clean fluid should be put into the seal chamber, With pumps under suction pressure this can be accomplished by bleeding all air and vapor out of the seal chamber and al- lowing the fluid to enter. With pumps not under suction pressure the seal chamber should be flushed liberally with clean fluid to provide initial lubrication. Make sure the me- chanical seal is properly adjusted and locked into place. ZX WARNING An OSHA screen guard is furnished with all pumps having a two piece head- shaft or an adjustable flanged coupling. This screen must be secured in place prior to pump start up to prevent possible contact with rotating parts. NOTICE After initial start up, pre-lubrication of the mechanical seal will usually not be re- quired as enough liquid will remain in the seal chamber for subsequent start-up lu- brication. ‘STUFFING BOX ADJUSTMENT On the initial starting it is very import- ant that the packing not be tightened too much, New packing must be run in prop- erly to prevent damage to the shaft and shortening of the packing life. ‘The stuffing box must be allowed to leak for proper operation. The proper amount of leakage can be determined by checking the temperature of the leakage, this should be cool or just lukewarm— NOT HOT - usually 40 to 60 drops per minute will be adequate. ingersoll-Dresser Pump Company 183011.CHP301.18 ‘When adjusting the packing gland bring both nuts down evenly and in small steps until the leakage is reduced as required. The nuts should only be tightened about one half turn at a time at 20 to 30 minute intervals to allow the packing to "run-in". Under proper operation a set of packing will last a long time. Occasionally a new ring of packing will need to be added to keep the box full. After adding two or three rings of packing, or when proper ad- justment cannot be achieved, the stuffing box should be cleaned completely of all old packing and re-packed. LINESHAFT LUBRICATION Open lineshaft bearings are lubricated by the pumped fluid on short coupled units (less than 50° long) and will usually not require pre-or post-lubrication. All open lineshaft pumps where the static water level is more than 50’ below the dis- charge head should be adequately pre-lu- bricated before starting pump. These units should have a non-reverse ratchet on the driver to prevent backspin when turning off pump. If there is no NR.R, post- lubrication is also necessary. INITIAL STARTING 1. lethe discharge line has a valve in it, it should be partially open for initial starting. 2. Start prelubrication liquid flow on pump if required. 3. Start the pump and observe the op- eration. If there is any difficulty, ex- cess noise or vibration, stop the pump immediately and refer to Trouble Shooting Chart for proba- ble cause. 4. Open the discharge valve as desired. 5. Check complete pump and driver for leaks, loose connections or im- proper operation. 6. Ifpossible, the pump should be left running for approximately one half hour on the initial start-up, this will allow the bearings, packing or seals, and other parts to “run-in" and re- duce the possibility of trouble on fu- ture starts. NOTICE If abrasives or debris are present upon start-up the pump should be allowed to run until the pumpage is clean. Stopping the pump when handling large amounts of abrasives (as is sometimes present on initial starting) may lock the pump and cause more damage than if the pump is al- lowed to continue operation. Z\ CAUTION Every effort should be made to keep abrasives out of lines, sump, etc. so that abrasives will not enter the pump. 183011.CHP. Tngersoll-Dresser Pump Company401 MAINTENANCE GENERAL GENERAL ‘A periodic inspection is recommended as the best means of preventing break- down and keeping maintenance costs toa minimum. Maintenance personnel should look over the installation each time the pump is inspected - a change in noise level, amplitude of vibration, or perfor- mance can be an indication of impending trouble. Any deviation in performance or opera- tion from what is expected can be traced to some specific cause. Determination of the cause of any change in performance or operation is essential to the correction of the trouble - whether the correction is done by the user, the dealer or reported back to the factory. Variances from initial performance will indicate changing system conditions, wear, or impending breakdown of unit. PERIODIC INSPECTION A periodic once-a-month inspection is suggested for all units. During this inspec- tion the pump and driver should be checked for performance, change in noise or vibration level, loose bolts or piping, dirt and corrosion. Clean and repaint all areas that are rusted or corroded. IMPELLER READJUSTMENT Ordinarily impellers will not require re- adjustment if properly set at initial instal- lation. Almost no change in performance can be obtained by minor adjustment of enclosed impellers. Alll adjustments of the impellers will change the mechanical seal setting. It is recommended that the seal be loosened from the shaft until the adjustment is complete and then reset. PUMP LUBRICATION Other than the stuffing box lubrication, mechanical seal, and/or lineshaft lubrica- tion, the pump will not require further pe- Tiodic lubrication. On water pumps the suction bearing on the bow! assembly should be repacked when repairs are made, however, no attempt should be made to repack until repairs to the bow! assembly are necessary. Pumps that pump hydrocarbons or have carbon, rubber, epoxy or teflon suction bearings do not have the suction bearing packed. DRIVER LUBRICATION Drivers will require periodic attention. Refer to the driver instruction manual for recommendations. ingersoll-Dresser Pump Company 1B401.CHP.4021 MAINTENANCE STUFFING BOX GENERAL Maintenance of the stuffing box will consist of greasing the box when re- quired, tightening the packing gland occa- sionally as the leakage becomes excessive, and installing new packing rings or sets as required. GREASE THE STUFFING BOX Under ordinary operation once-a- month greasing of the stuffing box will be adequate. A high quality industrial grade grease is recommended. REPLACING PACKING Remove gland and all old packing. If the box contains a lantern ring remove this and all packing below it using two long threaded machine screws. Inspect shaft or sleeve for score marks or rough spots. Be sure by-pass holes (if supplied) are not plugged. Repair or replace badly ‘worn shaft or sleeve. If wear is minor dress down until smooth and concentric. ‘Clean box bore. Oil inside and outside of replacement rings lightly and install in box, staggering joints 90 degrees. Be sure to replace lan- tern ring in proper position when used. Replace gland and tighten nuts finger tight. The packing gland must never be tightened to the point where leakage from the packing is stopped. A small amount of leakage is required for packing lubrication. START-UP WITH NEW PACKING Check to see that the by-pass line (if used) is connected and the packing gland is loose. Start pump and allow to run for 20 to 30 minutes. Do not tighten the gland during this "run-in" period even if leakage is excessive. Should the new packing cause excessive heating during *run-in*, flush the shaft and packing box area with cold water or shut the pump down and allow to cool. PACKING DIMENSIONS: saarrsax | ARRGRNG F ra Te ae Lr Tae ine we Lae 7 aie 7 ane ve Be ue rg a Sue ra zur a se oa 73 ro ingersoil-Dresser Pump Company 184021.CHPSOF TROUBLESHOOTING CHART nonin eee | Grae vecenioas Saues tse. isp es Sra epepepancenten fice cme = a Sica pectin cmmatoneem | sigerenie ieeciace a ere = impo SETS nom pappnatoee Bctacos Sitrorsomenrame ass fares hae eae a Smteaes | ieenme 4 cos HE oem en ine innveoes sere SSSsSe aceon era ia 1latabe miner or imple plugged, oe pur mud 1 Startand sop pump several tines or wt ine pressure if alable to beck lk. Pal psp A Impeller lowe on shat Sade, 15 Pll ent and repair Retend Copecty | 1 Bypesopea. 1 Check bypass aving, lapels Ei too high for pump 2 Check performance curve, 3. Motor aot coming up 1 Spend. 3. Check voltage we unit running 4 Strainer or peter party pinged. 4 Ser and op pump several timer x we line 5. Sealed or correed dacharg pape or ea ‘pressure evalabi to bac Gh, Pall pnp sod ane a eee = (6 Earn amos Of aor at ‘3. Replace pipe x repair oaks 17 Exeee wear det abraiven 6 Correct condition Impellers act property joni 17 Replace worn par 9 mpaiir loose oe shal ase ‘Adjusrment Serica 9. Pull unit and repair. “Motor Overloaded | 1 Lise voltage ot corres. 1 heck and corre 2 Faulty equipeeat wed to check 2 Gheck equipment 2 Specie prev higher than exis. 3. Correct sponte peviy or eerahace ete, ‘4 Operation a point on pump cure eher than | 4. Check performance curve. =. ‘Lie voltage to high or inorrecfrequeaey. 5. Matar epoed to high. 6 Reagjuet ‘6 lmpeen dragon. Pall mater switch, roeate pup by band check. 1 Pepi bind Digamemble voit io determine cause Pump Nowy sod 1. Uni maing bactwar 1 See “nial Starting f Unie, Vibrtig 2 Pump breaking suction and pumping air. 2 Lower pup o reduce capaci (GeeFlowetarton | 3 Looee fareners 3. Check all bot aut, ee, Decks of hi {4 Badly wore moeor or pump beariags 44 Pu unit and repair Pe) | Seber ome oe uh 5: Pull wait ad erp 6 Pamp aad Motor shals misaligned. 6 Pl wait and repel 1 Seren due to pring msalipamest, 1. Cocret one Wear L Abr 1 Ga Seon 2 Pump i bind, taster mitch, rotate pump by band to check, 3 Vibrson Disassemble wait to determine cuce. 11 Decermine couse and correct Conese, TV leparen 1 Asales Nak 2 Corrie guid, 2 Change to Corrosion resirant materia, ingersol-Dresser Pump Company 18S01.CHP018 VIBRATION TROUBLE SHOOTING FLOW CHART ‘CORRECT MISMATCHED 'BOLTING AND PUMP 1Bs01 CHP [— VISRATES LOOSEN MOTOR MOUNTING BOLTS. [Nor [CHECK VIBRATION. | REMOVE MOTOR CHECK MOUNTING BASE OF MOTOR ‘AND HEAD. REMOUNT JAND CHECK VIBRATION. rACT MOT MANUFACTURER LOOSEN ALL PIPING JAND HEAD MOUNTING| BOLTING. CHECK VIBRATION. T NOT OK OK OK 14 CORRECT MISMATCHED BOLTING AND PUMP: MOUNTING. CHECK VIBRATION. NOT Ingersoll-Dresser Pump Company502.2F REPAIR - PRODUCT LUBRICATED - STUFFING BOX SOLID SHAFT DRIVER eS GENERAL Eventually repairs will have to be made, either to the pump or to the motor. When regular maintenance checks indicate that an overhaul is required, it should not be delayed. Repairs will consist of removal of the unit and disassembly to the point neces- sary for replacement of worn parts. Disassembly should be performed in a clean area with sufficient space to lay out the parts in order of disassembly. Cleanli- ness throughout repairs is important - re- member this is a close tolerance, high speed machine and should be handled as such. ZX CAUTION Protect machined surfaces from burrs and scrapes which will cause misalign- ment on reassembly. |Z\ DANGER To prevent injury due to electric shock or rotating equipment, the pump controls must be locked and tagged in the off posi- tion, ZX DANGER To prevent injury due to lethal liquids, gases and/or hot parts, before disassem- bly the pump must be isolated from the system, drained of liquids, vented of fumes and brought to room temperature. DISASSEMBLY 1. Close gate valve in discharge line. 2. Lock out power supply to driver. 3. Disconnect all electrical connections and tag 4, Disconnect any external auxiliary piping connections. NOTICE Numbers in parentheses are part refer- ence numbers. See cross section drawings in Section 900, 5. Disconnect the driver shaft from the pump shaft by removing the socket head capscrews (364) from the flanged coupling. This will allow the pump shaft and impellers to drop down also. If coupling has a spacer remove the lower set of capscrews and nuts (363) only. 6. Remove bolts that attach driver to discharge. 7. Lift driver off pump and set on wooden supports. Be sure supports are high enough to clear shaft and shaft couplings. 8. Disconnect discharge piping from pump 9. Remove anchor bolts (or nus) or if the pump has a suction can, remove ~ the nuts attaching discharge head to suction can, ingersoll-Dresser Pump Company 185022.CHP502.28 10. Lift pump vertically until pump suc- 14. Remove slinger from shaft. Unbolt tion clears the base stuffing box and remove from dis- charge head. The stuffing box has 6 LI. Cover opening in foundation. rings of packing. A lantern ring is in the bottom of the stuffing box 12, Lower pump into a horizontal posi- are 3 rings of packing with the ends tion on suitable support and in a suit- of the packing staggered around the able area for disassembly. shaft at 90° from each other. The sec- ond lantern ring is next followed by the top three rings of packing, then the packing gland. NOTICE, If more than minor repairs are antici- pated it is recommended that the unit be NoTICE taken to a shop or other clear area with a smooth floor and overhead lifting equip- Before proceeding further make sure ment. the discharge head and bowl assembly are supported independently of eact 13, Remove the adjusting nut from the + other. pump shaft (left hand threads). Re- move the pump half of the flanged coupling with key from pump shaft. 185022.CHP Ingersoll-Dresser Pump CompanyREPAIR - FLANGE COLUMN - PRODUCT LUBRICATED 1. Remove the top column from dis- charge head. The nuts are located just under the discharge head. Re- move the discharge head, being care- ful not to damage or bend the shaft extending through the discharge 5. Each time a lineshaft coupling is ex- posed, the lineshaft and coupling should be removed by holding the lower lineshaft and turning the cou- pling (ineshaft threads are left hand). Bearing retainers should be head. removed after the lineshaft cou- pling. Before lifting the bearing re- NOTICE tainer out of the register in flanged column - remove any nicks or burrs If more than one length of column pipe on the shaft. is involved each column pipe and shaft . should be match marked to keep the 6. Repeat steps 4 and 5 for each piece shaft extensions the same during reassem- of column pipe removed. bly. ZX CAUTION When using wrenches on shafting al- 7. Refer to page 203.1 for reassembly. ae map tor | 12° THR 14° ways place the wrenches on the same side (12) UNESHAFT of the shaft to avoid excess side strain on (70) ET the shafting. Care should always be taken ao1) Gun so that exposed lengths of shafting are not damaged or bent. (4) VE Ge USD) 2, Remove the headshaft and coupling if it has not been removed earlier (left hand threads). (431) O-RING. (OPTIONAL) 3. Remove the bearing retainer by slip- ping it over the shaft. Any nicks or burrs on the shaft should be re- moved before removing the bearing (8) BEARING retainer. (08) SET spew (507) BEARING RETAINER 4, Remove the column pipe by unbolt- ing it at the nearest joint from the top of the pump. ingersoll-Dresser Pump Company 186017.CHP701.3 REPAIR - BOWL ASSEMBLY - KEYED IMPELLER FLANGED CONSTRUCTION DISASSEMBLY When disassembling the bowl assembly, always number and tag all bowls and im- pellers to ease reassembly. 1. Lay the bowl assembly in the hori- zontal position and block evenly. 2, Remove the suction bell (or case) plug, if supplied. 3. Measure the end play. A. Push the shaft down until the im- peller(s) seat against the bowl(s). B, Mark the shaft position. C. Pull the shaft up until the im- peller(s) hit. D.Record the distance traveled. End Play = 4. Remove the shaft coupling. Threads are left hand. 5. Ifa discharge case is supplied, re- move discharge case cap screws and slide the discharge case off of the shaft. 6. Remove bowl cap screws and slide the top intermediate bowl off of the shaft. NOTICE Do not allow the weight of bowls or im- pellers to rest on an unsupported shaft. 7. Impeller Removal. ‘A Pull the shaft up so that the im- peller is not against the bowl seat. B. Remove the socket head cap screws using an allen wrench. C. Slide the impeller down the shaft 3/16" minimum. D.Remove the split thrust rings. E. Slide the impeller off of the shaft. F, Remove the straight key from the shaft. 8. Repeat steps 6 and 7 until.all inter- mediate bowls and impellers have been removed. 9. Slide the suction bell off over the bottom end of the shaft. 11. Ifa sand collar is supplied, loosen the set screw and slide the sand col- lar off of the shaft. Dress the shaft where it was marred by the set screw. ingersoll-Dresser Pump Company 187013. CHP702.17 REPAIR OF BOWL ASSEMBLY - INSPECTION AND TOLERANCES - ENCLOSED IMPELLERS INSPECTION AND CLEANING and damage. “As New" Wear Ring Tolerance Chart tolerances. IMPELLERS After disassembly, all components soe, | CUARANCE should be thoroughly cleaned and exam- GaLL RING ENT, ined for physical defects, wear, corrosion ane Mis MMO pw [aa [a] w [un] asas [sa] ant (A owner | a 5 F E When repairing a bow! assembly that a has been in service for several years, the 7 [vias [wm | a3 | a physical condition or strength of all parts 3 [wna [97s] 0a | a such as cap screws, bowls and bow! 10 [wna | mas [104 | a threads must be carefully checked. jon [Tne vrs [90 uaa] we [mas [we | 99 waa | aie | ssa9 | we [9 4 | ane |_moo | aa] 104 AX caution eis | sine | ava [ ia | ae isis | ans [sama | as [9 When attempting to rework any part, ex- i617 | mae sya | as | wwe treme care must be taken to maintain ras | ane | ~eooe [128 | 10 alignment of mating parts and "as new" ei [ane [vas [inne | ws 1920 [wns [ ans | isms [ws won| wa | as | ws | as mz | war | was | ws | 2s am [wa | sa | wwe | as mu | woo | wo | 57 | ae Clear all passageways and check for mas | uno [at [ sr) signs of damage from abrasion or corro- 75:26 | sto | wen [6s | a sion, Replace any impeller which shows se [wm Tes | wer signs of excessive wear. Check impeller running clearances against “as new” tolerances as listed in the table to the right. If clearances exceed the maximum tolerances shown in the table by more than 50%, wear rings should be installed to obtain correct tolerances. If the original unit was furnished with bow! and/or impeller wear rings, they may be pressed or machined off. If the original unit did not have wear rings, impeller hub O.D. and bow! LD. must be machined to except wear rings. Recommended press fits are also shown in the table. NOTICE, Replacement wear rings are furnished semi-finished if ordered separate. Bowl wear rings will require machining of the bore after they have been pressed into the casting. Impeller wear rings will re- quire machining of outside diameter after they have been pressed onto the casting. Finish on wear ring surfaces must be smooth (63 RMS). ingersoll-Dresser Pump Company 187021.CHP702.18 BOWLS Clear all passageways and check for signs of damage from abrasion or corro- sion. Replace any bowl which shows ex- cessive damage. SHAFT Check the shaft for pitting, wear and straightness, Shaft damage is usually best corrected by replacing the shaft. The shaft must be straight to within .00S inches total indicator reading. The dia- gram below shows the recommended method for checking shaft straightness. If the shaft is not straight, it must be straightened or replaced. If the deflection is gradual over a considerable length, the shaft can usually be straightened by sup- porting on two blocks straddling the crooked section and applying pressure to the high side to deflect the shaft in the op- posite direction. If the shaft has a sharp crook (dog-leg), it is recommended that the shaft be replaced since the shaft will not always remain straight, even if satis- factorily straightened. BEARINGS ‘Check all bearings for total clearance over the shaft. It is recommended that all bearings indicating visual wear be re- placed. In addition, any bearing whose running clearance exceeds "As New" tol- erances by more than 50% should be re- placed (see the table to the right). Rubber bearings should always be re- placed when servicing a pump. DIAL INDICATOR SHAFT | es | ROLLERS Bronze, epoxy, carbon and hard-backed rubber bearings are pressed into their re- spective bores. They can either be pressed out or machined on the inside di- ameter until the wall is thin enough to collapse. ‘Some rubber bearings are the snap-in or glue-in type. These can be removed by prying inward on the outside of the bear- ing to collapse it. If the bearing bore of the housing is heavily scarred or corroded, the part should be replaced or reworked to pro- vide a true bore for the bearing. Replacement bearings are designed to be pressed into housings so bores will shrink to "as new” tolerances. Check the bore of bearings after pressing and ream as necessary to assure “as new” tolerances. REPLACEMENT PARTS Parts showing signs of damage, cracks or excessive wear should be replaced. In- gersoll-Rand assumes no responsibility or liability for damages caused by the use and/or failure of a pump which has been fitted with spare or repair parts not of our manufacture. Only genuine parts from In- gersoll-Rand or an authorized distributor should be used. Sas) (cur, ‘SRY SIZE | smart TOLERANCE | mus 187021.CHP Ingersoll-Dresser Pump Company708.2F REPAIR - BOWL ASSEMBLY - KEYED CONSTRUCTION PARTS PREPARATION Before proceeding with assembly, thor- oughly clean all boits, nuts, threaded con- nections and mating faces and apply white lead and oil or pipe joint com- pound. Clean up any burrs with a fle or emery cloth. Cleanliness and proper lubrication are required to guarantee ease of reassembly and proper pump operation. Check the shaft for straightness (less than .005 inches TIR) and remove all burrs or nicks. Even if the shaft is new or has been pre- viously straightened, it is recommended it be rechecked at this point to insure dam- age has not occurred in transit or ban- dling (see page 702). PUMP REASSEMBLY 1. Insert the shaft into the suction bell. Adjust so that the bottom of the shaft is even with the bottom of the suction bearing. 2. Place the straight key in the key seat of the next impeller to be assembled. 3, Slip the impeller over the shaft and key and seat in the suction bell or bowl. 4, (Semi-open/additional stages only) Slide shims over the shaft and insert into the impeller hub until the shims match the level of the circular key- way in the shaft. Be sure that all im- pellers are seated against their respective bowls. NOTICE Shims are used for semi-open impellers to insure that all impellers seat against their respective bowls. There is no need to shim the first stage of semi-open bowl assemblies or any stage of enclosed bow! assemblies. 5. Adjust the shaft so that the circular key seat is just above the hub of the impeller. 6. Insert the split thrust rings into the circular key seat with the counter bored holes away from the impeller, 7. Align the holes in the thrust rings and impeller. Insert socket head cap sctews and tighten evenly (see table on next page). 8, Ifthe pump was supplied with a sand collar, install it using the following procedure: A. Remove the shaft from the suction bell. B, Slide the sand collar with set screw onto the shaft. C. Reinsert the shaft into the bell as before. Make sure the impeller is seated. D. Pull the sand collar against the suc- tion bell hub. Ingersoll-Dresser Pump Company 187082.CHP708.28 E, Tighten the set screw. 9. Slide the intermediate bowl onto the shaft and mate with the suction bell or bowl. On bolted bowl assemblies, rotate the bow! to align its ribs with the bell ribs. 10. Insert and uniformly tighten cap screws on flanged bowls (see chart below); use heavy chain tongs to tighten threaded bowls. 11. Repeat steps 2,3,4(if applicl- able),5,6,7,9 and 10 until all bowls and impellers are reassembled. 12. Ifa discharge case was supplied, slide it aver the shaft and mate with the top intermediate bowl. Install and tighten cap screws (flanged con- struction) or tighten using chain tongs (threaded construction). 13. Grasp the shaft and rotate by hand to check for binding. Also check shaft end play against the value re- corded during disassembly. 14. Ifthe suction bearing was originally grease packed (bronze bearing with plug), repack with an insoluble grease such as Conoco Graphlube No. 30. Work the shaft up and down after greasing to remove excess grease, Remove enough grease to allow insertion of the plug without forcing the shaft up. 15, Install suction bell plug and tighten. 16. Screw the shaft coupling onto the shaft. 17. Check all bolts and nuts for tight- ness. Ifa threaded discharge case bearing is used, check it for tightness. 18. (Threaded construction only) Drill a 3/16 inch hole into each flange joint. Insert drive pins into holes to secure joints. FASTENERSIZE | U4 | sue | aa | me | 12 vie] se] |] 1 [mim lia Torquetum|) ss | 0 | 7 | 7 | 0 1o Toss [ass TT s00 ces [os te) Use. 75 x Table vale for 30 series sunles eel 187052.CHP Torque values suown are (or eandard fasteners Mbrcated wih a high sires uDncant (raphe and Ol, oly diulpite whit lead, ingersoll-Dreaser Pump CompanyBo1F PARTS ORDERING INFORMATION ORDERING INSTRUCTIONS By giving complete information you will enable us to fill your order correctly and avoid unnecessary delays, HOW TO ORDER REPLACEMENT PARTS When ordering replacement parts, please supply the information as noted on the back of this page. HOW TO SELECT RECOMMENDED SPARES Each Parts List shows the parts which are included in each of the following two classes or recommended spares: CLASS | MINIMUM ‘Suggested for Domestic Service when pump is handling clean noncorrosive liq- uuids and where interruptions in service are not important. CLASS II AVERAGE Suggested for Domestic Service when pump is handling abrasive or corrosive liquids and where some interruptions in continuity of service are not objection- able. Our Sales Representative in your area will gladly review the spares best suited to meet your requirements for Export, Marine or Domestic Service where inter- ruptions in service are objectionable. When ordering recommended spares, please follow the procedures as outlined for replacement parts. NOTICE, The cut away views shown in parts sec- tion of this manual are typical prints and may not show exact construction of a par- ticular pump. Ingersoll-Dresser Pump Company 1Ba01.CHP.8018 SPARE PARTS REQUEST Date: 1-R Order No. Purchase Order No.: Name: Address: Cit State: Special Marks: Zip: VIA: Pump Serial No. (located on pump serial plate) Size & Type: (located on pump seriai plate) Original Order Ne ay a PART NUMBER DESCRIPTTON Please enter my order for the above Please provide price and availability for the above. Class I Quote Class II Quote Class III Quote Send to: Ingersoll-Rand Co. Parts Distribution Center P.O. Box 3055 Scranton, PA 18505-3055 Or Call: Phone No. 1-717-451-2200 1-800-526-3569 Fax: 1-717-451-2280 Distributors 1-717-451-2284 Regional Sales Orders (Direct Customers) PLEASE KEEP ORIGINAL IN INSTRUCTION BOOK 18801.CaP Ingersoll-Dresser Pump CompanyBOWL ASSEMBLY 901.14 ENCLOSED KEYED IMPELLER PRODUCT LUBE (70) SHAFT COUPLING (6) PUMP SHAFT (472) DIFFUSION CONE (387) NUT (358) CAP SCREW (26) CAP SCREW (322) BOWL BEARING [7] (2) IMPELLER (310) Bow. (312) SPLIT THRUST RING (358) CAP SCREW (32) Key (85) SUCTION BELL (128) GREASE PLUG (323) SUCTION BEARING [7] NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: (cass 1&2 CLASS 2FLANGED COLUMN A L TO ALE-PRODUCT LUBE ° a a W/ SLEEVE & THI EADED COUPLING (12) LINE SHAFT (527) NuT | 1 (325) CaP SCREW /y (14) sHarT sueeve G7] | (101) COLUMN PIPE | Bast) o-rinc bo 5 (OPTIONAL) PY (39) une shart BEARING | (356) ser screw OH |-——— (70) SHAFT COUPLING fe a, (427) JACKSCREW (OPTIONAL) Ph NUMBERS IN PARENTHESES ARE. REFERENCE NUMBERS. OMMENDED SPARES: CLASS 1 & 2 CLASS 2 E Pm (12) LINE SHAFTDISCHARGE HEAD 9035.04.02 TYPE HFH (334) Lock ScREW (68) HEAD SHAFT NUT C }— (335) GiB KEY SOLID SHAFT DRIVER —] [_— HOLLOW SHAFT DRIVER (382) NUT L (469) JACKSCREW | (381) CAP SCREW DRIVE SHAFT SEE FLANGED COUPLING DETAIL (417) CAP SCREW —| (418) WASHER —J | f— (10) HEAD SHAFT (70) SHAFT COUPLING ATTRA {_ SEE SEALING DETAIL (131) COUPLING GUARD (304) DISCHARGE HEAD “4 (12a) TOP LINE SHAFT ——F (431) O-RING (327) NUT (101) COLUMN PIPE bs (326) sTuD NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: CLASS 1 & 2 CLASS 2SEALING DETAIL 904, STUFFING BOX 02 WITHOUT SLEEVE (346) SUNGER (328) STUD (17) PACKING GLAND (327A) HEX NUT (419) PIPE PLUG RELIEF LINE (13) PACKING (345) GREASE ZERK (354) stud (385) HEX NUT (347) o-RING Gi] (29) LANTERN RING (83) STUFFING 80x (117) Pressure (] REDUCING BUSHING NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: Z cass 1 & 2 @ cuss 2ADJUSTABLE FLANGED SPACER COUPLING (WSA/PSA) wo o oO CL (48A) ORIVE KEY (42) DRIVER COUPLING HALF NY (312A) SPUT THRUST RING (314) FLANGED SPACER a (364A) CAP SCREW (963) HEX NUT (66a) ADJUSTING NUT ——~ | (44) DRIVEN COUPLING HALF a (12a) TOP SHAFT NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. (364) CAP SCREW (48) KEY ASSEMBLYBOWL ASSEMBLY 901.14 ENCLOSED KEYED IMPELLER PROOUCT LUBE PUMP CROSS SECTION ASSEMBLY - TYPICAL (70) SHAFT COUPLING [J] (6) PUMP SHAFT [2] (472) OIFFUSION CONE (357) NUT (356) CAP SCREW (26) CAP SCREW > (322) Bow. BEARING [7] (2) IMPELLER (310) BOWL (312) SPLIT THRUST RING (358) CAP SCREW (32) KEY (85) SUCTION BELL (125) GREASE PLUG (323) SUCTION BEARING [7] NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS, RECOMMENDED SPARES: @ cuss i &2 CLASS 2FLANGED COLUMN ASSEMBLY 902.01.05 MALE TO FEMALE—PROOUCT LUBE. W/ SLEEVE & THREADED COUPLING PUMP CROSS SECTION ASSEMBLY - TYPICAL (12) LINE SHAFT pf (327) Nut (431) o-RING (OPTIONAL) oO rf (39) UNE sHaFT [7] BEARING _— (366) SET screw (] (325) CAP SCREW (14) SHAFT SLEEVE (J (101) COLUMN PIPE | ——— (70) SHAFT COUPLING ee sara IN (12) LINE SHAFT NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: CLASS 1 & 2 CLASS 2DISCHARGE HEAD TYPE HFH $03.04.02 PUMP CROSS SECTION ASSEMBLY - TYPICAL SOUD SHAFT ORIVER ~] (382) NUT (469) JACKSCREW (381) CAP SCREW ORIVE SHAFT SEE FLANGED COUPLING DETAIL (417) CAP screw —___ f} —-$20)-SHARTeoueuiNe- (418) WASHER ——T E (131) COUPLING GUARD (304) DISCHARGE HEAD I (12A) TOP UNE SHAFT (431) O-RING (327) NUT (101) COLUMN PIPE NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: @ cass 1 & 2 CLASS 2SEAUNG DETAIL STUFFING BOX 304.02 WITHOUT SLEEVE PUMP CROSS SECTION ASSEMBLY - TYPICAL (348) SLINGER (326) sTUD (17) PACKING GLANO (327A) HEX NUT (13) Packine (1) (345) GREASE ZERK (418) PIPE PLUG RELIEF LINE (354) sTup (355) HEX NUT (347) 0-RING (29) LANTERN RING (83) STUFFING 80x (117) pressure [J REDUCING BUSHING NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS. RECOMMENDED SPARES: @ cass 1 & 2 @ ciass 2ADJUSTABLE FLANGED SPACER COUPLING 5 (WSA/PSA) 805.0) PUMP CROSS SECTION ASSEMBLY - TYPICAL (48) ORIVE KEY (42) DRIVER COUPLING HALF (312A) SPLIT THRUST RING (364A) CAP SCREW (314) FLANGED SPACER (363) HEX NUT (664) ADJUSTING NUT (44) DRIVEN COUPLING HALF (364) CAP SCREW (48) KEY ASSEMBLY (124) TOP SHAFT NUMBERS IN PARENTHESES ARE REFERENCE NUMBERS.=] (SH/£N) SLANIM 43d SNOTIV I] (seez)ooso1 (r¥0z)o006 (gozI)ooSZ (s9¢t)ooo9 (ZzoL)oosr (1e9)o00e —_(I¥E)OOSI fol is ot peg oz INiOd hoisaq 81 d1H loc | AS? BI SdWNd 14M HOIH | 19) | a 3g ise (ovaH jor oor ale q 9) ee los Zlose % is li) © W oo 2I682 z Bizov) § loc Blose >| 2 5 oo a 8 o 2 B a3 & (eee (ct) 00s + los jose z B (evw zS1) 009 wa Bos 3 r—~ & (zzs [— + 891) 2 00d oss’ le Tae eerste ener ces| 070720 HOA, | (@zs)oo. wwe ae Re Senta ree Se ww! oy sos (1g)00z «udwr |_38M0 sONyAyiifa worst BOVIS b—TINSZ nnd edwng Gait a (og1z}o096 mo @/1-S800k- 24-96 WS jesse iM N73 *aRELSTO AISLEOOE ara] *OSORICHI ‘SNOILIONOD NOIS3O aT 1-H ‘SUONA NOTHO ‘Win, SON "Tous vAo0 UM NIDINGERSOLL DRESSER PUMP COMPANY - TANEYTOWN, MD S/N: 95=42-300375~1/2 MODEL: 25NKL-4 STAGE 8/0 No.: 42-300375 CUSTOMER: ELGIN WIP No. PUMPS: 2 PAGE 1 of 3 IDP ORDER No: 726-00010 DATE: 02-24-95 BILL OF MATERIALS BY: GREG YOHE QTy QTY PART REF DESCRIPTION MATERIAL REQ ASY NUMBER _NO. 1 36200599 424 SERIAL PLATE IDP TANEYTOWN 4 82130428 425 DRIVE SCREW F/SERIAL PLT ss 1 80715257 BLANKET MOTOR 1 86213790 304 HEAD 18HF 75HT 7.50BC 300FF 44M 52SQ FAB/STL 1 86213998 471 CPLG FLG 5PSA 5.00DR 2.69DN 4.25GV 1.25X8.0 STL 16 82188608 326 STUD THD .75 X 4.00 3048s 16 82091844 327 NUT HEX .75 3048S 8 82409236 381 SCREW CAP HEX 1.00-8UNC X 4.50 3048S 8 82112368 382 NUT HEX 1.00- 8UNC 30488 2 82123894 416 PLUG .50NPT SQ/HEAD A105STL 1 82123902 414 PLUG .75NPT SQ/HEAD GALV A197MAL 12 82064817 417 SCREW CAP .25 X .50 3048S a2 82231317 418 WASHER .25 a16ss 1 86213964 23 PLT BASE 60.00 SQ 50.00 HL 2.00 THK STL 4 82161647 412 STUD THD .88- 9UNC X 4.50 3048s 4 82161654 413 NUT HEX .88~ 9UNC 304ss 1 82194879 83 BOX STUFG STD 7.50 3.25 F/B-E F/2.69/SHF CT 1 82194887 117 BRG SLV 2.70 ID X 3.25 0D X 4.50 LG caag 1 82194903 17 GLAND PKG SPLIT 2.69 SHF BOLTED/304ss C865 1 82194911 13 PKG PROD/LUBE F/2.69 SHF .50 SQ 6 PER SET GRAPH 2 82194929 29 RING LTRN 2.69 SHF cena 1 82082884 347 ORING 5.73 ID +139 THK BUNA-N 6 82092339 354 STUD THD .63 X 3.00 3048s 6 82065509 355 NUT HEX .63 3048S 2 82065335 326A STUD THD .50 X 2.50 3048S